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Assessment of thermal spray coatings for wear and abrasion resistance applications

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dc.contributor.advisor Venkatesh, T. A. en_US
dc.contributor.author Karode, Ishaan Nitin en_US
dc.contributor.other Department of Materials Science and Engineering en_US
dc.date.accessioned 2017-09-18T23:49:53Z
dc.date.available 2017-09-18T23:49:53Z
dc.date.issued 2016-12-01 en_US
dc.identifier.uri http://hdl.handle.net/11401/76046 en_US
dc.description 99 pg. en_US
dc.description.abstract Thermal spray cermet and metallic coatings are extensively used for wear, abrasion and corrosion control in a variety of industries. The first part of the thesis focuses mainly on testing of sand erosion resistance of thermal spray coatings on carbon composites used in the manufacture of helicopter rotor blades. The test set-up employed is a sand blasting machine and is an effort to duplicate the in-flight conditions especially those encountered in hot arid conditions. The technique adopted follows the Department of Defence test method standard. Carbon Composites have excellent stiffness, strength and low weight/density. The strength to weight ratio is high. Hence, these are used in aerospace applications to a large extent. However, the biggest problem encountered with carbon composites is its low abrasion resistance as its surface is very weak. Hence, thermal spray coatings are used to improve the surface properties of CFRP. Zinc bond coats and WC-Co coatings were tested. However, high amount of thermal stresses were developed between the substrate and the coating due to large differences in the CTE’s of the both, leading to high mass losses within two minutes and just 130 grams of sand sprayed on to the coatings with the sand blasting machine built; and hence the coatings with CC as a substrate could not qualify for the application. The second part of the thesis focuses on the assessment of different thermal spray coatings used for manufacture of mechanical seals in pumps and analyze the best coating material for the wear resistance application through detail quantification of material loss by block-on-ring test set-up. A machine based on Block-on-ring test set-up following ASTM G77 (Measurement of Adhesive wear resistance of thermal spray coatings) standards was built to duplicate the pump conditions. Thermally sprayed coated materials were tested in different conditions (Load, time, abrasive). WC-Co had the highest wear resistance (lower volume losses) and proved to be the best coating amongst all the other ones followed by Cr2O3 and Al2O3 in deionized water. In the presence of abrasive alumina slurry WC-Co offered the highest abrasive resistance with the lowest volume losses followed by Al2O3 and Cr2O3. In both the testing conditions B4C coating showed lower wear/abrasion resistance giving the highest volume losses. en_US
dc.description.sponsorship This work is sponsored by the Stony Brook University Graduate School in compliance with the requirements for completion of degree. en_US
dc.format Monograph en_US
dc.format.medium Electronic Resource en_US
dc.language.iso en_US en_US
dc.publisher The Graduate School, Stony Brook University: Stony Brook, NY. en_US
dc.subject.lcsh Materials Science en_US
dc.title Assessment of thermal spray coatings for wear and abrasion resistance applications en_US
dc.type Thesis en_US
dc.mimetype Application/PDF en_US
dc.contributor.committeemember Raghothamachar, Balaji. en_US

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