Thirumalvalavan S, Perumal G, Senthilkumar N, Selvarasu S
Department of Mechanical Engineering, Arunai Engineering College, Tiruvannamalai, Tamil Nadu, 606603, India.
Department of Mechanical Engineering, V.R.S. College of Engineering and Technology, Villupuram Tamil Nadu, 607107, India.
Recent Pat Nanotechnol. 2025;19(4):544-567. doi: 10.2174/0118722105306841240808092616.
Thermal spray coatings have emerged as a pivotal technology in materials engineering, primarily for augmenting the characteristics related to wear and tribology of metallic substrates.
This study aims to develop into applying High-Velocity Oxygen Fuel (HVOF) thermalsprayed WC-Co nanocoatings on Titanium Grade-5 alloy (Ti64). The coating process, utilizing nano-sized WC-Co powder, undergoes systematic optimization of HVOF parameters, encompassing the flow rate of carrier gas, powder feed rate, and nozzle distance. Experimental assessments via Pin-on-Disc (PoD) tests encompass Loss of Wear (WL), Friction Coefficient (CoF), and Frictional Force (FF). Later, an exhaustive optimization of responses is conducted using the Technique for Order Preference by Similarity to the Ideal Solution (TOPSIS) method and the golden jack optimization algorithm (GJOA).
Outcomes show a substantial increase in WL, CoF, and FF with a rise in the carrier gas and powder feed rate. However, with increasing spraying distance of powder, the WL, CoF, and FF tend to lower due to higher bonding, which leads to increased wear resistance. The ideal parametric settings achieved from TOPSIS and GJOA are 245 mm of spray distance, 30 gpm rate of powder feed, and 11 lpm of carrier gas flow rate. The powder feed rate contributes 88.99% to the control action, as seen from ANOVA.
The confirmation experiment presents that the WL, CoF, and FF output responses are 42.33, 27.97, and 9.38% less than the mean of experimental data. These results highlight the HVOF process in spraying WC-Co nanocoatings to fortify the durability and performance of Ti64 alloy that can be patented for diverse engineering applications.
热喷涂涂层已成为材料工程中的一项关键技术，主要用于增强金属基体与磨损及摩擦学相关的特性。
本研究旨在开发在5级钛合金（Ti64）上应用高速氧燃料（HVOF）热喷涂WC-Co纳米涂层的方法。涂层工艺利用纳米级WC-Co粉末，对HVOF参数进行系统优化，包括载气流量、粉末进料速率和喷嘴距离。通过销盘（PoD）试验进行的实验评估包括磨损损失（WL）、摩擦系数（CoF）和摩擦力（FF）。随后，使用理想解相似排序法（TOPSIS）和黄金豺优化算法（GJOA）对响应进行详尽优化。
结果表明，随着载气和粉末进料速率的增加，WL、CoF和FF大幅增加。然而，随着粉末喷涂距离的增加，由于结合力增强，WL、CoF和FF趋于降低，这导致耐磨性提高。通过TOPSIS和GJOA获得的理想参数设置为喷涂距离245毫米、粉末进料速率30加仑/分钟和载气流量11升/分钟。从方差分析可以看出，粉末进料速率对控制作用的贡献率为88.99%。
验证实验表明，WL、CoF和FF输出响应比实验数据平均值分别低42.33%、27.97%和9.38%。这些结果突出了HVOF工艺在喷涂WC-Co纳米涂层以增强Ti64合金耐久性和性能方面的作用，该工艺可申请专利用于各种工程应用。
