thermal spraying .pptx thermal sprating marine haul

thermal sprating marine haul

1. MED- 421 Major Project Presented By : Harsh Kumar Meena(2021UME1476) Pankaj Barupal (2021UME1435) Kishan Choudhary(2021ume1432) Guided By : Dr. Anoj Meena Supervisor Prof. Amar Patnaik Co- Supervisor HVOF Thermal Spray Coating of AlCrCoTiCu High Entropy Alloy on 316 Stainless Steel Substrate for Marine Ship Hull Applications 1 Department of Mechanical Engineering Malaviya National Institute of Technology, Jaipur

2. Content Motivation Introduction Literature Review Research Gap and Objective Methodology Selection of HEA Elements 2

3. Motivation 3 Figure: Fatigue crack discovered in ship hull Source: www.marlinblue.com Figure: Metal deterioration due to corrosion in ship hull Source: www.marlinblue.com Figure: Corroded internal surface of a ship hull Source: www.twi-global.com Stainless Steel Grade 316 contains a minimum 2.0% molybdenum which makes it much more corrosion resistant than 304. Source: Materials Science and Engineering: An Introduction" by William D. Callister Figure: Biofouling on Marine ship Source: www.safety4sea.com

4. Methods for improving properties of Stainless Steel Nitriding Shot Peening Surface Treatments Alloying or Modification Techniques Coating Techniques Physical Vapor Deposition Chemical Vapor Deposition Motivation Electro polishing Thermal Spray Coatings Cryogenic Treatment Heat Treatment Why? The coating is uniform and dense. Unique advantage by providing simultaneous improvements in wear resistance, corrosion resistance, oxidation resistance, and other properties. 4

5. Introduction 5 HEA Elements: AlCrCoTi Cu Source: Ashok M et al./Thermal Spray Tech, 2020 Source: https://www.dierk-raabe.com Table 2.1: Elemental Selection Statistics of High-Entropy Alloys S. No. HEA element Application 1. Al, Cr, Ti, Si oxidation resistance 2. Cr corrosion resistance 3. Al-Ni/ Co/Fe wear resistance 4. Co/Ni Alloy Enhanced plasticity 5. V-Ti Alloy High Hardness 6. Cu Antimicrobial properties Figure: Selected HEAs for some suggested applications Source: Naresh Kaushik et al./ Materials and Manufacturing processes, 2021

6. Introduction Source: www.US thermalSpray.com Source: A.S.M. Ang et al./Int. Mater. Rev., 2014 6 Thermal spray processes: U se of combustion heat sources Ex: HVOF, detonation gun P lasma or arc formation using electrical energy Ex: APS(Atmospheric plasma spray) L ow-temperature processes that use energy evolving from gas expansion Ex: cold spray Why HVOF? Produces dense, high-hardness coatings with low porosity. Minimizes oxidation during the process. Excellent adhesion strength.

7. 7 Marine biofouling refers to  the attachment of undesirable organisms (e.g., bacteria, algae, and barnacles) on wetted surfaces . It is a global issue because the growth of fouling organisms on ship hulls increases surface roughness, leading to an increase in drag resistance. Introduction Role of Copper in Alloys for Antifouling & Antimicrobial Properties: Toxic to Marine Organisms: Cu ions disrupt the cellular metabolism of bacteria, algae, and barnacle larvae, preventing biofouling on ship hulls and underwater structures. Self-Sterilizing Effect: Copper kills bacteria and viruses on contact, making it useful in medical and hygiene applications. Source: www.onboardonline.com Source: www.dialogueearth.com Source: Dong Ho Kim et al./ Scienece of total Environment, 2024

8. Literature Review 8 HEA Coating Material Methodology Improvement Application Reference AlCoCrFeNi APS (Atmospheric Plasma spray) Microhardness, wear resistance and corrosion resistance increase, low current density and high current potential Automobile component, Marine Ships Niveditha et al./Tribology international 2023 NixCO0.6Fe0.2CrySizAlTi APS Hardness and Coarsening Resistance performance increase Machine tools, coating of dies L.M. Wang et al./Materials chem. and physics, 2011 NiCrBSi addition of the WC-Co powder HVOF (High Velocity Oxy Fuel) Hardness and wear resistance increase, Flame remelting led to better cohesion reducing microdefects Machinery S. Shuecamlue et al./Surfaces and interfaces, 2024 NiCoCrAlY APS Modulus of elasticity is higher ,high metallic bond with substate Steam Turbines, Marine Engines Animesh Kumar Basak et al./Designs, 2024 Ni-5Al, NiCoCrAlY , and CoNiCrAlY HVOF Corrosion Resistance increases Molten Salt Storage Tanks, Heat Exchangers Ning Li et al./Solar Enery Materials and solar cells, 2023 CoCrFeMnNi0.8V / Wc -CO HVOF Strength and corrosion resistance increases Turbine blade, exhaust nozzle Stavros Kiape et al./Composites Science, 2024 TiNbMoMnFeOX HVOF Mechanical alloying effectively produced MPEA coatings and 86% reduction in Wear rate Chemical, biomedical, nuclear N.V. Abhijith et al./International Journal of refractory metals and hard materials, 2024 CoCr0.65FeNi-BSiC spark plasma sintering High sliding wear resistance Superimposed tribological and corrosive stresses. Bianca Preub et al./Surface and coating technology, 2024 AlCoCrFeMo low-pressure cold spray (LPCS) Higher hardness, lower wear rates and lower frictional coefficient Aerospace applications P. Patel et al./surface and coating technology, 2024 FeCr and FeCoCr Electric arc thermal spray process High adhesive strength and corrosion resistance Marine components F. jose Antunes et al./Applied adhesion science, 2013 Ti alloy(Ti-6Al-4v) HVOF Fatigue failure reduced, total deformation reduced, shear stress and shear strain reduce Wind turbine gear J. Ahmed et al./Journal of Manufacturing,2024 Mo feeding powder LAPS (Laser assisted plasma spraying) Dense microstructure, Microhardness and wear resistance increase Piston rings for cylinder Panpan Zhang et al./ Therm Spray Tech, 2024 Thermal Spray Coating of Different HEA on Stainless Steel Substrate: Conclusion: The literature review demonstrates that HEA coatings on stainless steel substrates for enhancing hardness, wear resistance, and corrosion protection using thermal spray methodologies. These coatings are widely used in aerospace, marine, energy, and biomedical sectors.

9. Research Gap and Objective 9 Research Gap: Investigation into the biofouling resistance of HEA coatings and the impact of their growth on the mechanical properties. Develop New High Entropy alloys for increasing the corrosion resistance of Marine ships. Studies on the performance of HEA coatings under cyclic loading, focusing on crack formation, delamination, and other failure modes in marine hull applications. Study of unidentified precipitates formed during the thermal spray process. Need of more work on properties characterization of non equimolar high-entropy alloys (HEAs). Objectives: Synthesis and Characterization of AlCoCrTiCu High Entropy Alloy Powder by powder metallurgy process. Thermal spray coating of HEA on 316 Stainless Steel and sample properties Examination. Aim to improve corrosion resistance and Wear resistance compared to previous coatings. Increase Biofouling Resistance of Marine ship hull structures. S. No. Uncoated AlCoCrFeNi Coating on Steel Improvement Electro chemical Corrosion Resistance E(mv) 210.526 227.082 60% Corrosion Resistance Increases I(µA) 0.775 0.522 Rp( Ω cm2 ) 68673.11 218297.08 Wear Rate (1) 54.49% decrement: sliding velocity (0.5m/s) (2) 74.59% decrement:3.5 m/s 62.5 % wear resistance increases Micro hardness (HV) 324.9 800.08 2.46 times Source: Niveditha ,, Tribology international 2023 Stern-Geary equation: Polarization resistance (RP) Anodic and cathodic Tafel constants (βa and βc)

10. Methodology 10

11. Selection of HEA Elements 11 Table 6.1 Metallurgical properties of High entropy alloy elements S. No. Element Crystal Structure Melting Point (K) Density at 20 (gm/cm3) Elastic Modulus( Gpa ) Atomic Radius(pm) Valence cell electron 1. Al FCC 933.3 2.7 70 143 3 2. Cr BCC 2180 7.19 248 130 6 3. Co HCP 1768 8.84 209 124 9 4. Ti HCP 1998 4.5 120 147 4 5. Cu FCC 1358 8.96 110 128 11 S. No. Element Crystal Structure Melting Point (K) Elastic Modulus( Gpa ) Atomic Radius(pm) Valence cell electron 1. Al FCC 933.3 2.7 70 143 3 2. Cr BCC 2180 7.19 248 130 6 3. Co HCP 1768 8.84 209 124 9 4. Ti HCP 1998 4.5 120 147 4 5. Cu FCC 1358 8.96 110 128 11 The High Entropy Effect The presence of multiple principal elements maximizes configurational entropy. )   The Sluggish diffusion effect It explains the lethargic behavior of atomic diffusion in the lattice during solidification. VEC=   The lattice distortion effect -It tells about the movement of atoms in the crystal due to lattice energy and temperature effect.   The Cocktail effect This effect explains the mixing properties of alloy based on different elements.   Basic Core Effects of High Entropy Alloys - Adjust element percentages to enhance specific properties. -Ex:   HEA Composition Equi atomic HEA Non- Equiatomic HEA - Each element is present in equal atomic percentages. -Ex:  

12. Feasibility of HEA Composition 12 HEA Elements: AlCrCoTi Cu S.No . Thermodynamic Parameter Formula Thermodynamic Parameters of Successfully Synthesized HEA Thermodynamic Parameter for AlCrCoTiCu Composition 1 Entropy ) 1.5R 1.68R 2 Valence Electron Concentration (VEC) VEC= 7.84 for FCC 6.84 to 7.84 for FCC+BCC <6.84 for BCC 6.6-BCC 3 Enthalpy of Mixing -22 ≤ ​≤7 kJ/mol -14.72 KJ/Mol 4 Atomic Size Difference( δ≤ 0.06 0.06 5 Thermodynamic Parameter( 1.488 S.No . Thermodynamic Parameter Formula Thermodynamic Parameters of Successfully Synthesized HEA Thermodynamic Parameter for AlCrCoTiCu Composition 1 1.68R 2 Valence Electron Concentration (VEC) 6.6-BCC 3 -14.72 KJ/Mol 4 δ≤ 0.06 0.06 5 1.488 = Atomic fraction of element = Atomic fraction of element = radii of the different element = mixing enthalpy for the alloys   Gibbs Free energy=   Element Pair (KJ/mol) Al-Co -19 Al-Cr -10 Al-Ti -30 Al-Cu -1 Co-Cr -4 Co-Ti -16 Co-Cu 4 Cr-Ti -10 Cr-Cu 4 Ti-Cu -10 Element Pair Al-Co -19 Al-Cr -10 Al-Ti -30 Al-Cu -1 Co-Cr -4 Co-Ti -16 Co-Cu 4 Cr-Ti -10 Cr-Cu 4 Ti-Cu -10 Source: Akira Takeuchi et al./Materials Transactions(2005) Table 6.2 Feasibility Checking of AlCrCoTiCu HEA Composition Table 6.3 The values of (kJ/mol) calculated by Miedema’s model for atomic pairs between the elements  

13. 13 Thank You

14. Methodology: HEA Composition 14

15. Methodology: HEA Composition 15 Element Weight(gm) Al 10.82 Co 23.63 Cr 20.85 Ti 19.21 Cu 25.48

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17. 17 Link for Research Paper study Conclusion: https://docs.google.com/spreadsheets/d/1URCjDE20WNH33yRi3BY5HmAvUAj1Cfwc4SytojSXcdM/edit?usp=sharing