A groundbreaking technique for synthesizing thin hard surface coatings using high velocity air fuel spraying is poised to revolutionize the automotive and manufacturing industries by offering a safer and more environmentally friendly alternative to traditional chrome plating.
Chrome plating, long prized for its hardness and wear resistance, has come under scrutiny due to its carcinogenic nature, attributed to the presence of chromates, fluorites, and hexavalent chromium. In response, researchers have been on the quest for a safer alternative with comparable or superior wear resistance, but without the harmful chemical components.
The new technique, developed by scientists from ARCI, an institution under the Department of Science and Technology (DST), involves the synthesis of thin hard coatings using a composite alloy of Tungsten, cobalt, and chromium (WC-10Co-4Cr) through high velocity air fuel spraying. This innovative approach offers several advantages over conventional thermal spray techniques, including lower temperatures, higher particle velocities, and the ability to deposit coatings using finer sized powders.
By depositing thin coatings with a thickness of 50 µm and achieving surface roughness close to 1.5 µm on stainless steel substrates, the researchers have demonstrated the efficacy of the new technique. Moreover, comparative studies have revealed superior sliding wear performance and corrosion resistance of the HVAF sprayed coatings compared to conventional Hard Chrome Plating (HCP), making it an ideal alternative for heavy load applications such as hydraulic shafts, valves, and piston rods.
One of the key advantages of the new technique is its ability to reduce post-coating finishing operations significantly, thereby lowering processing and raw material costs while offering better wear resistance than HCP. Additionally, the coatings can be deposited on machined surfaces to achieve a smooth finish, further streamlining the manufacturing process.
Published in the Journal of Thermal Spray Technology, this study is expected to provide valuable insights into optimizing thermal energy and kinetic energy for enhanced wear resistance, paving the way for widespread adoption of this innovative coating technique across various industrial sectors. With its potential to replace carcinogenic chrome plating, the new coating technique represents a major step towards achieving safer and more sustainable manufacturing practices.
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