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The use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips

Year 2022, , 739 - 744, 01.06.2022
https://doi.org/10.2339/politeknik.865736

Abstract

The wear during the sliding of wire in GMA welds causes the contact tips to be replaced after a certain number of hours of service. In order to reduce the wear, GMAW weld contact tips were coated by NiAl using ESD (Electro Spark Deposition) with 60V and 500 Hz under Argon. The testing of contact tips were done on robotic GMAW stations and standard metallographic techniques and SEM microscopy were used to reveal the microstructure. The results indicate that the service life of contact tips can be extended as much as 50 % compared to uncoated contact tips in concern via the use of W and NiAl coating, affecting the wire friction wear performance during high temperature welding process

Supporting Institution

R&D Center, Şahinkul Machine and Spare Parts Manuf. Ltd. Co., Bursa,Turkey,

Project Number

ARGE_2019_011

Thanks

This study was financially supported by Şahinkul Machine Parts Manuf. Ltd. Co, Research and Development Center with the project number of ARGE_2019_011.

References

  • [1] Lancaster J.F., “The physics of welding”, Physics in Technology, 15:73-79, (1984).
  • [2] Adam G., Sievert T.A., Quinn T., Vigliotti P., “Contact Tube Temperature during GMAW”, Welding Journal, December, 37-41, (2001)
  • [3] Yamada T. and Takana O., "Fluctuation of the Wire Feed Rate in Gas Metal Arc Welding", Welding Journal, 66: 35-42, (1987).
  • [4] Villafuerte J., "Stronger copper for longer lasting contact tips and electrodes", Welding Journal, 82: 50-52, (2003).
  • [5] de Meneses V.A., Gomes J.F.P. and Scotti A., “The effect of metal transfer stability (spattering) on fume generation, morphology and composition in short-circuit MAG welding”, Journal of Materials Processing Technology, 214: 1388-1397, (2014).
  • [6] Childs T.H.C, “The sliding wear mechanisms of metals, mainly steels”, Tribology International, 13(6): 285-293, (1980).
  • [7] Shimizu H., Yokota Y., Mizuno M. and Kurokawa T., “Wear mechanism in contact tube”, Science and Technology of Welding and Joining, 11: 94-105, (2006).
  • [8] Matsui H. and Hattori T., “Abrasion phenomena of the contact tip in consumable electrode arc welding”, Welding International, 32: 475-484, (2018)
  • [9] Rigney D.A., “Sliding wear of metals”, Annual Review of Materials Science, 18: 141-163, (1988).
  • [10] Wang J.S., Meng H.M., Yu H.Y., Fan Z.S. and Sun D., “Characterization and wear behavior of WC-0.8 Co coating on cast steel rolls by electro-spark deposition”. International Journal of Minerals, Metallurgy and Materials, 16(6): 707-713, (2009).
  • [11] Kayalı Y. and Talaş Ş., “Investigation of Wear and Corrosion Behaviour of AISI 316 L Stainless Steel Coated By ESD Surface Modification”, Protection of Metals and Physical Chemistry of Surfaces, 55(6): 1148-1153, (2019).
  • [12] Talaş Ş., Mertgenç E. and Gökçe B., “ESD coating of copper with TiC and TiB2 based ceramic matrix composites”, IOP Conference Series-Materials Science and Engineering, 146: 012005, (2016).
  • [13] Talaş Ş., “Nickel Aluminides” in “Intermetallic Matrix Composites: Properties and Applications”, Ed. by Rahul Mitra, Series in Composites Science and Engineering (2018).
  • [14] Miracle D.B., “The physical and mechanical properties of NiAl”, Acta Materialia, 41: 649–684, (2003)
  • [15] Sikka V.K., Deevi S.C., Viswanathan, S., Swindeman, R.W. and Santella, M.L., “Advances in processing of Ni3Al-based intermetallics and applications”, Intermetallics, 8: 1329–1337, (2000).
  • [16] Gong K., Luo H.L., Feng D. and Li C.H., “Wear of Ni3Al-based materials and its chromium-carbide reinforced composites”, Wear, 265: 1751–1755, (2005)
  • [17] Demirel M. & Mehtap Muratoglu, M., “Influence of load and temperature on the dry sliding wear behavior of aluminium-Ni3Al composites”, Indian Journal of Engineering & Materials Sciences, 18: 268-282, (2011).
  • [18] Jozwik P., Polkowski W. and Bojar., “Applications of Ni3Al based intermetallic alloys- current stage and potential perceptivities”, Materials, 8: 2537-2568, (2015).
  • [19] Xue, B., Zhu, H., Shi, X., “Tribological performance of NiAl alloy containing graphene nanoplatelets under different velocities”, Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 231(6): 799-809, (2016).
  • [20] Hawk J.A. and Alman D.E., “Abrasive wear of intermetallic-based alloys and composites”, Materials Science and Engineering A, 239–240: 899-906, (1997).
  • [21] Hawk J.A. and Alman D.E., “Abrasive wear behavior of NiAl and NiAl–TiB2 composites”, Wear, 225–229: 544-556, (1999).
  • [22] Kah P., Suoranta R. & Martikainen J. Advanced gas metal arc welding processes. International Journal of Advanced Manufacturing Technology, 67: 655–674 (2013).
  • [23] Kristóf D., Németh L. “Investigation of the Contact and Wear of the Welding Wire and MIG-Welding Contact Tips”. In: Jármai K., Farkas J. (eds) Design, Fabrication and Economy of Metal Structures, Springer, Berlin (2013).
  • [24] Porobova S., Markova T., Klopotov V., Klopotov A., Loskutov O. and Vlasov V., “Copper-based alloys, crystallographic and crystallochemical parameters of alloys in binary systems Cu-Me (Me=Co, Rh, Ir, Cu, Ag, Au, Ni, Pd, Pt)”, AIP Conference Proceedings, 1698: 030005, (2016).
  • [25] Raghavan V., “Al-Cu-Ni (Aluminum-Copper-Nickel)”, Journal of Phase Equilibria and Diffusion, 27: 389-391, (2006).
  • [26] Pinomaa T., Laukkanen A. and Provatas N.“Solute trapping in rapid solidification”, MRS Bulletin, 45(11), 910-915, (2020).
  • [27] Brumm M.W, Grabke H.J, “The oxidation behaviour of NiAl-I. Phase transformations in the alumina scale during oxidation of NiAl and NiAl-Cr alloys”, Corrosion Science, 33: 1677-1690, (1992).
  • [28] Johnson B.J., Kennedy F.E. and Baker I., “Dry sliding wear of NiAl”, Wear, 192(1–2): 241-247, (1996).
  • [29] Zhang Y.S., Wang K., Han Z. and Liu G., “Dry sliding wear behavior of copper with nano-scaled twins”, Wear, 262(11–12): 1463-1470, (2007)

Gazaltı Kaynak Kontak Uçlarında Kayar Tel Aşınmasına Karşı ESD ile Yığılan NiAl Kaplamaların Kullanımı

Year 2022, , 739 - 744, 01.06.2022
https://doi.org/10.2339/politeknik.865736

Abstract

The wear during the sliding of wire in Gas Metal Arc Welding (GMAW) causes the contact tips to be replaced after a certain number of hours of service. In order to reduce the wear, GMAW weld contact tips were coated by NiAl using ESD (Electro Spark Deposition) with 60V and 500 Hz under Argon. The testing of contact tips were done on robotic GMAW stations and standard metallographic techniques and SEM microscopy were used to reveal the microstructure. The results indicate that the service life of contact tips can be extended as much as 50 % compared to uncoated contact tips in concern via the use of NiAl coating, affecting the wire friction wear performance during high temperature welding process. 

Project Number

ARGE_2019_011

References

  • [1] Lancaster J.F., “The physics of welding”, Physics in Technology, 15:73-79, (1984).
  • [2] Adam G., Sievert T.A., Quinn T., Vigliotti P., “Contact Tube Temperature during GMAW”, Welding Journal, December, 37-41, (2001)
  • [3] Yamada T. and Takana O., "Fluctuation of the Wire Feed Rate in Gas Metal Arc Welding", Welding Journal, 66: 35-42, (1987).
  • [4] Villafuerte J., "Stronger copper for longer lasting contact tips and electrodes", Welding Journal, 82: 50-52, (2003).
  • [5] de Meneses V.A., Gomes J.F.P. and Scotti A., “The effect of metal transfer stability (spattering) on fume generation, morphology and composition in short-circuit MAG welding”, Journal of Materials Processing Technology, 214: 1388-1397, (2014).
  • [6] Childs T.H.C, “The sliding wear mechanisms of metals, mainly steels”, Tribology International, 13(6): 285-293, (1980).
  • [7] Shimizu H., Yokota Y., Mizuno M. and Kurokawa T., “Wear mechanism in contact tube”, Science and Technology of Welding and Joining, 11: 94-105, (2006).
  • [8] Matsui H. and Hattori T., “Abrasion phenomena of the contact tip in consumable electrode arc welding”, Welding International, 32: 475-484, (2018)
  • [9] Rigney D.A., “Sliding wear of metals”, Annual Review of Materials Science, 18: 141-163, (1988).
  • [10] Wang J.S., Meng H.M., Yu H.Y., Fan Z.S. and Sun D., “Characterization and wear behavior of WC-0.8 Co coating on cast steel rolls by electro-spark deposition”. International Journal of Minerals, Metallurgy and Materials, 16(6): 707-713, (2009).
  • [11] Kayalı Y. and Talaş Ş., “Investigation of Wear and Corrosion Behaviour of AISI 316 L Stainless Steel Coated By ESD Surface Modification”, Protection of Metals and Physical Chemistry of Surfaces, 55(6): 1148-1153, (2019).
  • [12] Talaş Ş., Mertgenç E. and Gökçe B., “ESD coating of copper with TiC and TiB2 based ceramic matrix composites”, IOP Conference Series-Materials Science and Engineering, 146: 012005, (2016).
  • [13] Talaş Ş., “Nickel Aluminides” in “Intermetallic Matrix Composites: Properties and Applications”, Ed. by Rahul Mitra, Series in Composites Science and Engineering (2018).
  • [14] Miracle D.B., “The physical and mechanical properties of NiAl”, Acta Materialia, 41: 649–684, (2003)
  • [15] Sikka V.K., Deevi S.C., Viswanathan, S., Swindeman, R.W. and Santella, M.L., “Advances in processing of Ni3Al-based intermetallics and applications”, Intermetallics, 8: 1329–1337, (2000).
  • [16] Gong K., Luo H.L., Feng D. and Li C.H., “Wear of Ni3Al-based materials and its chromium-carbide reinforced composites”, Wear, 265: 1751–1755, (2005)
  • [17] Demirel M. & Mehtap Muratoglu, M., “Influence of load and temperature on the dry sliding wear behavior of aluminium-Ni3Al composites”, Indian Journal of Engineering & Materials Sciences, 18: 268-282, (2011).
  • [18] Jozwik P., Polkowski W. and Bojar., “Applications of Ni3Al based intermetallic alloys- current stage and potential perceptivities”, Materials, 8: 2537-2568, (2015).
  • [19] Xue, B., Zhu, H., Shi, X., “Tribological performance of NiAl alloy containing graphene nanoplatelets under different velocities”, Proceedings of the Institution of Mechanical Engineers, Part J: Journal of Engineering Tribology, 231(6): 799-809, (2016).
  • [20] Hawk J.A. and Alman D.E., “Abrasive wear of intermetallic-based alloys and composites”, Materials Science and Engineering A, 239–240: 899-906, (1997).
  • [21] Hawk J.A. and Alman D.E., “Abrasive wear behavior of NiAl and NiAl–TiB2 composites”, Wear, 225–229: 544-556, (1999).
  • [22] Kah P., Suoranta R. & Martikainen J. Advanced gas metal arc welding processes. International Journal of Advanced Manufacturing Technology, 67: 655–674 (2013).
  • [23] Kristóf D., Németh L. “Investigation of the Contact and Wear of the Welding Wire and MIG-Welding Contact Tips”. In: Jármai K., Farkas J. (eds) Design, Fabrication and Economy of Metal Structures, Springer, Berlin (2013).
  • [24] Porobova S., Markova T., Klopotov V., Klopotov A., Loskutov O. and Vlasov V., “Copper-based alloys, crystallographic and crystallochemical parameters of alloys in binary systems Cu-Me (Me=Co, Rh, Ir, Cu, Ag, Au, Ni, Pd, Pt)”, AIP Conference Proceedings, 1698: 030005, (2016).
  • [25] Raghavan V., “Al-Cu-Ni (Aluminum-Copper-Nickel)”, Journal of Phase Equilibria and Diffusion, 27: 389-391, (2006).
  • [26] Pinomaa T., Laukkanen A. and Provatas N.“Solute trapping in rapid solidification”, MRS Bulletin, 45(11), 910-915, (2020).
  • [27] Brumm M.W, Grabke H.J, “The oxidation behaviour of NiAl-I. Phase transformations in the alumina scale during oxidation of NiAl and NiAl-Cr alloys”, Corrosion Science, 33: 1677-1690, (1992).
  • [28] Johnson B.J., Kennedy F.E. and Baker I., “Dry sliding wear of NiAl”, Wear, 192(1–2): 241-247, (1996).
  • [29] Zhang Y.S., Wang K., Han Z. and Liu G., “Dry sliding wear behavior of copper with nano-scaled twins”, Wear, 262(11–12): 1463-1470, (2007)
There are 29 citations in total.

Details

Primary Language English
Subjects Engineering
Journal Section Research Article
Authors

Mustafa Yazar 0000-0001-9927-3268

Milat Kul 0000-0003-0732-9354

Ali Kemal Alp 0000-0002-4770-4123

Şükrü Talaş 0000-0002-4721-0844

Project Number ARGE_2019_011
Publication Date June 1, 2022
Submission Date January 20, 2021
Published in Issue Year 2022

Cite

APA Yazar, M., Kul, M., Alp, A. K., Talaş, Ş. (2022). The use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips. Politeknik Dergisi, 25(2), 739-744. https://doi.org/10.2339/politeknik.865736
AMA Yazar M, Kul M, Alp AK, Talaş Ş. The use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips. Politeknik Dergisi. June 2022;25(2):739-744. doi:10.2339/politeknik.865736
Chicago Yazar, Mustafa, Milat Kul, Ali Kemal Alp, and Şükrü Talaş. “The Use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips”. Politeknik Dergisi 25, no. 2 (June 2022): 739-44. https://doi.org/10.2339/politeknik.865736.
EndNote Yazar M, Kul M, Alp AK, Talaş Ş (June 1, 2022) The use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips. Politeknik Dergisi 25 2 739–744.
IEEE M. Yazar, M. Kul, A. K. Alp, and Ş. Talaş, “The use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips”, Politeknik Dergisi, vol. 25, no. 2, pp. 739–744, 2022, doi: 10.2339/politeknik.865736.
ISNAD Yazar, Mustafa et al. “The Use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips”. Politeknik Dergisi 25/2 (June 2022), 739-744. https://doi.org/10.2339/politeknik.865736.
JAMA Yazar M, Kul M, Alp AK, Talaş Ş. The use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips. Politeknik Dergisi. 2022;25:739–744.
MLA Yazar, Mustafa et al. “The Use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips”. Politeknik Dergisi, vol. 25, no. 2, 2022, pp. 739-44, doi:10.2339/politeknik.865736.
Vancouver Yazar M, Kul M, Alp AK, Talaş Ş. The use of NiAl Coating Deposited by ESD Against the Wear of Sliding Wire in GMAW Contact Tips. Politeknik Dergisi. 2022;25(2):739-44.
 
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