Presentation on

C. K. PITHAWALA COLLEGE OF ENGINEERING

AND TECHNOLOGY, SURAT
COMPETING FAILURE MECHANISM AND LIFE PREDICTION OF
PLASMA SPRAYED COMPOSITE CERAMIC COATING IN
ROLLINGSLIDING CONTACT CONDITION
PREPARED BY:
Name
1. Mr. RAHUL PATEL
2. Mr. HITESH RANA
3. Mr. AVADHESH H. VYAS

Enrollment No.
(150090709014)
(150090709017)
(150090709018)

Subject : Tribology ( RP )
M.E., 2nd Semester, Machine Design,
GTU, Surat, Gujarat.
2

GUIDED BY:
Prof. MAHESH J. PATEL
Mechanical Engineering Department.
CKPCET, SURAT.

AGENDA

Introduction

Experimental test procedure

Results and discussion

Conclusion

Introduction
Composite ceramic coating :

Thermal sprayed Al2O3-40 wt%.TiO2 composite ceramic coatings (AT40coatings)

Excellent high- temperature resistance, corrosion resistance and wear resistance

Supersonic plasma spraying method preparing AT40 coating

Flame temperature

Failure

Wear

2.

Rolling contact fatigue (RCF)

Particle velocity

modes of AT40 coatings under rollingsliding contact condition

1.

Wear

&

failure - In the form of surface material removal occurs under sliding contact

RCF failure - Persistent damage process, involves cracking or pitting/ delamination

limited to the subsurface of materials under rolling contact condition

4

 Wear

and RCF simultaneously occur & influence each other under rolling-sliding contact

condition Because of main parameters contact stress, surface roughness, coating thickness,
bonding strength, rolling velocity, and coating hardness on the RCF failure mechanism and
RCF. Components are not usually under pure rolling contact but rollingsliding contact.
The

mechanism of competing between wear and RCF of thermal sprayed coatings under

rolling-sliding contact conditions with large range of

slip ratio (0-75%) should be

investigated in detail. In the present research, the competing failure mechanism and life
evolution with the slip ratios of R1= 0%, R2= 25%, R3= 50%, and R4= 75% were in detail
studied on a double-roll test machine.

Introduction

Experimental test procedure

Coating deposition :

AT40

coatings and Ni/Al

bonding coatings were deposited

on the tempered AISI1045 steel
rollers using supersonic plasma
spray technology. The substrate
surface was sand blasted and
then preheated to about 200 C
before spraying.

Monitoring by Spray Watch-2i monitor

Coating
quality

Affected by

Temperature
of melted particles

Velocity
of melted particles

2400-2500 C

460-500 m/s

Impact energy of
particles

Bonding strength
betn coating and
substrate

Surface Morphologies :
The coating surface was relatively smooth, and
almost no unmelted particle or micro crack was
observed
7

Exp. Test Proce.

Cross section Morphologies :

Fig. shows the dense micro- structure of
the cross section of AT40 coating. Only a
few micro- pores existed in the coating.
Thickness - 400 m
Bonding strength - 35MPa
Dual tensile test method
Porosity - 1.12%
Image analysis method (IAM)

Exp. Test Proce.

Experimental conditions and procedures :

Novel RCF/wear
multifunctional test M/c

Used to

investigate RCF/wear competing failure

mechanism

prominent characteristic
Slip ratio between the
rollers is able to change
from 0% to 100%

Experimental setup :

Figure given below shows the schematic of the test roller and standard roller. The load was

applied to the test roller. The failure process of coating of test roller was monitored by an
acoustic emission(AE) probe for its sensitivity to plastic deformation and brittle fracture of
materials. The threshold value of AE signals was set as 60 dB, and the failure point was
defined when the AE count was higher than 350 dB.
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Exp. Test Proce.

Material of
Standard
roller

tempered
AISI52100
steel

Surface
Roughness
By
Olympus
OLS4000
laser 3D
microscope

Test roller :
0.62 0.01
m

Microhardness
values By
Vickershardness
tester load
of 100 gm
10

Std roller:
0.36 0.01
m

Test roller :
910 HV 0.1
Std roller:
770 HV 0.1

Exp. Test Proce.

 The

competing life tests for AT40 coatings were performed under a fixed contact stress of

0.75GPa. The corresponding load was calculated by the Hertz equation,

max

F ( )
L((1 12 ) / E1 (1 2 2 ) / E2 )

where max = max contact stress, 0.75 Gpa

F is the load;
L is the length of the contact line = 5 mm

&

E1 & E2

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= Poisson's ratio
test roller (AT40 coating) and standard roller (AISI 52100 steel) = 0.3
= Elastic modulus , Test roller and standard roller = 173 GPa & 219 GPa
= Sum of principal curvatures of the test roller and standard roller = 1/15mm-1

Exp. Test Proce.

Results and discussion

Failure modes and competing lives:

DE: Delamination
SP: Spalling
SA: Surface Abrasion

12

Life Prediction plots:

Two-parameter Weibull function was used to analyze the competing life data of
AT40 coatings.
( )=1

Where P(N) is the failure probability; N the number of cycles; Na the characteristic
life under the failure probability of 63.2%; the slope of Weibull curve .

The two parameters( and ) of Weibull function were evaluated using the
maximum likelihood estimation(MLE) method as,
ln

ln

and,

=0

It can be seen from Fig. that

the bigger the slip ratio, the
shorter the life. In addition,
the value of increases with
the slip ratio.

It can be

concluded that the bigger the

slip ratio, the larger the
dispersion of the competing
lives.
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Result & Disc.

Competing failure mechanism under rolling-sliding contact:

Subsurface shear stresses:

The peak values of MSS
under

different

conditions

all

contact
located

inside the coating. Both of

the peak value and the
distance of the peak value
position

from

coating/substrate interface
slightly increased with the
slip ratios increasing.
15

Result & Disc.

Surface abrasion:

Slip ratio R2 = 25% :

16

Result & Disc.

Slip ratio R3 = 50% :

It can be concluded that the formation of abrasive particles is associated with adhesion,
collision, and plastic deformation in the contact region. Therefore, furrows would be
generated under the plowing effect caused by abrasive particles between the rollers

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Result & Disc.

Slip ratio R4 = 75% :

The damaged surface with a large area of surface material removal was more serious. In
addition, microcracks occurred on the failed surface Fig. Under high slip ratio, the high
MSS on the coating promoted the initiation and propagation of microcracks.

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Result & Disc.

It can be seen from the fig.

that an interfacial crack had

initiated and propagated at the
interface under the wear scar. It
can

be

delamination

concluded
between

that
the

coating and substrate would

occur if the test continues.

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Introduction
Result & Disc.

The oil film parameter which can be calculated by Eq. given below is a commonly
used characteristic parameter to characterize the lubricant state between the rollers.
The relationship between the ratio and lubrication state is shown in table below.
=

20

Result & Disc.

Transition

21

of lubrication state

Result & Disc.

Delamination:

The

delamination failure exhibited common characteristics as follows:

(1) The delamination failure area was relatively large

(2) Delamination happened at the interface between the coating and substrate
(3) Cliff edge with a few of micro cracks was generated

R2=25%, N=3.06 X 104

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Introduction
Result & Disc.

R3=50%, N=2.38 X 104

R4=75%, N=2.15 X 104

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Introduction
Result & Disc.

It can be seen from Fig. that the delamination failure tended to occurrence at the
interface between the coating and substrate, which was mainly due to the initiation and
propagation of interfacial crack. The interlayer crack between the AT40 coating and bonding
coating also can be observed in Fig. It is obvious that the crucial reason of delamination
failure was the initiation and propagation of interfacial crack but not the interlayer crack.

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Introduction
Result & Disc.

The

variation

of

coating

thickness during different test

stages under various slip ratios
were investigated by SEM, as
shown in Fig. The increase of
slip ratio could accelerate the
thinning process.

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Introduction
Result & Disc.

The

variation

of

coating

thickness could influence the

MSS as shown in fig.

With the slip ratio increasing,

the position of MSS peak
value moved away from the
coating surface because of the
thinning effect. Namely, the
MSS at the interface would
increase, which induced the
adhesive delamination failure .
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Introduction
Result & Disc.

Competing failure mechanism betn surface abrasion & delamination :

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Introduction
Result & Disc.

Conclusion
The

evolution laws of competing lives of AT40 coatings under different slip ratios can be

characterized by Weibull curves. Moreover, the bigger the slip ratio, the larger the dispersion
of the competing lives.
The

failure modes of AT40 coatings in rolling-sliding contact condition were mainly surface

abrasion and adhesive delamination. The probability of delamination failure increased

with the slip ratio increasing.
The

sliding abrasion on the AT40 coating in rolling-sliding contact condition could

accelerate the adhesive delamination failure because of : (1) MSS at the interface, act as a
main driving force of adhesive delamination increased sharply under the effect of thinning
process of coating thickness due to surface abrasion. (2) Brittle fracture caused due to surface
abrasion could induce the initiation of vertical cracks, leads adhesive delamination failure.

So, the life of a coating can be predicted by Weibull probability density function.
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Reference
[1] Jia-jie Kang et al, Competing failure mechanism and life prediction of plasma sprayed
composite ceramic coating in rollingsliding contact condition, Tribology International
73 (2014) 128137.

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