Microstructure and Wear Behavior of Cermet/Iron Alloy Cladding Layers on A6061 Alloy Coated by Resistance Seam Welding Method

doi:10.1007/s40195-015-0210-3

Abstract

Abstract:

Cermet/iron alloy cladding layers were coated on the surface of Al-Mg-Si alloy (A6061) plates by resistance seam welding method with tungsten carbide (WC) and high-carbon iron alloy (SHA) powders. The cladding layer consisted of WC reinforcement, SHA binder, A6061 and FeAl₃. The effect of WC ratio (30 wt%, 50 wt% and 70 wt%) on the microstructure and wear behavior of the cladding layers was investigated in detail. Abrasive wear test was performed under two kinds of load condition by using a rubber wheel apparatus to evaluate wear resistance. The results showed that the wear resistance of the cladding layer was improved by 3.5-5 times than that of the substrate. At lower load, the wear resistances of the samples 30% and 70% WC were nearly the same, which suggested that FeAl₃ played an important role in improvement of the wear resistance instead of WC. While at higher load, the amount of WC determined the wear resistance of the cladding layer. Furthermore, wear behavior of these cladding layers was explained with reference to the observed microstructure of the worn surface.

Key words: Resistance seam welding, A6061, WC, Cladding layer, Wear resistance

Wen-Qin Wang, Tomiko Yamaguchi, Kazumasa Nishio. Microstructure and Wear Behavior of Cermet/Iron Alloy Cladding Layers on A6061 Alloy Coated by Resistance Seam Welding Method[J]. Acta Metallurgica Sinica (English Letters), 2015, 28(4): 414-423.

Figures/Tables 15

Fig. 1 SEM images of the premixed precursor powders: a WC, b SHA

Table 1 Chemical composition of SHA powders (wt%)

Fe	Cr	C	Mo	Ni	Si
Bal.	9.84	4.99	4.92	4.83	0.99

Fig. 2 a Schematic diagram of the sample b resistance seam welding method

Table 2 Conditions of resistance seam welding

Welding speed (m/min)	Electrode force (N)	Welding current (kA)
0.5	98	3.0

Fig. 3 a Schematic diagram of the rubber wheel test, b schematic diagram of specimen for rubber wheel test, c measurement of the abrasion depth

Fig. 4 SEM images of the cladding layers on the cross section: a 30%WC, b 50%WC, c 70%WC, d, e, f enlarged view near surface region in a, b, c, respectively

Fig. 5 EPMA mapping images of the sample consisting of 50% WC at near surface region

Fig. 6 XRD analysis results of the sample consisting of 50% WC

Fig. 7 EPMA mapping images of the sample consisting of 50% WC at near bottom region

Table 3 Abrasion depth of the substrate and samples tested at different loads

Load (N)	Abrasion depth (µm)
Load (N)	A6061	30% WC	50% WC	70% WC
3.64	216	46	61	45
23.5	804	230	224	199

Fig. 8 Abrasion depth of substrate and samples at different loads

Table 4 Average roughness (μm) of the cladding layer before and after wear test

Sample	Before wear test	Load (3.64 N)	Load (23.5 N)
30% WC	0.78	2.92	2.98
50% WC	1.14	3.06	3.24
70% WC	1.18	3.09	3.60

Fig. 9 SEM images, reconstructed 3D-SEM image and corresponding height profile: a surface before wear test in the sample consisting of 70% WC, b surface after wear test in sample consisting of 30% WC, c surface after wear test in sample consisting of 70% WC

Fig. 10 SEM images of the worn surfaces of different components in the sample consisting of 70% WC SHA at load of 3.64 N: a low magnification image, b SHA and FeAl3, c junction of FeAl3 and SHA, d WC, e delamination area, f enlarged view in e

Table 5 Results of EDS analysis in Fig. 9e, f (wt%)

Element	C	Al	W	Fe	Ni	Cr
Point 1	5.18	54.57	30.00	6.98	1.15	2.13
Point 2	5.62	1.01	93.3	0.06	0.00	0.00

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