This manuscript deals with the cavitation erosion resistance of low-velocity oxy-flame (LVOF) sprayed Al2O3–40%TiO2/NiMoAl cermet coatings, a new functional application of cermet coatings. The aim of the study was to investigate the cavitation erosion mechanism and determine the effect of feedstock powder ratio (Al2O3–TiO2/NiMoAl) of LOVF cermet coatings on their cavitation erosion resistance. As-sprayed coatings were investigated for roughness, porosity, hardness, Young’s modulus. Microstructural characteristics of the cross-section and the surface of as-sprayed coatings were examined by light optical microscopy (LOM) and scanning electron microscopy (SEM) equipped with the EDS and XRD methods. Coatings cavitation tests were conducted in accordance with the ASTM G32 standard with usage of reference samples made from steel, copper and aluminum alloys. Cavitation erosion resistance was measured by weight and volume loss, and normalised cavitation erosion resistance was calculated. Surface eroded due to cavitation was examined in successive time intervals by LOM and SEM-EDS. On the basis of coating properties and cavitation investigations, a phenomenological model of the cavitation erosion of Al2O3–40%TiO2/NiMoAl cermet coatings was elaborated. General relationships between their properties, microstructure and cavitation wear resistance were established. The Al2O3–40%TiO2/NiAlMo composite coating containing 80% of ceramic powder has a higher cavitation erosion resistance than the reference aluminium alloy.

Literature review indicates that the basic microstructure of Ti-6Al-4V is bimodal which consist of two phases: α + β, and it occurs after the fabrication in conventional methods such as casting, plastic forming or machining processes. After the additive manufacturing methods, there could be significant changes in the microstructure. Due to the rapid heat exchange during heat-treatment process, bimodal microstructure transforms into lamellar microstructure which consists of two phases α′ + β. Despite applying optimum printing parameters, 3D-printed products exhibit typical surface defects and discontinuities. Recently, two of the primary technologies for the improvement of surface layer properties of titanium alloys are shot peening and electropolishing. Literature review signalizes that shot peening and electropolishing processes have positive impact on the corrosion behaviour, mechanical properties and the condition of the surface layer of titanium alloy. Furthermore, there is a lack of studies about combining shot peening and electropolishing in one hybrid process on titanium alloys, which could synthesize the benefits of both processes. The scope of future investigation is also included in this review.

The tribological performance of metalwork steel tools is of vital importance in both cold and hot working processes. One solution for improving metal tool life is the application of coatings. This paper investigates the effect of CrAlSiN thin-film PVD-deposition on the tribological behaviour of tool steel K340. The sliding wear performance of the coated K340 steel is analysed in relation to both the uncoated K340 steel and a range of tool steels dedicated to hot- and cold-working, such as X155CrVMo12-1, X37CrMoV5-1, X40CrMoV5-1, 40CrMnMo7 and 90MnCrV8. The investigated tool steels were heat-treated, while K340 was subjected to thermochemical treatment and then coated with a CrAlSiN hard film (K340/CrAlSiN). The hardness, chemical composition, phase structure and microstructure of steels K340 and K340/CrAlSiN are examined. Tribological tests were conducted using the ball-on-disc tester in compliance with the ASTM G99 standard. The tests were performed under dry unidirectional sliding conditions, using an Al2O3 ball as a counterbody. The wear factor and coefficient of friction are estimated and analysed with respect to hardness and alloying composition of the materials under study. SEM observations are made to identify the sliding wear mechanisms of the analysed tool steels and PVD-coated K340 steel. In contrast to the harsh abrasive-adhesive wear mechanism observed for uncoated tool steels, the abrasive wear dominates in case of the AlCrSiN. The deposited thin film effectively prevents the K304 substrate from harsh wear severe degradation. Moreover, thanks to the deposited coating, the K304/CrAlSiN sample has a COF of 0.529 and a wear factor of K=5.68×10−7 m3 N−1 m−1, while the COF of the reference tool steels ranges from 0.702 to 0.885 and their wear factor ranges from 1.68×10−5 m3 N−1 m−1 to 3.67×10−5 m3 N−1 m−1. The CrAlSiN deposition reduces the wear of the K340 steel and improves its sliding properties, which makes it a promising method for prolonging the service life of metalwork tools.

The study presents the effect of annealing process parameters on the microstructure, hardness and strain hardening coefficients i.e., the strength coefficient c and the strain hardening exponent n, of 42CrMo4 steel. Seven selected annealing time-temperature schemes are examined for superior steel formability in cold metal forming conditions. The c and n coefficients are first determined in experimental upsetting of annealed samples and then used in FEM simulations of the upsetting process. The results demonstrate that the strain hardening coefficients (c and n) depend on the employed annealing scheme. Compared to the as-received sample, the annealing process reduces the true stress and effectively decrease the hardness of 42CrMo4 steel, improves microstructural spheroidization and, consequently, facilitates deformability of this material. The annealing schemes relying on heating the material to 750 °C and its subsequent slow cooling lead to the highest decrease in hardness ranging from 162 to 168HV. Results obtained with the SEM-EDS, LOM and XRD methods lead to the conclusion that the employed heat treatment schemes cause the initial ferritic-pearlitic microstructure to develop granular and semi-lamellar precipitation of cementite enriched with Mo and Cr in the ferrite matrix. In addition, the annealing process affects the growth of α-Fe grains. The highest cold hardening rate, and thus formability, is obtained for the annealing scheme producing the lowest hardness. The results of FEM simulations are positively validated by experimental results. Obtained results are crucial for further numerical simulations and experimental research connected with developing new cold metal forming methods for producing parts made of 42CrMo4 steel.

Stainless steel grade AISI 304 is one of the most widespread modern structural material, alas its sliding wear and cavitation wear resistance are limited. Thus, AlTiN and TiAlN coatings can be deposited for increasing the resistance to wear of stainless steel components. The aim of the work was to investigate the cavitation erosion and sliding wear mechanisms of magnetron sputtered AlTiN and TiAlN coatings deposited on SS304 stainless steel. Films surface morphology and structure were examined using a profilometer, light optical microscope (LOM) and scanning electron microscope (SEM). The mechanical properties (hardness, elastic modulus) were tested by nanoindentation tester. The adhesion of deposited coatings was determined by means of the scratch test and Rockwell test. Cavitation erosion tests were performed according to ASTM G32 (vibratory apparatus) with stationary specimen procedure. Sliding wear tests were conducted using a nano-tribo testes i.e. ball-on-disc apparatus. Wear mechanisms are strongly contingent upon the structure and morphology of the tested materials. In relation to stainless steel substrate, the PVD films present a superior resistance to sliding wear and cavitation erosion. Higher resistance was noticed for AlTiN than for TiAlN film, mainly due to its superior hardness and elastic modulus. Cavitation erosion mechanism of both, AlTiN and AlTiN coatings is prone to embrittlement, imputable to fatigue processes that result in coating rupture and spallation that consist in coating fragmentation, formation of pits and finally detachment from the substrate. Additionally, films nanoindentation results measured before and after cavitation testing indicate changes in coatings structure, that acknowledged wear mechanism that starts with coating internal delamination in flake spallation mode. In contrary to PVD coatings, steel substrate is characterized by developed cavitation erosion wear with roughened surface and plastically deformed, semi-brittle, eroded surface. Sliding wear of thin films is based on micro-ploughing mechanism. For stainless steel adhesive sliding wear mode and plastic deformation with smearing, material transfer and grooving were observed. It was confirmed that various fluid machinery components made from austenitic stainless steel that undergo cavitation erosion, can be prevented by deposition of AlTiN and TiAlN films.

The study aims to elaborate a neural model and algorithm for optimising hardness and porosity of coatings and thus ensure that they have superior cavitation erosion resistance. Al2O3-13wt.%TiO2 ceramic coatings were deposited onto 316L stainless steel by atmospheric plasma spray (ASP). The coatings were prepared with different values of two spray process parameters: the stand-off distance and torch velocity. Microstructure, porosity and microhardness of the coatings were examined. Cavitation erosion tests were conducted in compliance with the ASTM G32 standard. Artificial neural networks (ANN) were employed to elaborate the model, and the multi-objectives genetic algorithm (MOGA) was used to optimise both properties and cavitation erosion resistance of the coatings. Results were analysed with Matlab software by Neural Network Toolbox and Global Optimization Toolbox. The fusion of artificial intelligence methods (ANN+MOGA) is essential for future selection of thermal spray process parameters, especially for the design of ceramic coatings with specified functional properties. Selection of these parameters is a multicriteria decision problem. The proposed method made it possible to find a Pareto front, i.e. trade-offs between several conflicting objectives – maximising the hardness and cavitation erosion resistance of Al2O3-13%TiO2 coatings and, at the same time, minimizing their porosity.

From the wide range of engineering materials traditional Stellite 6 alloy exhibits excellent cavitation erosion (CE) resistance. In this work, the effect of nitrogen ion implantation of HIPed Stellite 6 on the improvement of CE resistance and both cobalt-rich matrix phase transformation due to nitrogen implantation and CE were stated. The CE resistance of stellites ion-implanted by 120 keV N+ ions two fluences: 5x1016 cm-2 and 1x1017 cm-2 were comparatively analysed with the unimplanted stellite and AISI 304 stainless steel. CE tests were conducted according to ASTM G32 with stationary specimen method. Erosion rate curves and mean depth of erosion confirm that the nitrogen implanted HIPed Stellite 6 two times exceeds the resistance to CE than unimplanted stellite, and has almost 10 times higher CE reference than stainless steel. The X-ray diffraction (XRD) confirms that HIPed Stellite 6 nitrogen ion implantation favours transformation of the ɛ(hcp) to γ(fcc) structure. Unimplanted stellite ɛ-rich matirx is less prone to plastic deformation than γ and consequently, increase of γ phase effectively holds carbides in cobalt matrix and prevents Cr7C3 debonding. This phenomenon elongates three times the CE incubation stage, slows erosion rate and mitigates the material loss. Metastable γ structure formed by ion implantation consumes the cavitation load for work-hardening and γ → ɛ martensitic transformation. In further CE stages, phases transform as for unimplanted alloy namely, the cavitation-inducted recovery process, removal of strain, dislocations resulting in increase of fcc phase. The CE mechanism was investigated using a surface profilometer, atomic force microscopy, SEM-EDS and XRD. HIPed Stellite 6 wear behaviour relies on the plastic deformation of cobalt matrix, starting at Cr7C3/matrix interfaces. Once the Cr7C3 losing their restrain, are debonding and removed. Carbides detachment creates cavitation pits which initiate cracks propagation through cobalt matrix, the loss of matrix phase and CE proceeds with a detachment of massive chunk of materials.

Post-mortem characterisation is a pivotal tool to trace back to the origin of structural failures in modern engineering analyses. This work presents a comparison of both the crack propagation profiles and the rupture roughness profiles based on areal parameters for total fracture area. Notched and smooth samples made of weather-resistant structural steel (10HNAP), popular S355J2 structural steel and aluminium alloy AA2017A under bending, torsion, and combined bending-torsion are investigated. After the fatigue tests, fatigue fractures are measured with an optical profilometer, and the relevant surface parameters are critically compared. The results show a great impact of the loading scenario on both the local profiles and the total fracture areas. In this work, the results of both approaches (local and total fracture zones) for specimens with different geometries are investigated. For all specimens, measured texture parameters decreased in the following order: total area, rupture area, and propagation area.

17-4PH steel is a widely used grade for precipitation hardening. The growing demand for modern materials with high corrosion and tribological resistance has led to its increased use for the production of medical devices. With additive manufacturing (AM), complex functional shapes can be achieved for medical applications. Direct laser metal sintering (DMLS) technology makes it possible to obtain products with complex architectures, but it also faces various challenges, including imperfections in the surface layer of products due to the use of 3D printing technology itself. This study analyzed the abrasive wear resistance in 0.9% NaCl solution of 17-4PH steel produced by DMLS technology. In order to improve the properties of the surface layer after 3D printing and to improve the tribological wear resistance of the steel, a shot peening (SP) process using CrNi shot and ceramic beads (based on ZrO2) was applied. The chemical and phase composition of the materials obtained, Vickers hardness, surface roughness, and microscopic and SEM imaging were investigated. Tribological tests were carried out using the ball-on-disc method, and the surfaces that showed traces of abrasion to identify wear mechanisms were subjected to SEM analysis. The chemical composition was in accordance with the EOS manufacturer's declarations, and the presence of austenite and martensite was found in the post-production state, while a higher content of martensitic phase was found in the case of peened samples due to phase transformations. The surface hardness of the peened samples increased more than twice, and the post-treatment roughness increased by 12.8% after peening CrNi steels and decreased by 7.8% after peening ZrO2 relative to reference surfaces. Roughness has an identifiable effect on sliding wear resistance. Higher roughness promotes material loss. After the SP process, the coefficient of friction increased by 15.5% and 20.7%, while the wear factor (K) decreased by 25.9% and 32.7% for the samples peened with CrNi steels and ZrO2, respectively. Abrasive and adhesive mechanism were dominant featured with slight fatigue. The investigation showed a positive effect of SP on the tribological properties of DMSL 17-4PH.