Faculty Publications
Permanent URI for this communityhttps://idr.nitk.ac.in/handle/123456789/18736
Publications by NITK Faculty
Browse
18 results
Search Results
Item High-Temperature Sliding Wear Characterization Studies of AISI 316 L(N) by Surface Profilometry(Springer Science and Business Media Deutschland GmbH, 2020) Aruldev, N.; Parthasarathi, N.L.; Rajasekaran, B.; Borah, U.The major construction material in the Prototype Fast Breeder Reactor (PFBR) is AISI-type 316 L(N) austenitic stainless steel due to its good mechanical properties and compatibility with liquid sodium.Sliding wear experiments were carried out at various temperatures up to 550 ℃ at constant load (20 N) and sliding speed (0.8 m/s) using a pin-on-disc test rig as per the ASTM standard G99-05. Analysis of the test results presented that the wear increased considerably with the temperature. The characterization of worn surface topography is done by a complete profilometry study using Talysurf CLI 1000 surface profilometer. The 3D surfaces were captured both by induction mode by diamond stylus as well as non-contact high-resolution confocal point gauge having range of 3000 μm with 0.25 nm resolution was used for surface profiling. The cold-welded surfaces were analysed by the profilometer, and the geometry of the deposit on the wear track was analysed by the profilometer. The roughness parameters were correlated with the amount of wear data obtained from the experiments at various testing temperatures. As the temperature increases during the sliding wear, the material loss is presented with more furrows resulting in enhanced surface roughness values. © 2020, Springer Nature Singapore Pte Ltd.Item Hot corrosion behaviour of plasma and d-gun sprayed coatings on t91 steel used in boiler applications(Institute of Physics Publishing helen.craven@iop.org, 2020) Sundaresan, C.; Rajasekaran, B.; Govindarajan, G.; Rao, D.S.Material degradation by salt induced hot corrosion is a serious threat to Coal fired Boiler components. Corrosion resistant thermal spray coatings is a proven solution for this problem. Thiswork compares the hot corrosion behaviour of a NiCoCrAlY coating on T91 boiler steel deposited using two different thermal spray methods namely Atmospheric Plasma Spray (APS) and Detonation Gun (D-Gun) spray. The coated samples were exposed to 650C for 100 cycles (1 cycle being 1 hour holding plus 20 minutes cooling in air) in a thermal cycling furnace under a mixed deposit containing Na2SO4, K2SO4 and Fe2O3 to simulate the real time coal ash environment. The exposed coatings were examined using FESEM/EDS and XRD to analyze the extent and nature of corrosion attack. The results indicate that the D-Gun sprayed coatings provided superior corrosion resistance over their APS sprayed counterparts. NiO and Spinel oxide NiCr2O4 which offers corrosion resistance were formed in both the coatingswith the APS sprayed coatingbeing rich in the fast growing NiO which affected its corrosion performance. The enhanced corrosion resistance of the D-Gun sprayed coatings was attributed to its dense microstructure with minimal porosity and good intersplat bonding which minimized corrosion ingress. © Published under licence by IOP Publishing Ltd.Item Sliding wear behaviour of Ni-5 %Al coating deposited by detonation spray on IN718(Elsevier Ltd, 2022) Purushotham, N.; Rajasekaran, B.; Parthasarathi, N.L.; Praveen, K.; Govindarajan, G.Ni-5 %Al metallic coating was deposited on Nickel-based superalloy (IN718) specimens using the detonation spray coating (DSC) method. Detonation spraying yielded coating with extreme chemical bond strength, hardness, and less porosity. The microstructure, microhardness, and room temperature pin-on-disc sliding wear behavior of the Ni-5 %Al coating and the as-received IN718 superalloy were evaluated. Sliding wear tests were done at room temperature (25 °C), under different loading conditions (6 N and 10 N), using an alumina (Al2O3) ball-on-disk tribometer and friction coefficients were measured. The study of worn surfaces conducted by SEM indicated that both Ni-5 %Al coating and the substrate suffered significant abrasive wear with occasional adhesion and spalling of the coating. The 3D topography of the wear track was examined by a 3D non-contact profilometer, which enabled the quantification of the wear. The friction coefficient values of the tests and the wear in terms of mass loss were in good correlation. © 2022Item Comparative hot corrosion performance of APS and Detonation sprayed CoCrAlY, NiCoCrAlY and NiCr coatings on T91 boiler steel(Elsevier Ltd, 2021) Sundaresan, C.; Rajasekaran, B.; Varalakshmi, S.; Santhy, K.; Rao, D.S.; Govindarajan, G.Hot corrosion performance of Atmospheric Plasma Spray (APS) and Detonation spray (DSC) CoCrAlY, NiCoCrAlY, and NiCr coatings on T91 steel were investigated at 650 °C for 100 cycles under Na2SO4-K2SO4-Fe2O3 mixed salt deposit in ambient air. The hot corrosion resistance of DSC coatings was found to be superior to their APS counterparts. Chromia and spinel oxides provided excellent corrosion resistance while no ?-Al2O3 was observed. DSC NiCr and APS NiCoCrAlY offered the most and the least corrosion resistance, respectively. DFT calculation was performed to validate the thermodynamic stability of each oxide and identify the precise oxide formation. © 2021 Elsevier LtdItem Understanding the initial stage oxidation and microstructural evolution of detonation sprayed NiCoCrAlY bond coat using in-situ high-temperature X-ray diffraction(Elsevier Ltd, 2022) Kala, V.; Santhy, K.; Govindarajan, G.; Rajasekaran, B.This study focuses on in-situ high-temperature X-ray diffraction (HT-XRD) investigation to understand the oxidation, microstructural evolution, and recrystallization of the NiCoCrAlY bond coat. HT-XRD analysis was carried out at a constant temperature of 1423 K for 3 h in a 10−4 Pa vacuum. The formation of α-Al2O3, Cr2O3, Co3O4, and NiCr2O4 oxides and microstructural evolution, such as homogenization of phases (γ and β) during in-situ HT-XRD, has been analyzed with FE-SEM (EDS), Density Functional Theory calculations and Rietveld refinement's support. β-(Ni,Co)Al phase depletion (by 77%) was found at 1423 K during the HT-XRD; however, no TGO formation was noticed. © 2022 Elsevier LtdItem Thermal expansion of Crofer 22 APU steel used for SOFC interconnect using in-situ high temperature X-ray diffraction(Elsevier Ltd, 2023) Manjunath, N.; Santhy, K.; Rajasekaran, B.Crofer 22 APU is ferritic stainless steel extensively used as metallic interconnect material in Solid Oxide Fuel Cell (SOFC) applications. The interconnects are exposed to both oxidizing and reducing atmospheres at high temperatures. As SOFCs are operated above 700 °C, understanding the thermal expansion behavior of the interconnect material with other components (anode, cathode, electrolyte) of the fuel cells is essential. Metallic interconnects should have a matchable thermal expansion to other ceramic materials such as anode, cathode, and solid electrolyte used in SOFCs. The present study evaluates the thermal expansion of Crofer 22 APU steel from 25 to 950 °C in a controlled atmosphere (10-4 mbar pressure) using in-situ high-temperature X-ray diffraction (XRD). The XRD patterns were analyzed using the ‘High Score Plus Software’ attached to the system, and the phases were identified using the standard Crystallographic Open Database (COD). The coefficient of thermal expansion (CTE) was determined based on the change in lattice parameter/peak shift to a lower 2θ value as a function of temperature. The normal XRD data showed no oxide formation on the Crofer steel after heating until 950 °C in in-situ high-temperature conditions. The peak shift to the lower 2θ degree observed in the XRD data was due to the relaxation of residual stress upon heating. The isothermal section and phase fraction of Crofer 22 APU alloys are analyzed with the help of thermo-calc with the iron database of TCFE7. The Fe-rich bcc phase was found to be stable up to high temperatures. The major phases are the Fe-rich bcc, Cr-rich BCC, and sigma phase in the solid state. The minor phases are FCC, M3P, TiC, Laves, and Ti4C2S2. The calculated lattice parameter of the Fe-rich BCC phase matches with the experimentally calculated data using XRD. The thermal expansion of Crofer 22 APU was found to be 11.9181 × 10-6 /°C at 950 °C. The in-situ high-temperature XRD technique has been an effective methodology for determining the thermal expansion behavior of the as-received Crofer steel. © 2023Item Thermal expansion and microstructure evolution of atmospheric plasma sprayed NiCrAlY bond coat using in-situ high temperature X-ray diffraction(Elsevier B.V., 2023) Abhijith Vijay, V.; Santhy, K.; Govindarajan, G.; Rajasekaran, B.The paper focuses on in-situ high-temperature X-ray diffraction (HT-XRD) study on atmospheric plasma sprayed NiCrAlY coating. The sample was in-situ heated from 25 °C to 1150 °C in a controlled atmosphere (3 × 10−4 bar), and the corresponding X-ray diffraction patterns for different temperatures were recorded. The effect of temperature on crystallite size, lattice strain, and coefficient of linear thermal expansion was studied. Major phases identified are γ-Ni, γ’-Ni3Al, β-NiAl, and α-Cr. The formation of stable α-Al2O3 and spinel was found above 1000 °C. The transformation of β to γ’ and γ phase was observed as a function of temperature. The equilibrium phases and the thermal expansion of disordered Face Centered Cubic (FCC) and Body Centered Cubic (BCC) phases were predicted and supported by Thermo-Calc prediction for the stable temperature range. Results showed that the non-equilibrium microstructure produced by thermal spray process did not alter the thermal expansion behaviour. In-situ treatment resulted in microstructure and elemental homogenization. The thermal expansion and mechanism of phase evolution were discussed. © 2022 Elsevier B.V.Item Characterization of Plasma Sprayed Mn1.0Co1.9Fe0.1O4 Coating on Crofer 22 APU Interconnect for Solid Oxide Fuel Cell Application(Springer, 2023) Naik, M.; Rajasekaran, B.Atmospheric plasma sprayed Mn1.0Co1.9Fe0.1O4 (MCF) coating is regarded as one of the excellent materials in mitigating Cr-evaporation in Crofer 22 APU ferritic steel during high-temperature operation in solid oxide fuel cell (SOFC) conditions. In this study, MCF-coated Crofer steel has been characterized by examining the cross-section of as-sprayed coating. A network of micro-cracks and globular pores was seen in the cross-section analysis. The porosity of as-sprayed MCF coating was 10.93 ± 1.323%. XRD data revealed α-Fe as the major phase in as-received Crofer steel and CoO as the major phase in MCF coating. Micro-hardness measurements of MCF coating was 163.5 ± 1.5 HV0.1N. The measured values revealed strong metallic interlocking between the coating and substrate. Four-probe method employed on MCF coating showed a decrease in resistance as a function of temperature, indicating an increase in electrical conductivity. The spinel coating on Crofer steel was found to be beneficial for SOFC operation. © 2022, The Indian Institute of Metals - IIM.Item Effect of thermal expansion on the high temperature wear resistance of Ni-20%Cr detonation spray coating on IN718 substrate(Elsevier B.V., 2023) Purushotham, N.; Parthasarathi, N.L.; Babu, P.S.; Govindarajan, G.; Rajasekaran, B.The temperature-dependent materials properties on the dry sliding wear resistance of the detonation sprayed Ni-20%Cr coating have been studied. In-situ high-temperature X-ray diffraction (HT-XRD) was used to investigate high-temperature properties such as stress relieving, recrystallization, and thermal expansion. The dry sliding wear test was performed by using a ball-on-disc tribometer by sliding velocities (0.1 m/s), varying loads (6 N and 10 N), and temperatures (25 °C and 850 °C) against alumina (Al2O3) ball. The phase evolution, thermal expansion, crystallite size, and lattice strain were determined by the Williamson-Hall method. Field emission scanning electron microscopy and a non-contact optical profilometer was used to characterize the wear scar and calculate the wear rate. The wear test results demonstrated that the as-deposited coatings coefficient of friction (CoF) and wear rate (ω) continuously decreased as the temperature increased. The primary wear mechanism changed from abrasive and surface fatigue to adhesive and oxidative wear. The impact of stress relieving, recrystallization, and forming a composite tribolayer (Cr2O3, NiO) at elevated temperatures reduced the friction and enhanced the wear resistance. The effect of stress relieving, recrystallization, thermal expansion, and oxidation on the wear resistance of the coating has been discussed with a suitable mechanism. © 2023 Elsevier B.V.Item High Velocity Air Fuel Spraying for Metal Additive Manufacturing - A Study on Copper(Springer, 2024) Sreerag, M.P.; Vijay, V.A.; Varalakshmi, S.; Rajasekaran, B.Owing to its reflectivity, Copper manufacturing has always been challenging through laser-based additive manufacturing. In this study, we demonstrate additive/bulk manufacturing of copper using high velocity air fuel (HVAF) spray technology, an emerging variant in the thermal spray family. Rapid deposition of millimeter scale copper parts with good mechanical integrity and decent ductility, comparable to that of cold spray, has been shown feasible. The mechanical properties measured along different built directions showed no significance to be considered anisotropic. Electron backscattered diffraction analysis revealed the possibility of developing favorable bimodal grain distribution with a high volume fraction of ultrafine grains (>50%). However, the intersplat porosities and continuous pores were found to be detrimental despite the low overall porosity. HVAF technology demonstrates great potential and appears to be a promising process methodology for bulk/additive manufacturing of metals with a rapid production rate. Graphical Abstract: (Figure presented.). © ASM International 2024.