Faculty Publications
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Item Developing partially oxidized NiCr coatings using the combined flame spray and plasma spray process for improved wear behaviour at high temperature(Elsevier Ltd, 2021) Medabalimi, S.R.; Ramesh, M.R.; Kadoli, R.The powders of NiCrBSiFe and NiCr are partially oxidized using a flame spray process and are deposited on MDN321 steel substrate using a plasma spray process. The effect of partial oxidization on microstructure, microhardness, density, bond strength, and porosity of the coatings is analyzed. The friction and wear behaviour of the coatings was assessed using a pin-on-disc tribometer by varying loads (10, 20 and 30 N), sliding velocities (1, 2 m/s) and temperatures (RT, 200, 400 and 600 °C). Worn surfaces of NiCrBSiFe and NiCr coatings consist of oxide phases of SiO2, NiO, Cr2O3 and NiCr2O4 at elevated temperatures. These phases contributed to reducing the wear rate by five folds in coated steels compared to uncoated steels at 600 °C. The wear rate in coating decreases with an increase in temperature. The coefficient of friction was reduced gradually with the temperature in coatings and substrate. The wear rate coefficient of NiCr coating was 1.7 times higher than the NiCrBSiFe coating. © 2021 Elsevier B.V.Item High temperature erosion performance of NiCrAlY/Cr2O3/YSZ plasma spray coatings(Taylor and Francis Ltd., 2023) Reddy, G.M.S.; Prasad, C.D.; Patil, P.; Shetty, G.; Naresh, N.; Ramesh, M.R.The current investigation's objective was to assess the air jet erosion tester's ability to measure the erosive behaviour of plasma sprayed coatings on titanium-15 alloy. 65% NiCrAlY, 30% Cr2O3, and 5% YSZ make up the coating's chemical composition. A study of microstructure and phases was carried out. Microhardness and adhesive strength have both been measured in this work. With impact angles of 30° and 90° at 300°C, 500°C, and 700°C, Al2O3 erodent was utilised in a solid particle erosion test. An optical profilometer was used to calculate the erosion volume loss. The coating erosion resistance was found to be higher than the substrate sample for the test temperature that was employed, and this was more obvious at higher impact angles and higher temperatures The ductile character of the coating is seen in the contour of the deteriorated coating surface. © 2023 Institute of Materials Finishing Published by Taylor & Francis on behalf of the Institute.Item Effect of Microwave Hybrid Heating on High-Temperature Adhesive Wear Behavior of High-Velocity Oxygen Fuel-Sprayed WC-CrC-Ni and WC-Co/NiCrFeSiB Coatings(Springer, 2023) Medabalimi, S.; Ananthu, M.R.; Gudala, S.; Ramesh, M.R.HVOF-processed coatings are chemically inhomogeneous and are not metallurgically bonded to the substrate. As a result, components coated with HVOF experience considerable material degradation during sliding wear. Microwave hybrid heating (MHH) is a novel surface modification technique for modifying the as-sprayed properties of the coating. Hence, this paper investigates and compares the wear and frictional behavior of HVOF as-sprayed coatings against MHH samples of WC-CrC-Ni and WC-Co/NiCrFeSiB coatings at elevated temperatures. MHH had a significant impact on wear rate and coefficient of friction by optimizing the porosity, integrated oxide phases and intersplat cohesion strength of the coatings. A modified domestic oven was used to perform MHH on HVOF-coated samples for 5 min at 1200 °C. Wear tests were performed using a pin-on-disk tribometer from room temperature to 200, 400, and 600 °C with Al2O3 disk as a counterface. SEM/EDS and XRD were utilized to examine the microstructural characterization of the coatings and substrate. Both the coatings showed higher wear resistance than the substrate at all temperatures. The WC-Co/NiCrFeSiB coating produced an oxide layer on the worn surfaces and integrated WC, CoWO4, and Fe2SiO4 splats, enhancing wear resistance. The MHH WC-CrC-Ni coating formed Cr2O3 and NiWO4 phases on the worn surfaces, increasing the intersplat cohesion strength between matrix and carbide splats, lowering the overall wear rate. After MHH, the wear rate of a substrate and WC-CrC-Ni coating was 3.5 and 1.12 times more at room temperature and 8.07 and 2.92 times more at 600 °C than WC-Co/NiCrFeSiB coating. © 2022, ASM International.Item Investigation of the effect of NiCrAlY/Cr2O3/YSZ plasma coatings on erosion performance of MDN 420 steel at high temperature(Inderscience Publishers, 2023) Reddy, G.M.S.; Prasad, C.D.; Patil, P.; Shetty, G.K.; Kakur, N.; Ramesh, M.R.The purpose of the current study was to use an air jet erosion tester to examine the erosive behaviour of plasma sprayed coatings on MDN-420 that were composed of 70% NiCrAlY, 25% Cr2O3, and 5% YSZ. Microstructure and phase studies were performed. Measurements were made on the microhardness and adhesion strength. Al2O3 erodent was used in a solid particle erosion test with impact angles of 30° and 90° at 300°C, 500°C, and 700°C. The erosion volume loss was measured using an optical profilometer. For the test temperature used, it was found that the coating’s erosion resistance was greater than that of the substrate and that it was more pronounced at higher impact angles and higher temperatures. The shape of the degraded coating surface reflects the coating’s ductile nature. © © 2023 Inderscience Enterprises Ltd.Item Effect of temperature on wear and friction performance of WC-Co and Cr3C2 reinforced with 17-4PH Fe-based composite coatings(Springer Science and Business Media Deutschland GmbH, 2024) Chandramouli, T.V.; Joladarashi, S.; Ramesh, M.R.; Rahman, M.R.Surface protection is crucial in industrial equipment and tools to prevent wear and friction in harsh environments, particularly at high temperatures, where anti-friction coatings are essential for optimal performance. The present research investigates the tribological properties of high-velocity oxy-fuel sprayed coatings of 17-4PH stainless steel reinforced with tungsten carbide and chromium carbide powders. The coatings are deposited onto a maraging steel substrate. A dry sliding wear test was performed using an alumina ball as a counter body under various test temperatures (25 °C, 300 °C, and 600 °C) and loads (10 N and 30 N). The coating is characterized by employing SEM, XRD, micro-hardness tester, particle analyzer, and bond strength tester, and the mechanism of wear reduction was discussed. The post-wear analysis was carried out on the wear track using SEM/EDS and 3D non-contact optical profilometers. The micro-hardness and bond strength of both (17-4PH-30%WC-Co and 17-4PH-30%Cr3C2) coatings are compared. The test results revealed that at all temperatures and loads, 17-4PH-30%WC-Co coating shows better wear resistance and lower friction coefficient than the 17-4PH-30%Cr3C2 coating. The significant influence of the tribo-oxide layer at high temperatures, which contributed to decreasing wear rate and coefficient of friction, was premeditated. © 2023, International Institute of Welding.Item An investigation on tribological performance in HVOF sprayed of Amdry1371 and Amdry 1371/WC-Co coatings on Ti6Al4V(Elsevier B.V., 2024) Behera, N.; Srihari, M.; Sharma, Y.K.; Ramesh, M.R.This study investigates the effect of 30 wt% WC addition into Mo-based coating on the microstructure and dry sliding wear performance at elevated temperatures. A ball-on disk tribometer assessed coating wear and friction behavior at room temperature (RT), 300, and 600 °C with loads of 10 and 20 N. The wear rate and mechanism were assessed using SEM-EDX and an optical profilometer. The coating characteristics included density, porosity, surface roughness, microstructure, and microhardness. The bond strength of Amdry1371 and Amdry1371/30%WC-Co coatings is analyzed using the scratch test. During the scratch test, both coatings show cohesive failure at 30-50 N and cohesive along with adhesive failure at 70 N loads. Compared to Amdry1371 coating, Amdry1371/30%WC-Co coating has greater microhardness and bond strength. The wear rate and friction coefficients of Amdry1371 and Amdry1371/30%WC-Co coatings increase with temperatures up to 300 °C and decrease at 600 °C. Wear debris is generated when contact surfaces fracture under the applied load, acting as a third body in the sliding process. This phenomenon, observable from room temperature to 300 °C, increases wear rate and friction coefficients. Protective oxide phases formed on worn surfaces like MoO3, NiMO4, CoWO4, Cr3O8, and WO3 film at 600 °C. This glaze layer is present on worn surfaces, significantly reducing friction coefficients and the wear rate of coatings. Amdry1371/30%WC-Co coating exhibits superior wear resistance and lower friction coefficients than Amdry1371 coating due to MoO3 and WO3. At RT, the dominant abrasive wear mechanism shifts to oxidative wear at 600 °C for both coatings. © 2024 Elsevier B.V.Item 4D printing of heat-stimulated shape memory polymer composite for high-temperature smart structures/actuators applications(John Wiley and Sons Inc, 2024) Kumar, S.; Ojha, N.; Ramesh, M.R.; Doddamani, M.High temperature shape memory polymers (HT-SMPs) have great utilization in self-deployable hinges/morphing structures for space/aerospace, and high-temperature sensors/actuators for electronics. However, HT-SMPs have many drawbacks, such as low stiffness, strength, thermal stability, and dynamic mechanical properties. This work aims at improving these properties of highly utilized space grade HT-SMP, PEKK (polyether ketone ketone), by reinforcing it with low-cost carbon fibers (CFs), and developing its composite via additive manufacturing. The additively manufactured CF/PEKK composites are annealed at 200 °C (CF/PEKK-A200) and 250 °C (CF/PEKK-A250), and for the first time, investigated for shape memory effect (SME). The shape fixity and the shape recovery of the CF/PEKK-UNA (un-annealed), CF/PEKK-A200, and CF/PEKK-A250 are noted to be 95.97%, 88.95%, and 86.40%, and 88.70%, 92.70%, and 95.19%, respectively with a significant weight saving potential of ?21%. Dispersion of CFs in PEKK and suitability of processing parameters (blending, extrusion, and 3D printing) are confirmed through scanning electron microscopy (SEM). Thermal degradation temperature ((Formula presented.)) of the printed CF/PEKK composite (?568 °C) is found to be ?3.5% higher than PEKK (?549 °C). CF/PEKK-A250 exhibited the highest storage modulus (4438.23 MPa), ~158% higher than PEKK (1722.3 MPa), while CF/PEKK-A200 demonstrated the highest tensile modulus (10.9 GPa), which is 138.5% higher than PEKK (4.57 GPa) and 312.88% higher than CF/PEKK-UNA (2.64 GPa). Moreover, CF/PEKK-A200 exhibited 237.46%, 138.51%, 127.08%, 61.48%, 32.93%, and 50.35% higher tensile modulus than PEEK, PEKK, PEK, CF/PEK, CF/PEEK, and CF/PEKK composites, respectively, showing great potential to replace them. Highlights: Printed CF/PEKK composites are investigated for shape memory behavior. The printed composites exhibited outstanding shape memory properties. Printed-A200 exhibited 138.51% enhanced tensile modulus than pure PEKK. Also, the printed-A200 showed 313% enhanced modulus than printed-UNA. (Formula presented.) (568 °C) of the printed composites is found ?4% greater than pure PEKK. © 2024 Society of Plastics Engineers.Item Establishing high temperature tribological performance and wear mechanism map of engineered in-situ TiB2 reinforced Mg-RE metal matrix composites(Elsevier Ltd, 2025) Sahoo, S.K.; Ramesh, M.R.; Panigrahi, S.K.The high temperature sliding wear behavior of microstructurally engineering in-situ sub-micron sized TiB2 reinforced ZE41 composite was studied and compared with it's base counterpart at varying loading conditions. The wear mechanism maps were constructed by correlating the microstructures of worn surfaces with different test parameters. The severe and catastrophic wear mechanisms like delamination and melt wear were wider in base and composite, while in the case of engineered composite, these zones are significantly narrow down. Due to the presence of thermally stable in-situ TiB2 particles and bimodal precipitates in engineered composite, the material showed sufficient resistance against wear induced deformation. Furthermore, the study established scientific knowhow on high-temperature wear induced deformation behavior by analyzing microstructural evolution in wear subsurface zone. © 2024Item Microstructure, Mechanical, and Dry Sliding Wear Performance of Equimolar CoCrNiTiMo and CoCrNiTiW High-Entropy Alloy Coatings(Springer, 2025) Addepalli, S.N.; Joladarashi, S.; Ramesh, M.R.In the present investigation, mechanical alloyed CoCrNiTiMo and CoCrNiTiW equimolar HEA powders were employed as feedstock in the development of dense coatings using high-velocity oxy-fuel technique. The dry sliding wear behavior of uncoated substrate and high-entropy alloy (HEA) coatings were extensively investigated at different temperatures and loads using a pin-on-disk tribometer. The microstructures and phases of the mechanical alloyed powders, deposited coatings, and worn surfaces were thoroughly studied. The mechanical alloyed CoCrNiTiMo and CoCrNiTiW HEAs demonstrated the evolution of two BCC solid solutions. However, the deposited coatings reported the formation of additional phases, including Co3Ti intermetallic and NiTiO3 spinel. The microstructural analysis of CoCrNiTiMo and CoCrNiTiW coatings unveiled a compact lamellar structure characterized by robust mechanical interlocking to the substrate. The CoCrNiTiMo and CoCrNiTiW HEA coatings displayed porosities of 1.12 ± 0.05% and 1.39 ± 0.03%, respectively. Additionally, the microhardness assessments revealed superior values for CoCrNiTiMo and CoCrNiTiW HEA coatings, measuring at 927 ± 45 HV0.3 and 951 ± 38 HV0.3, correspondingly. The wear rate of CoCrNiTiMo HEA coating dropped by 70.5%, from 17.34 ± 2.8 × 10?6 mm3/N-m to 5.1 ± 1.6 × 10?6 mm3/N-m with an increment in the wear testing temperature from ambient to 600 °C. Concurrently, the CoCrNiTiW coating experienced a 76.3% drop in the wear rates from 15.8 ± 3.7 × 10?6 mm3/N-m to 3.73 ± 2.1 × 10?6 mm3/N-m. The significant fall in the wear rates at higher temperatures was accredited to the development of oxide tribofilms. CoCrNiTiMo exhibited discernible oxide phases, including CoMoO4, TiO2, and NiO. In contrast, its counterpart, CoCrNiTiW, generated WO3, CoWO4, and TiO2 oxides at a temperature of 600 °C. The adhesive wear at RT transitioned to predominant oxidative wear with slight fatigue and abrasive wear at high temperatures. © ASM International 2025.Item Effect of molybdenum on high-temperature tribological performance in HVOF sprayed of WC-based coatings on superni-76(SAGE Publications Ltd, 2025) Behera, N.; Sarmah, P.; Chandramouli, T.V.; Ramesh, M.R.This study examines the effects of Mo on the high-temperature wear and friction behavior of HVOF-sprayed 70%WC-Co/25%Mo/5%C and 70%WC-CrC-Ni/30%Mo coatings on Superni-76. The ball-on-disc tribometer wear tests were conducted at different temperatures (300°C and 600°C) and loads (10 and 30?N) against counter body Al2O3 ball. Microstructures and phase formation were investigated using SEM/EDS and XRD. The characterization of coating microhardness, surface roughness, and coating density was examined. The 70%WC-Co/25%Mo/5%C coating showed lower surface roughness and higher microhardness values than the 70%WC-CrC-Ni/30%Mo coating. The wear rate of the substrate increases with an increase in temperature, whereas 70%WC-Co/25%Mo/5%C and 70%WC-CrC-Ni/30%Mo coatings decrease with temperature from 300°C to 600°C. The coefficient of friction of substrate and coating decreases with increasing temperatures. The worn surfaces of 70%WC-Co/25%Mo/5%C and 70%WC-CrC-Ni/30%Mo coating contain oxide phases (WO3, Cr2O5) and lubrication phases (M0.2W0.8O3, CoMoO4, and MoO3) at 600°C. These oxide phases reduced the coating wear rate and coefficient of friction at 600°C. The 70%WC-Co/25%Mo/5%C coating showed improved resistance to wear and lower friction coefficient than the substrate and 70%WC-CrC-Ni/30%Mo coating. At temperatures of 300°C, the main abrasive wear mechanism changes to oxidative wear when the temperature reaches 600°C for both coatings. © The Author(s) 2025.