Effect of abrasive particle sizes on abrasive wear of ceramic coatings sprayed by plasma process

Abstract

This study examines the effects of abrasive grain size on abrasive wear behaviors on surfaces coated with different types of ceramics. To this end, the surface of AISI 1040 steel was is coated with the ceramic materials of 5% SiO₂– 3% TiO₂– 92% Cr₂O₃, 60% Al₂O₃– 40% TiO₂, pure Al₂O₃ and 87% Al₂O₃– 13% TiO₂ using the plasma method. Following the coating process, the abrasive wear resistance of each sample is tested by the ring-on-disc method. 80–220 mesh SiC abrasive paper is used as abrasive. The best wear resistance was is obtained with the ceramic coating containing 92% Cr₂O₃, which was is followed by pure Al₂O₃ and 87% Al₂O₃– 13% TiO₂, respectively. The lowest wear resistance was is observed in 60% Al₂O₃– 40% TiO₂ ceramic coating. Wear resistance of the samples increasesd with increasing hardness value and decreasing abrasive grain size. It is observed that wear mechanisms occurring on the samples’ wear surfaces changed with changing abrasive grain size. Wear mechanisms such as microscratching, microcracking, and plastic deformation were are observed in the samples.