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Impact of cobalt content and grain growth inhibitors in laser-based powder bed fusion of WC-Co
(2022)
Processing of tungsten carbide‑cobalt (WC-Co) by laser-based powder bed fusion (PBF-LB) can result in characteristic microstructure defects such as cracks, pores, undesired phases and tungsten carbide (WC) grain growth, due to the heterogeneous energy input and the high thermal gradients. Besides the processing conditions, the material properties are affected by the initial powder characteristics. In this paper, the impact of powder composition on microstructure, phase formation and mechanical properties in PBF-LB of WC-Co is studied.
Powders with different cobalt contents from 12 wt.-% to 25 wt.-% are tested under variation of the laser parameters.
Furthermore, the impact of vanadium carbide (VC) and chromium (Cr) additives is investigated. Both are known as grain growth inhibitors for conventional sintering processes. The experiments are conducted at a pre-heating temperature of around 800 ◦C to prevent crack formation in the samples. Increasing laser energy input reduces porosity but leads to severe embrittlement for low cobalt content and to abnormal WC grain growth for high cobalt content. It is found that interparticular porosity at low laser energy is more severe for low cobalt content due to poor wetting of the liquid phase. Maximum bending strength of σB > 1200 MPa and Vickers hardness of approx. 1000 HV3 can be measured for samples generated from WC-Co 83/17 powder with medium laser energy input. The addition of V and Cr leads to increased formation of additional phases such as Co3W3C, Co3V and Cr23C6 and to increased lateral and multi-laminar growth of the WC grains. In contrast to conventional sintering, a grain growth inhibiting effect of V and Cr in the laser molten microstructure is not achieved.
In this study, the characteristics of HVOF sprayed WC/Co-Cr and WC/Cr3C2/Ni coatings were investigated in correlation with the variation of the powder feed rate. For this purpose, the mass flow was adjusted to four different levels. The other process parameters were all kept constant. The morphological and mechanical properties as well as the electrochemical corrosion behaviour were investigated and associated with the achieved microstructure.
Both scanning electron microscopy and confocal laser scanning microscopical images of the cross sections demonstrated a good correlation between the selected powder feed rate and the degree of internal porosity produced, which can be attributed to the deposition process. The coatings which fulfilled the requirements of the pre-qualification step were selected for further hardness measurements, tribological tests and electrochemical corrosion measurements in a 3.5 wt% NaCl aqueous solution.
It was found that the powder feed rate strongly influenced the characteristics of the HVOF-sprayed cermet coatings. The tendency to crack formation, especially at the interface coating/substrate, was lower for the samples coated with a lower mass flow rate. These studies have shown that the applied powder feed rates had an important influence on the coatings microstructure and implicitly on the sliding wear behavior respectively on the electrochemical corrosion resistance of the investigated cermet coatings.
Even though we live in a period when the word digitization is prevalent in many social areas, the COVID-19 pandemic has divided mankind into two main categories: some people have seen this crisis as an opportunity to move the activities online and, furthermore, to accelerate digitization in as many areas as possible, while others have been reluctant, keeping their preferences for face-to-face activities. The current work presents the results of an analysis on 249 students from 11 engineering faculties. The study aims to identify the impact of the COVID-19 pandemic on students’ educational experiences when switching from face-to-face to online education during a public health emergency or COVID 19-related state of alert. The overall conclusion was that, although the pandemic has brought adverse consequences on the health and life quality of many people, the challenges that humankind has been subjected to have led to personal and professional development and have opened up new perspectives for carrying out the everyday activities.
Tape brazing constitutes a cost-effective alternative surface protection technology for complex-shaped surfaces. The study explores the characteristics of high-temperature brazed coatings using a cobalt-based powder deposited on a stainless-steel substrate in order to protect parts subjected to hot temperatures in a wear-exposed environment. Microstructural imaging corroborated with x-ray diffraction analysis showed a complex phased structure consisting of intermetallic Cr-Ni, C-Co-W Laves type, and chromium carbide phases. The surface properties of the coatings, targeting hot corrosion behavior, erosion, wear resistance, and microhardness, were evaluated. The high-temperature corrosion test was performed for 100 h at 750 C in a salt mixture consisting of 25 wt.% NaCl + 75 wt.% Na2SO4. The degree of corrosion attack was closely connected with the exposure temperature, and the degradation of the material corresponding to the mechanisms of low-temperature hot corrosion. The erosion tests were carried out using alumina particles at a 90 impingement angle. The results, correlated with the microhardness measurements, have shown that Co-based coatings exhibited approximately 40% lower material loss compared to that of the steel substrate.
The printing variable least addressed in previous research aiming to reveal the effect of the FFF process parameters on the printed PLA part’s quality and properties is the filament color. Moreover, the color of the PLA, as well as its manufacturer, are rarely mentioned when the experimental conditions for the printing of the samples are described, although current existing data reveal that their influence on the final characteristics of the print should not be neglected. In order to point out the importance of this influential parameter, a natural and a black-colored PLA filament, produced by the same manufacturer, were selected. The dimensional accuracy, tensile strength, and friction properties of the samples were analyzed and compared for printing temperatures ranging from 200 C up to 240 C. The experimental results clearly showed different characteristics depending on the polymer color of samples printed under the same conditions. Therefore, the optimization of the FFF process parameters for the 3D-printing of PLA should always start with the proper selection of the type of the PLA material, regarding both its color and the fabricant.
Flame-sprayed NiCrBSi/WC-12Co composite coatings were deposited in different ratios on the surface of stainless steel. Oxyacetylene flame remelting treatment was applied to surfaces for refinement of the morphology of the layers and improvement of the coating/substrate adhesion.
The performance of the coated specimens to cavitation erosion and electrochemical corrosion was evaluated by an ultrasonic vibratory method and, respectively, by polarization measurements. The microstructure was investigated by means of scanning electron microscopy (SEM) combined with energy dispersive X-ray analysis (EDX). The obtained results demonstrated that the addition of 15 wt.% WC-12Co to the self-fluxing alloy improves the resistance to cavitation erosion (the terminal erosion rate (Vs) decreased with 15% related to that of the NiCrBSi coating) without influencing the good corrosion resistance in NaCl solution. However, a further increase in WC-Co content led to a deterioration of these coating properties (the Vs has doubled related to that of the NiCrBSi coating).
Moreover, the corrosion behavior of the latter composite coating was negatively influenced, a fact confirmed by increased values for the corrosion current density (icorr). Based on the achieved experimental results, one may summarize that NiCrBSi/WC-Co composite coatings are able to increase the life cycle of expensive, high-performance components exposed to severe cavitation conditions.
In this work, a novel polymer electrolyte membrane water electrolyzer (PEMWE) test cell based on hydraulic single-cell compression is described. In this test cell, the current density distribution is almost homogeneous over the active cell area due to hydraulic cell clamping. As the hydraulic medium entirely surrounds the active cell components, it is also used to control cell temperature resulting in even temperature distribution. The PEMWE single-cell test system based on hydraulic compression offers a 25 cm2 active surface area (5.0 × 5.0 cm) and can be operated up to 80°C and 6.0 A/cm2. Construction details and material selection for the designed test cell are given in this document. Furthermore, findings related to pressure distribution analyzed by utilizing a pressure-sensitive foil, the cell performance indicated by polarization curves, and the reproducibility of results are described. Experimental data indicate the applicability of the presented testing device for relevant PEMWE component testing and material analysis.
The present paper presents one- and two-step approaches for electrochemical Pt and Ir deposition on a porous Ti-substrate to obtain a bifunctional oxygen electrode. Surface pre-treatment of the fiber-based Ti-substrate with oxalic acid provides an alternative to plasma treatment for partially stripping TiO2 from the electrode surface and roughening the topography. Electrochemical catalyst deposition performed directly onto the pretreated Ti-substrates bypasses unnecessary preparation and processing of catalyst support structures. A single Pt constant potential deposition (CPD), directly followed by pulsed electrodeposition (PED), created nanosized noble agglomerates. Subsequently, Ir was deposited via PED onto the Pt sub-structure to obtain a successively deposited PtIr catalyst layer. For the co-deposition of PtIr, a binary PtIr-alloy electrolyte was used applying PED. Micrographically, areal micro- and nano-scaled Pt sub-structure were observed, supplemented by homogenously distributed, nanosized Ir agglomerates for the successive PtIr deposition. In contrast, the PtIr co-deposition led to spherical, nanosized PtIr agglomerates. The electrochemical ORR and OER activity showed increased hydrogen desorption peaks for the Pt-deposited substrate, as well as broadening and flattening of the hydrogen desorption peaks for PtIr deposited substrates. The anodic kinetic parameters for the prepared electrodes were found to be higher than those of a polished Ir-disc.
Various aqueous citrate electrolyte compositions for the Ni-Mo electrodeposition are explored in order to deposit Ni-Mo alloys with Mo-content ranging from 40 wt% to 65 wt% to find an alloy composition with superior catalytic activity towards the hydrogen evolution reaction (HER). The depositions were performed on copper substrates mounted onto a rotating disc electrode (RDE) and were investigated via scanning electron microscopy (SEM), X-ray fluorescence (XRF) and X-ray diffraction (XRD) methods as well as linear sweep voltammetry (LSV) and impedance spectroscopy. Kinetic parameters were calculated via Tafel analysis. Partial deposition current densities and current efficiencies were determined by correlating XRF measurements with gravimetric results. The variation of the electrolyte composition and deposition parameters enabled the deposition of alloys with Mo-content over the range of 40-65 wt%. An increase in Mo-content in deposited alloys was recorded with an increase in rotation speed of the RDE. Current efficiency of the deposition was in the magnitude of <1%, which is characteristic for the deposition of alloys with high Mo-content. The calculated kinetic parameters were used to determine the Mo-content with the highest catalytic activity for use in the HER.
For proton exchange membrane water electrolysis (PEMWE) to become competitive, the cost of stack components, such as bipolar plates (BPP), needs to be reduced. This can be achieved by using coated low-cost materials, such as copper as alternative to titanium. Herein we report on highly corrosion-resistant copper BPP coated with niobium. All investigated samples showed excellent corrosion resistance properties, with corrosion currents lower than 0.1 µA cm−2 in a simulated PEM electrolyzer environment at two different pH values. The physico-chemical properties of the Nb coatings are thoroughly characterized by scanning electron microscopy (SEM), electrochemical impedance spectroscopy (EIS), X-ray photoelectron spectroscopy (XPS), and atomic force microscopy (AFM). A 30 µm thick Nb coating fully protects the Cu against corrosion due to the formation of a passive oxide layer on its surface, predominantly composed of Nb2O5. The thickness of the passive oxide layer determined by both EIS and XPS is in the range of 10 nm. The results reported here demonstrate the effectiveness of Nb for protecting Cu against corrosion, opening the possibility to use it for the manufacturing of BPP for PEMWE. The latter was confirmed by its successful implementation in a single cell PEMWE based on hydraulic compression technology.
