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International Journal of Mechanical Engineering and Technology (IJMET)
Volume 10, Issue 03, March 2019, pp. 1285
 – 
1300, Article ID: IJMET_10_03_131 Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=10&IType=3 ISSN Print: 0976-6340 and ISSN Online: 0976-6359
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FATIGUE PERFORMANCE OF THERMAL SPRAY COATINGS ON CARBON STEEL: A REVIEW
M. A. M. Halmi
 
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia (UTHM), 86400 Johor, Malaysia
M. A. Harimon
Faculty of Mechanical and Manufacturing Engineering, Centre for Technology Oil & Gas, Teaching Factory, Universiti Tun Hussein Onn Malaysia (UTHM), 86400 Johor, Malaysia
L. Mohd Tobi
 
Centre for Technology Oil & Gas, Teaching Factory, Universiti Tun Hussein Onn Malaysia (UTHM), 86400 J
o
hor, Malaysia
M. F. Mahmod
Faculty of Mechanical and Manufacturing Engineering, Universiti Tun Hussein Onn Malaysia (UTHM), 86400 Johor, Malaysia
ABSTRACT
This paper contributes to a review of the research of the fatigue behaviour of thermal spray coatings on carbon steel. Previous studies provide the experimental characterization of the fatigue resistance of coated carbon steel. Different coating  powders were deposited to a different type of carbon steels. Also, S-N curves were drawn from axial- and rotating bending fatigue test to determine the fatigue strength or  fatigue limit of the samples. Thermal spray coatings showed great improvement to the work hardening effect but worsen the fatigue life due to the inclusion of oxide and pores, the presence of stress concentrators, and high microcrack density. Moreover, the effects of the surrounding environment have also resulted in pros and cons towards the fatigue  strength. An improvement, however, can be done with the shot peening treatment, which  significantly increases the compressive residual stress at interfaces of coating/substrate. The high compressive residual stress could delay the crack nucleation, thus increasing the fatigue life of the coated part.
Key words:
 Carbon steel, Coating, Fatigue, Thermal spray
 
 
Fatigue Performance of Thermal Spray Coatings on Carbon Steel: A Review
 
http://www.iaeme.com/IJMET/index.asp 1286 editor@iaeme.com
Cite this Article:
 M.A.M. Halmi, M.A. Harimon, A.L. Mohd Tobi, M.F. Mahmod, Fatigue Performance of Thermal Spray Coatings on Carbon Steel: A Review,
 International Journal of Mechanical Engineering and Technology
 10(3), 2019, pp. 1285
 – 
1300. http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=10&IType=3
1. INTRODUCTION
Application of thin film of functional material to an object (usually referred to as the substrate) is known as a coating process. The functional material may be solid, liquid or gas; organic or inorganic; metallic or non-metallic. In many cases, coatings are applied to improve the surface  properties of the substrate [1]. Composite coating innovation primarily has been created to satisfy the mechanical requests for coatings whose details surpass the capabilities of customary coating innovations, which are able of working in extreme environments and within the confront of challenges postured by temperature, corrosion, abrasion, fatigue, friction, and erosion [2]
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[4]. Nowadays thermal spray coatings have been broadly applied to improve functions such as wear resistance, corrosion resistance, bioactivity and dielectric properties to light metals. The characteristics of the deposition process, including splat cooling and successive stacking of splats, create coatings of unique microstructure which are different from conventional materials [5]. The common processes of thermal spray are arc spray, flame spray, high-velocity oxy-fuel spray, and plasma spray. High-velocity oxygen fuel (HVOF) spraying is widely utilized in groups of thermal spraying and it has been extensively used for tungsten carbide (WC) feedstock powder in order to obtain good bond strength, higher density, and less decarburization. This is because of the lower temperature and higher velocities experienced by the powder particles as compared to other thermal spray technique like vacuum/low-pressure plasma (VPS/LPPS), and atmospheric  plasma (APS) with a higher temperature around with lower velocities [6]
 – 
[11]. However, the effect of the coating on the fatigue performance influenced the acceptance of thermal spray coatings in many applications. When a structure is loaded, a crack will be nucleated (crack nucleation) on a microscopically small scale, this crack then grows (crack growth), then finally complete failure of the specimen [12]
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[17]. The factors causing fatigue failure can be divided into basic factors and additional factors. For the basic factors are a high maximum tensile stress value, a large amount of variation or fluctuation in the applied stress, and a sufficiently large number of cycles of the applied stress. While for the additional factors are stress concentration (geometry), corrosion (environment), temperature (environment), overload (loading), metallurgical structure (material), residual stress (manufacturing) and combined stress (loading). One of the factors that influence the fatigue life of thermal spray-coated components is the residual stress in the coating. It was found that there is a direct relation between the residual stress in the coating and the fatigue life of the coated part. Fatigue life can be changed by a factor of ten due to the level of compressive residual stress in the coating [18]
 – 
[21]. On the other hand, surface defects (such as roughness or scratches and notches or shoulders), corrosion and galling (due to rubbing of mating surfaces) may reduce the fatigue strength of the coated part [12]. This work focuses on the main results available in the literature on the fatigue behaviour of thermally sprayed carbon steel. In actual fact, the current development of coating technique rises significantly to fulfil industrial demands in the best possible ways. Also, the possibility to withstand in extreme environments and in the challenges posed by fatigue, temperature, corrosion and abrasive is expected to become more and more dominant. From these  perspectives, the utilization of thermal spray coating having a better performance than those of
 
M.A.M. Halmi, M.A. Harimon, A.L. Mohd Tobi, M.F. Mahmod
 
http://www.iaeme.com/IJMET/index.asp 1287 editor@iaeme.com
traditional coating would be recommended for a number of applications. Therefore, to achieve significant results, numbers of research studies would be necessary.
2. THERMAL SPRAY COATINGS PREPARATION
2.1. Material selection
Material selection is very significant due to their benefits and limitations. In this paper, carbon steel will be reviewed as a fixed substrate with different coating powder characteristics functioned to protect the metal substrate. Every coating powder has its own benefits toward improving the substrate's characteristics. In [22], [23] the coating powder comprised of cobalt element, which acts to provide a ductile metallic binder for hard carbide particles. Besides that, cobalt can also help the coating powder to achieve a high density of deposition as its wetting or capillary action during liquid phase sintering. In the study [9], [24]
 – 
[30], the coating powder comprised of nickel element, which acts to improve the corrosion and oxidation resistance of the substrate. However, nickel does not wet the WC particles as effectively as cobalt, resulting in low strength, hardness and wear resistance. 
2.2. Substrate and specimen preparation
For material preparation, metal substrate was first grounded and polished using SiC sandpaper with 60 to 200 grit range [22], [23], [27], [30]. Then the substrate will be quenched from 815
 - 845
 for 45 minutes and cooled in oil (20
). After that, the substrate was tempered in the range of 220
 to 260
 for 2 hours and then it will be cooled in the air [22]
 – 
[25], [28]. Fatigue specimens were then machined and sectioned according to the ASTM-E466 [9], [22]
 – 
[30]. To reduce residual stress induced by machining, the specimen underwent stress relieving heat treatment at 190
 for four hours [22]
 – 
[25]. Before coating deposition, the substrate underwent a grit blasting process, which main purposed to generates surface roughness ensuring mechanical anchoring between coating and substrate surface. Grit blasting process can be inputted with different alumina size, pressure and distance, which produce variable significant surface roughness. Also, this process will help to remove any contaminants on the surface of the substrate before coating deposition taking place [26], [27]. Optionally, the surface roughness of the substrate will be kept constant to prevent any cause on the fatigue strength due to low/high bonding between substrate and coating. 
2.3. Coating deposition
 Nowadays there is plenty type of coating guns/ machines used to thermally spray the coating  powder to the substrate. For instance, Jet Kote thermal spray system [22], [23], JP-5000 HP/HVOF spray system [22], [23], JP-5000 TAFA 1310 VM Technologies [24], [25], [28], and Praxair-TAFA JP-5000 gun [26], [27]. Furthermore, the coating parameter such as powder feeding rate, the distance of the spray, number of coating's layer, oxygen pressure, fuel pressure, air flow, fuel flux, oxygen flux, etc. play important roles for the result of coating deposition. The change of the parameter could possibly affect the properties of the specimens. On the other hand, the coating thickness and surface roughness of the specimens must be kept constant. The coating thickness was kept constant at 100-150 µm in [22], [23], [28], and at 170 µm in [24]. In [22], [23], surface roughness of the specimens was 4 µm, and 6.4 µm in [26].
2.4. Fatigue test

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