Atmospheric plasma spraying of industrial waste to enhance the erosion property of metal

Abstract

Our investigation is to utilize the industrial waste as a erosion resistance material using plasma spray technology. Utilization of such kind of industrial waste as coating material minimizes the cost of plasma spray coating deposition. We are taking fly-ash composite powder that is to be deposited on mild steel and copper substrates by atmospheric plasma spraying. We are varying the plasma gun operating power levels ranging from 11 to 21 kW during plasma spraying. Different morphology with different kind of splat characterized have been done using SEM. Coating porosity is measured by image analysis technique. The phase developed due to high temperature plasma are analysed by the XRD pattern. Coating interface adhesion strength is evaluated using coating pull out method, confirming to ASTM C-633 standard. The erosion resistance have been analysed by using Air Jet erosion test Reg (As per ASTM G76) with silica erodent typically 150-250 μm in size. Multiple tests were performed at increasing the time duration from 60 sec to 180 sec with increasing pressure (from 1 bar to 2.5 bar) and angle (60° & 90°). The analysis of these coating concluded that with low cost, these are excellent candidates for providing protection against abrasive wear and resistant to erosion.