Optimization of WC-NiCrB-Al-Co coating powder composition for enhanced microhardness and reduced porosity: An I-Optimal design approach

Sabanayagam Sundaram; Chockalingam Singaravelu; Vikneswaran Malaiperumal

doi:10.3989/revmetalm.e276.1705

Authors

Sabanayagam Sundaram Department of Mechanical Engineering, Kings College of Engineering https://orcid.org/0000-0001-7414-3977
Chockalingam Singaravelu Department of Mechanical Engineering, E.G.S. Pillay Engineering College https://orcid.org/0000-0001-6931-5578
Vikneswaran Malaiperumal Department of Mechanical Engineering, SRM Institute of Science and Technology https://orcid.org/0000-0002-2922-7423

DOI:

https://doi.org/10.3989/revmetalm.e276.1705

Keywords:

Coating composition, Coating powder optimization, High-performance coatings, I-optimal design, Microhardness enhancement, Porosity reduction

Abstract

This study investigates the optimization of coating powder composition for enhanced microhardness and reduced porosity. Using an I-optimal design approach, the research explores the effects of varying weight percentages of Tungsten Carbide (WC), Nickel-Chrome-Boron (Ni-Cr-B), Aluminum (Al), and Cobalt (Co) on coating properties. The experimental design matrix consisted of 16 trials, including four replicated experiments. Response surface methodology and ANOVA were employed to analyze the relationship between formulation factors and responses. Results indicate that WC content positively correlates with microhardness, while Al content increases porosity. The optimal coating composition was determined to be 65% WC, 25% Ni-Cr-B, 5% Al, and 5% Co, achieving a desirability value of 0.881. This study provides insights into the complex interactions between coating components and their impact on critical properties, offering a foundation for developing high-performance coatings with enhanced resistance to oxidation, corrosion, and erosion for various industrial applications.

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References

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