Study of Titanium based Composite Coatings for Resistance against Molten Aluminium Soldering on H13 Tool Steel
type: CreativeWork
description: The service life of industrial components is limited predominantly by chemical corrosion, mechanical failure or mechanical wear. In the aluminium high pressure die casting industry, liquid aluminium is extremely reactive with the constituents of H13 die steel and has a tendency to form intermetallic layers. This chemical interaction results in sticking of molten metal to the die surface which produces defective castings and also damages the die surface. The use of thermal spray coatings provides protection to the surfaces operating in severe environments. An HVOF thermally sprayed coating has the advantage of having excellent bond strength and very low porosity levels (< 1%). This research work is concerned with producing and evaluating the performance of titanium/alumina based composite coatings to improve the service life of tool steel (H13) used for dies in aluminium high pressure die casting and dummy blocks used in Al extrusion. In this research work, the powder feedstocks for making the composite coatings were produced by high energy mechanical milling of a mixture of Al and TiO₂ powders in two different molar ratios followed by a thermal reaction process. The feedstock powder was then thermally sprayed using a high velocity oxygen fuel (HVOF) technique on H13 steel substrates to produce Ti(Al,O)/Al₂O₃ and TiAl/Al₂O₃ composite coatings. The performance of the coatings was assessed in terms of Al soldering, liquid metal corrosion resistance, thermal shock resistance and wear resistance. In an immersion test, the coated specimens were dipped into molten Al at a temperature of 700 ± 10 °C for different intervals of time. The performance of the coatings was tested in terms of liquid metal corrosion resistance and propensity to Al soldering. The dissolution behaviour of the coatings was evaluated by measuring weight loss after dipping the samples in to molten aluminium. The immersion test results showed that the coated samples have relatively few locations where al…
abstract: The service life of industrial components is limited predominantly by chemical corrosion, mechanical failure or mechanical wear. In the aluminium high pressure die casting industry, liquid aluminium is extremely reactive with the constituents of H13 die steel and has a tendency to form intermetallic layers. This chemical interaction results in sticking of molten metal to the die surface which produces defective castings and also damages the die surface. The use of thermal spray coatings provides protection to the surfaces operating in severe environments. An HVOF thermally sprayed coating has the advantage of having excellent bond strength and very low porosity levels (< 1%). This research work is concerned with producing and evaluating the performance of titanium/alumina based composite coatings to improve the service life of tool steel (H13) used for dies in aluminium high pressure die casting and dummy blocks used in Al extrusion. In this research work, the powder feedstocks for making the composite coatings were produced by high energy mechanical milling of a mixture of Al and TiO₂ powders in two different molar ratios followed by a thermal reaction process. The feedstock powder was then thermally sprayed using a high velocity oxygen fuel (HVOF) technique on H13 steel substrates to produce Ti(Al,O)/Al₂O₃ and TiAl/Al₂O₃ composite coatings. The performance of the coatings was assessed in terms of Al soldering, liquid metal corrosion resistance, thermal shock resistance and wear resistance. In an immersion test, the coated specimens were dipped into molten Al at a temperature of 700 ± 10 °C for different intervals of time. The performance of the coatings was tested in terms of liquid metal corrosion resistance and propensity to Al soldering. The dissolution behaviour of the coatings was evaluated by measuring weight loss after dipping the samples in to molten aluminium. The immersion test results showed that the coated samples have relatively few locations where al…
author: Salman, Asma Siddiq
keywords: mechanical milling, thermal spraying, HVOF, composite coatings, soldering, H13 tool steel
license: https://researchcommons.waikato.ac.nz/bitstreams/56ee6c13-d204-4d6d-ba29-af8623734212/download
date published: 2011
date modified: 2026-07-24T05:57:27Z
provider: University Waikato
publisher: Networked Digital Library of Theses and Dissertations
type: WebPage
source organization: University of Waikato