Manufacturing of a Cemented Carbide Coated Component on Design for Manufacturing Toward Combined Impact and Wear Resistance

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Abstract Manufacturing of components with hard, wear-resistant coatings to operate under impact service condition is a high-performance challenge for mechanical equipment in industry. On a new strategy of design for manufacturing with integrated design and processing toward desired performance, the manufacturing process optimization of WC-Ni cemented carbide coated components was implemented with a two-layer coating design onto a steel substrate, comprised of a WC-Ni outer layer and a Ni-based alloy interlayer. In the design phase, numerical analysis of impact stress and strain field evolution was carried out comparatively for the two-layer coating and the conventional single-layer coating design under an impact load of 10-kN order. The high stresses localized on the coating surface and interfaces under the impacts may cause surface integrity changes of the coated components, including surface cratering upon plastic deformation as well as cracking both in coating and at coating-substrate interface. Introducing the interlayer of material with intermediate elastic modulus and hardness in between the steel substrate and the outer layer, as well as of an appropriate thickness, can mitigate the surface integrity changes to cracking failure of coated components. The manufacturing processes of high velocity oxy-fuel spraying and/or high frequency induction cladding technologies were accordingly optimized with the two-layer design, in good agreement with the numerical analysis. The two-layer coated component showed a better impact resistance over the single-layer coating, with less plastic deformation, interlayer and/or interface cracks. A further improvement was achieved by synergistically optimized induction cladding in a process chain to enhance the interlayer cohesive and adhesive strengths metallurgically bonded to steel substrate.

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