Fatigue effect of WC coatings thermal sprayed by HVOF and laser

treated, on medium carbon steel

J.R. Garca

, J.E. Fernndez, J.M. Cuetos, F.G. Costales

University of Oviedo, Mechanical Engineering Area, Campus Universitario, mod. 5. 33203 Gijn, Spain
a r t i c l e i n f o
Article history:
Received 30 July 2010
Received in revised form 16 March 2011
Accepted 23 March 2011
Available online 2 April 2011
Keywords:
WC coatings
Coating failures
Cracks
HVOF
Laser treating
a b s t r a c t
Tungsten carbide coatings thermal sprayed by High Velocity Oxy-Fuel (HVOF) could be
employed to obtain very hard surfaces and for the recovery of shafts or pieces with worn
zones, like bearing supports, retaining rings, and so on. The aim of this study is to analyse
the effects of fatigue in the WC thin coatings (about 0.1 mm thick) sprayed by HVOF on
medium carbon steel substrate.
Rotational bending fatigue tests were carried out with test specimens, having applied the
coating over the raw materials (without anchorage layer), and the different resistance to
fatigue was analysed on the uncoated material, laser surface hardened samples, the sam-
ples with the WC coating thermal sprayed by HVOF and last with the same WC coating
treated by laser. Results show the possibility of predicting the fatigue life of materials with
this coating and these treatments and the huge differences between them.
2011 Elsevier Ltd. All rights reserved.
1. Introduction
The application of WC coatings in order to improve wear resistance is becoming more frequent than the chromium based
coatings and there have been several researches comparing both coatings [13]. Laser treatment was also used widely to
reduce friction and obtain harder surfaces resistant to friction and abrasion [414].
The surface coatings produce hard lms and in most cases compressive residual stress [2,3,1518], which inuenced the
decrease of resistance to fatigue of mechanical components that it is working with these technologies.
Recent works have used post-fused treatments using vacuum furnace, an electric furnace, or an induction heating system
working at temperatures near 1100C and very different results were obtained. Akebono et al. [19] found a decrease in fa-
tigue strength on the Ni coatings and Oh et al. [20] found the opposite (increase of the fatigue resistance) in coatings Co-
based.
Some authors found that laser surface modication was a good technique to improve life and eliminate crack propagation
[21], and we found, like other authors, that the proper laser treatment provides a more homogenous surface of the treated
material [1].
In this paper the inuence of laser treatments over WC coatings sprayed by HVOF was studied.
This paper studied the inuence of the WC coatings sprayed by HVOF in the resistance to fatigue and the inuence of laser
treatment on these coatings.
1350-6307/$ - see front matter 2011 Elsevier Ltd. All rights reserved.
doi:10.1016/j.engfailanal.2011.03.026

Corresponding author. Tel.: +34 652651505.

E-mail address: garciapjose@uniovi.es (J.R. Garca).
Engineering Failure Analysis 18 (2011) 17501760
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2. Experimental procedure
Material: AISI 1045 was employed as substrate, with chemical composition:
0.43 C, 0.6 Mn, 0.12 Si, P and S <0.035.
The composition of the coating was 17% Co and valance WC.
The specimens chosen are indicated in Fig 1. They were machined in one lathe, and the nal surface had a roughness of Ra
3.2 lm like pieces used in industrial applications. These samples allow us to test materials with a surface nish similar to the
real pieces of machinery, without relying on the inuence of the degree of curvature between the different sections. To the
right, it could be seen the housing for the rolling bearing, where we hold the load. With these samples we investigate the
behaviour of the metal in practical applications rather than the determination of coefcients K.
The fatigue tests were carried out on the rotating bending fatigue testing machine shown schematically in Fig. 2. The fre-
quency was 36 Hz.
All the samples were made from rolled bars and in the rst stage were tested to fatigue tests without any treatment to
know the fatigue behaviour of the material. Then we did several tests in the laser beam machine to ascertain the proper laser
parameters and we tested the samples laser treated in the rotating bending fatigue machine. Next we sprayed the WC
0.1 mm thick coating by HVOF over the machined specimens without any treatment, and after that we tested them in the
rotating bending fatigue machine. Finally we did several tests in the laser beam machine to ascertain the proper laser param-
eters to the WC HVOF and laser treated samples and we tested these samples to know their resistance to fatigue. The sam-
ples with these processes are shown in Fig. 3.
Previous to being sprayed by HVOF the samples were blasted with angular metallic particles to enhance adhesion of the
coating. The sprayed parameters were: 17%Co.
Hydrogen Fuel pressure: 9.7 bar.
Fuel Flow: 696NLPM.
Oxygen pressure 11.7 bar.
Oxygen Flow 214NLPM.
Air pressure: 6.9 bar.
Air Flow 344NLPMPowder feed gas pressure 1.4 bar.
Nitrogen FLOW 12.5NLPM.
Spraying distance 200 mm.
The laser treatment was carried out with a CO
2
laser (Ron Sinar, model RS 1700SM) with a 10,6 lm wavelength and a
nominal power of 1.700 W. The laser beam was operated in pulse mode with a distribution of energy in mode TEM 01

[4,611]. An integrator mirror was used to homogenise the energy distribution.

The samples were rotated by a divider plate at the same time that the laser beam was moved slowly in the direction of the
axis as if we were making a thread.
Fig. 1. Test specimens chosen for the fatigue tests.
Fig. 2. Scheme of the rotating bending fatigue testing specimens.
J.R. Garca et al. / Engineering Failure Analysis 18 (2011) 17501760 1751
During the laser process special attention was paid to the increasing temperature of the samples. To eliminate the energy
of the beam that could overheat and burn the samples, they were semi submerged in water to maintain a warm temperature
during the tests. A scheme of laser treatment is shown in Fig. 4.
Tests yielded satisfactory results appearing in Table 1, which shows the process parameters and overlapping. The power
and spot diameter were different in the samples uncoated and coated specimens due to the very different laser beam absorp-
tion of the two surfaces. In both cases the beam was in pulse mode 1 ms High1 ms Low.
The stress amplitudes were calculated using the substrate specimens diameter of 8 mm.
3. Results and discussion
3.1. Uncoated samples
The samples show the typical micro structure of carbon steel with laminated imprints above all in the middle of the bar.
The material has an average hardness of HV 238.
Fig. 3. Aspect of the test specimen tested, from the top, rob material, laser hardened, HVOF sprayed and HVOF and laser treated.
Fig. 4. Scheme of the laser treatment.
Table 1
Process parameters of laser irradiation.
Power (W) Spot diameter (mm) Overlapping (%) Speed (mm min
1
) Power density (J s
1
mm
2
)
Surface hardening 735 3 85 325 75
HVOF + laser 1000 4 70 325 102
1752 J.R. Garca et al. / Engineering Failure Analysis 18 (2011) 17501760
Fig. 5. Shape of the rupture in an uncoated sample.
Fig. 6. Aspect of the cross section of the sample laser surface treated.
0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1 1,1
0
50
100
150
200
250
300
350
400
450
HV after laser hardening
HV laser
hardening
Distance from surface (mm)
H
V
Fig. 7. Microhardness variation of a sample laser surface hardened from the surface.
J.R. Garca et al. / Engineering Failure Analysis 18 (2011) 17501760 1753
The fatigue results of these samples are indicated in Fig. 10. These results are the ones we could expect of this soft
material.
Like many studies reported, the coarse grain size has strong inuence in the fatigue strength of this material [22]. The
cracks on the surface start in several places near where the specimen supports higher stress. The connection of two or more
cracks, produce a crack growth and causes the rupture of the sample. This shape of rupture can be seen in Fig. 5. The initi-
ation and slow crack growth, the occurrence of crack arrest and the traversing crack beyond which the crack changes its
direction and grows, has been studied by various authors [23,24].
3.2. Laser treated uncoated samples
The micrograph of these samples is shown in Fig. 6 and is similar to the one for surface hardening, where the imprints of
the way of the laser beamcan be seen. There is a variation in the hardness between the surface and the interior of the sample,
which was not affected by the laser beam, this is shown in Fig. 7.
The fatigue strength of these samples was higher than the previous ones, as could be expected because of the slightly
higher hardness of the material. The surface treated has HV 400, while the raw material and the samples without laser treat-
ment has HV 238. Theses fatigue lives are compared in Fig. 10.
In previous studies, researchers have done laser surface hardening [25] and they reached greater hardness by cooling
the surface by conduction towards the inside of the piece [26], but in our case we did not achieve a very high speed of cooling
[27] and so the hardness here is not very high. The laser surface hardening we have done is low due to the fact that our axis
has a diameter of only 8 mm. With greater diameter it is possible to cool the surface faster reaching higher hardness, but
then other fatigue tests have to be done, in those conditions and microhardness of the surface.
The fatigue life increases with the laser surface hardening. In these treated samples the higher homogeneity of the surface
and the mitigation of crack propagation have more importance [1,21]. The microstructure of the material of the surface
changes to austenitic structure during the laser treatment for a very short time, as a consequence, a ne martensitic struc-
ture is reached in the treated surface [26,27]. This ne martensitic microstructure in the surface of the cylindrical samples
provides greater strength to bending fatigue tests.
0,10
0,15
0,20
0,25
0,30
0,35
0,40
0,45
0
50
100
150
200
250
300
350
HV from the interface
HV
substrate
after HVOF
Distace from the interface (mm)
H
V
Fig. 8. Microhardness variation of the samples sprayed by HVOF, from the interface coatingsubstrate.
Fig. 9. Scheme of the stress distribution in coated specimens.
1754 J.R. Garca et al. / Engineering Failure Analysis 18 (2011) 17501760
3.3. WC HVOF coating
Typical microstructure of HVOF coating with low porosity was obtained.
The surface presents the proper roughness of the HVOF sprayed coatings.
The hardness of the coating is HV 1315, and the substrate shows a variation indicated in Fig. 8.
In the fatigue tests we observe that when the samples break down and show cracks in the coating in the nearest area
(Fig. 11 a and b), this indicates that the coating was damaged before. To detect this behaviour in particular, samples with
this shape, and with the length of area sprayed are especially useful.
This behaviour is similar to that of other coatings that produce compressive residual stress, as was reported by other
authors [15] and in this case is due to the higher elasticity modulus that the WC coating has, absorbing more stress than
the substrate for the same deformation, see Fig. 9.
Due to the contribution to the strength of the WC coating, the samples with the thin coating of WC sprayed by HVOF have
quite good fatigue strength in low cycles of fatigue. When the number of the cycles of the tests increases, the WC HVOF coat-
ing cracks due to the high stress that it supports. The porosity of the coating and the high roughness of the interface coating
substrate together are the most important factors here in producing the crack initiation.
The Fig. 12 shows a micrograph of a sample in the same situation as the samples of the Fig. 11 a and b. This Fig. 12 also
shows the not very high adherence between coating and substrate, when the sample is bended by the external load. Once the
crack is formed and/or the coating is separated from the substrate the base material is in worse situation than the uncoated
samples due to the easier formation of cracks, caused by the surface substrate roughness.
Therefore the strength reached and shown in Fig. 10, which is greater than the uncoated material should be taken only for
fatigue strength at low number of cycles.
As can be seen in Figs. 12 and 14, the interface coatingsubstrate has the morphology of a shot peened surface. The inden-
tations of the WC particles sprayed at high pressure and temperature, produce the local plastic deformation. The mechanical
anchoring between the coating and the substrate produces the adherence of the coating, and it is responsible for the plastic
deformation of the substrate. Compressive residual stress of mechanical treatments, could reach values between 300 MPa
S - N
0
50
100
150
200
250
300
350
400
450
500
0
1
1
0
2
2
0
3
3
0
4
4
0
5
5
0
6
6
0
7
7
0
8
8
0
9
9
0
1
1
0
0
N ciclos * 1000
S

(
M
P
a
)
Mat. base
Trat. laser
WC HVOF
WC + laser
Fig. 10. SN diagram of the fatigue strength of the samples studied.
Fig. 11. Two samples HVOF sprayed, with cracks in the coating in the nearest area of the broken section.
J.R. Garca et al. / Engineering Failure Analysis 18 (2011) 17501760 1755
according to Vohringer [28] or Carvalho et al. [29] and 600 MPa according to Kobayashi et al. [30]. But these results had not
did account for the elevated temperature at which the surface of the substrate undergoes in HVOF projection. In the spec-
imens coated by HVOF WC, we attribute the increase in fatigue strength to the action of the coating, rather than the residual
stress of the substrate.
The results here are similar to other authors [31], but with specimens the way that we used in our study, we have a large
area in which it can lead to fracture (Fig. 11), while in other studies, the break will occur in a single section. In our case, in
that area, initial cracks appear parallel and as they grow, change direction of growth; when they occur and one small crack
joint together with another, a bigger crack grows faster and produces the rupture (Figs. 11 and 13).
The origin of the cracks in this samples with the WC HVOF coating were found:
In the nucleation of local stress around the pores in the coatings [3234].
In the roughness of the surface, which causes the decrease in fatigue life, compared with smooth surfaces [35]. And
In the non linear and non continuous transmission of stress between the coating and the substrate, due to the different
Youngs modulus, increased by the roughness of the interface coatingsubstrate.
3.4. HVOF and Laser treated samples
After the laser treatment the microhardness of the coating is HV between 900 and 1300. The variation of hardness in the
substrate is indicated in Fig. 14.
In the laser treatment done here, we saw an excessive overlapping. This overlapping had no inuence in the fatigue life in
the laser surface hardening, but in the WC coated samples, this overlapping had a strong inuence in fatigue life due to the
Fig. 12. Sample HVOF sprayed, with cracks in the coating in the area closest to the broken section.
Fig. 13. Sample HVOF sprayed, with initial and intersecting cracks changing its direction in the broken section.
1756 J.R. Garca et al. / Engineering Failure Analysis 18 (2011) 17501760
four repeated cycles of heating and cooling over the same surface. These four cycles of heating and cooling produced by the
laser beam passing successively over the same place, produce the dilatation and contraction of the coating together with the
sub-surface hardening of a ne coating of the substrate (see Fig. 15).
The following occurred during this treatment:
The pore reduction and the creation of compressive residual stress in the coating during the cooling period.
The heat treatment done here affects the substrate and changes its structure as in the laser surface hardening did before.
The adhesion between coating and substrate increases. The adhesion between the coating and the heat affected substrate
is very high, noticeable by the fact that the crack formation in the coating in many cases continues in the substrate (Figs.
16 and 17) and because no delamination was observed after the laser treatment, or after fatigue tests [1]. The crack for-
mation happens in many studies [36] despite the causes being different.
As a result, the coating cracked due to the different coefcients of expansion of the coating and substrate, the adhesion
between coating and substrate and the thinness of the coating. The compressive stress of the coating was so strong that it
produced the cracking of the substrate, shown in Figs. 16 and 17. The tension to which the substrate is subjected by the coat-
ing, is very near of the stress limit of the machined and uncoated substrate. Fig. 17 represents this transfer of stress.
Unlike the previous case, the samples have cracks before the fatigue tests (Fig. 17). The strength of the sample is higher
than the previous case and similar to that of the laser surface hardened carbon steel, but once the bending fatigue test began,
the cracks continued aided by the tensile stress in the end of the cracks and the sample broke down within a few cycles.
The formation of a diffusion layer at the interface that could contribute to effectively increase of the fatigue strength at
long cycle [34] was not formed. These diffusion layers are formed by post-fused thermal treatments, but in the case of WC
coating there is not enough Co to the form this layer and with the laser treatment we found the opposite effect due to the
Fig. 14. Hardness of the substrate, after HVOF and laser treatment, from the interface coatingsubstrate.
Fig. 15. Sample HVOF + laser treated, with the coating cracked before fatigue test.
J.R. Garca et al. / Engineering Failure Analysis 18 (2011) 17501760 1757
increased adherence and reduction of porosity of the coating. As a consequence, cracks of length longer than 100 lm were
formed on both the coating and the substrate.
The initial cracks grew as soon as the fatigue test started and produced the decrease in fatigue strength. The compressive
residual stress in the coating became tensile stress in the substrate, to which the applied stress had to be added. These resid-
ual tensile stresses have been shown to signicantly reduce the fatigue strength and have been reported by other authors in
other conditions [37].
Other authors have represented their conclusions in the end of theirs cracks and the mechanisms that are present, where
the material has a damaged section at the end of the crack and is plastically deformed [3840].
4. Conclusions
The strength to rotating bending fatigue or the AISI 1045 and the same steel laser treated, the same steel with WC HVOF
coatings and the previous laser treated, has been studied.
The strength to rotating bending fatigue of the AISI 1045 laser hardened is higher than the untreated material even for
low and high cycles fatigue, but in the case or other diameters or shape of the piece it is needed to reproduce the test because
of the different speeds of cooling after the laser treatments.
The resistance to rotating bending fatigue in the HVOF coated test samples is stronger than in the uncoated material. Due
to a larger elasticity module, the WC coating suffers more stress than the steel for the same deformation, but when there is a
failure in the fatigue test and the WC coating cracks the substrate gets in one of the cracks in the coating and this may cause
faster fracture. This fact has already been mentioned in the literature, and in our case it should be considered better than the
raw material only as low cycle fatigue, the risk of cracks in the coating in the large cycle fatigue is very high.
Fig. 16. Crack initiated in the coating that continuous in the substrate, in a sample HVOF + laser treated.
Fig. 17. Sample HVOF sprayed and laser treated, with cracks distributed regularly, before the rotating bending fatigue test.
1758 J.R. Garca et al. / Engineering Failure Analysis 18 (2011) 17501760
The samples shown in Fig. 3 are very useful to do rotating bending fatigue tests, since cracks may appear in different sec-
tions at the same time, which corresponds with the putting into practice of mechanical parts.
The overlapping of the laser treatment has a strong inuence in crack formation in the WC HVOF coatings. The results in
fatigue strength were worse than the previous case and the presence of cracks in the coating, that in some cases continue
into the substrate, before the test, is the worst way to make these laser treated coatings (with the overlapping made here)
to work to breaking point.
The WC HVOF coatings when exposed repeatedly to high localized temperatures, undergo a process of cracking, which
has a negative effect on the fatigue strength.
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