EFFECT OF THE ROUGHNESS AND TEMPERATURE OF THE SURFACE OF THE BASE MATERIAL ON THE MECHANICAL PROPERTIES OF THE COATING LAYER (NICKEL - ALUMINUM) SPRAYED THERMALLY BY FLAME

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International Journal of Mechanical Engineering and Technology (IJMET)
Volume 9, Issue 11, November 2018, pp. 391–404, Article ID: IJMET_09_11_039
Available online at http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=9&IType=11
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication Scopus Indexed
EFFECT OF THE ROUGHNESS AND
TEMPERATURE OF THE SURFACE OF THE
BASE MATERIAL ON THE MECHANICAL
PROPERTIES OF THE COATING LAYER
(NICKEL - ALUMINUM) SPRAYED THERMALLY
BY FLAME
Ammar Razzaq Hasan, Al-Hadrayi Ziadoon M.R and Ibrahim Joodi Hadi
Department of Materials Engineering
Faculty of Engineering, University of Kufa, Iraq
ABSTRACT
In this research, the thermal coating process was carried out using flame spraying
technique using a gas mixture of oxygen and acetylene for the purpose of obtaining a
surface layer of nickel-aluminum (metco450) coating on the surface of medium carbon
steel type (AISI 1050) which provide an increase in surface properties and compensation
of the base material when lost due to friction or wear.
The research was carried out in three successive stages. The first stage included the
preparation of the specimens and the design of the base surface of these specimens and
Preparation of powder coating and analysis of chemical components for base material
and powder coating. The second stage included the implementation of the coating process
of (nickel-aluminum) powder by using the flame spray. The coating process was carried
out in different ways for each model by changing the different spraying factors, which
included the surface roughness of the specimens and the surface temperature of the
specimens before the coating process. The third stage of the research included
mechanical testing procedures of the coating layer.
The tests showed that adhesion increases with increasing surface roughness of the
sample prior to coating and the best adhesion is obtained when the base surface of the
sample is heated to a temperature of (350 ºC) before the coating process. The resistance
of the coating layer to wear is increased with the roughness of the base material surface
of the sample due to the increased adhesion of the coating layer and the best resistance
to wear when heating the surface of the base material of the sample before coating to
temperature (350 ºC). The hardness of the coating layer is increased by increasing the
roughness of the surface of the base material of the sample before the coating process
and the best surface hardness of the coating layer when heating the surface of the base
material of the sample before the coating process to (350 ºC).

Key words: flame spraying, coating (nickel- aluminum), adhesion, wear resistance,
hardness
Cite this Article Ammar Razzaq Hasan, Al-Hadrayi Ziadoon M.R and Ibrahim Joodi Hadi,
Effect of the Roughness And Temperature of the Surface of the Base Material on the
Mechanical Properties of the Coating Layer (Nickel - Aluminum) Sprayed Thermally by
Flame, International Journal of Mechanical Engineering and Technology, 9(11), 2018, pp.
391–404.
http://www.iaeme.com/IJMET/issues.asp?JType=IJMET&VType=9&IType=11
1. INTRODUCTION
The definition of thermal spraying according to the ASM is the set of processes that lead to the
mineral or non-metallic coating material deposited in a molten or semi-molten state on the surface
layer of metals or alloys to form the coating or coating layer [1]. The method of thermal spraying
by flame is one of the oldest types of thermal spraying and the most common in the world because
of its simplicity and low cost [2]. The thermal spraying by flame uses compressed air or oxygen
mixed with a fuel type (ethylene, propylene, propane or hydrogen) to melt and accelerate molten
particles [3]. Inert gas such as arcon or nitrogen can be used to emit molten particles if oxidation
of the sprayed particles is undesirable [4]. This is due to the relatively low velocity of molten
particles (50 m / sec) and relatively low temperatures (approximately 3000 ºC). Coating can be
improved by processes called spray and fusion. After spraying, the combustion process is used
to increase the temperature of the base material to a degree close to that of the previous melting
powder [5]. The result is a very high density coating and high adhesion due to metallurgical
bonding between the base material and the coating layer. A wide range of materials can be
thermally sprayed in various applications ranging from thermal machine technology (gas turbine)
to electrical industries [6].
2. RESEARCH OBJECTIVES
In view of what it represents the thermal spraying by flame of the possibility of obtaining high
performance engineering surfaces in a wide range of industrial applications operations, the
research aims to:
1) Determine the relationship between the surface roughness of the base material and the
mechanical properties of the coating layer by conducting hardness, wear, adhesion and roughness
tests for the coating layer.
2) Determine the relationship between the surface temperature of the base material and the
mechanical properties of the coating layer by conducting hardness tests, wear, adhesion and
roughness of the coating layer.
3) Reduce the losses caused by the failure of the engineering surfaces due to the various types
of wear and tear that are exposed to the surfaces of machines with friction or sliding or frequency
movements made of Medium carbon steel by spraying with a coating of nickel-aluminum instead
of replacing the part.
3. EXPERIMENTAL WORK
3.1 Materials used
The materials used include:
3.1.1. Medium carbon steel (the base material)
A medium carbon steel rod (AISI-1050) was used and cut to obtain the required samples in
cylindrical form (mm10 * mm20) and (mm20 * mm10). The component analysis of these samples

Effect of the Roughness And Temperature of the Surface of the Base Material on the Mechanical
Properties of the Coating Layer (Nickel - Aluminum) Sprayed Thermally by Flame
was carried out in the Materials Engineering Department by Metal analysis device (Portable
metals Analyses), Manufactured by ARUN Technology; the results appeared as shown in Table
(1).
Table 1 Chemical Analysis of Medium Carbon Steel Type (AISI-1050)
Co%Al%Mn%Si%C%Fe%elements
0.181<0.0200.3080.8110.51097.2Percentage of elements%
V%Ti%Ni%Mo%Cu%Cr%elements
0.116<0.0200.128<0.3770.320<0.030Percentage of elements%
3.1.2. Powder coating used
The use of powder coating of (Ni- Al) type (Metco 450) works to generate chemical reactions
areas deliberately to enhance the strength of adhesion, heating to a temperature When (1400 ºC)
will happen reaction between nickel and aluminum leads to the generation of high temperatures
of up to about (3180 ºC) temperature is sufficient to bring about the fusion of the base areas, and
be a coating material in the form of the aluminum powder is coated with nickel metal. Table (2)
represents the chemical analysis of the powder coating using X-ray machine (X-Ray) type (Twin-
X) manufactured by the company (Oxford Instruments).
Table 2 Chemical analysis of powder coating (nickel - aluminum)
Percentage of elements%Elements of powder coating( Al-Ni)
93 %Ni
7 %Al
Table (3) presents the most important characteristics of the powder coating used.
Table 3 the characteristics of the powder coating
powder coating color Melting point Particle size
(nickel - aluminum) gray 1350 ºC 50 µm
3.2 Stages of the implementation of the practical part
The implementation of the practical side in three successive stages:
3.2.1 The first stage
Samples Preparation Stage
For the purpose of preparing the samples and preparing their surfaces for thermal spraying
using flame, the following is followed:
1- Cutting the steel rod into cylindrical shape and dimensions (20mm*10mm) through
cutting and cutting operations with electric saw.
2- Manufacture hardness samples with cylindrical shape and dimensions (10mm*20mm).
3- Making an internal screw tooth in one side of the sample for the purpose of fixing the
sample in the sample load axis.
4- Smoothing the outer surface of sample (1) by continuous sanding paper (600, 400, 300,
220 and 120).
5- Increase the roughness of the external surface of the sample (2) by running the sample
on the lathe using sandpaper in successive degrees (100, 80, 60, and 40).

6- Increase the roughness of the external surface of the sample (3) by running the sample on
the lathe using sandpaper (40).
Measure the surface roughness of all samples prior to the coating process to be taken as a
variable using the roughness device. Three readings were taken for different areas of the sample
surface where the roughness was calculated as shown in Table (4).
Table 4 the roughness of the samples before coating
Sample number 1 2 3
Surface roughness as measured by (Ra) 0.95 µm 2.65 µm 5.45 µm
3.2.2 The second stage
Coating Operation Stage
The Flam Spray System is designed and implemented in the welding laboratory of the
material engineering department using a spray gun. The heat flame is produced by burning
oxygen gas and acetylene, which carries the molten powder in the gas mixture stream and attaches
to the surface to be coated by the high temperature of the flame which may Up to (3000 ºC).
It is necessary to control the pressure of the gases to obtain the flame equal to the speed of
the powder rush. The oxygen pressure should be adjusted according to the spray gun used no
more than (4 bar) and the acetylene pressure not more than (0.7 bar) before spraying, see Figure
(1).
Figure 1 Spray gun type (Rototec80)
3.2.2.1. Coating the first group samples
The samples of the first group included three samples with different rough surfaces. The samples
were tested according to the three methods mentioned above, as shown in Table (4) and the
powders were dried in a drying oven to (250 ºC) for (20 minutes).
Where the coating process was carried out according to the following sequence:
1. Install the sample on the axis that is associated with the lathe sample.
2. Install the spray gun on the arm directed to the sample and vertically.
3. Cleaning the outside of the sample with a chemical cleaner (Trichloroethylene
(C2HCI3)), while avoiding touching the sample after cleaning to prevent contamination with oils
and impurities.
4. Rotate the sample at a slow and steady speed during the spraying process.

5. The oxygen pressure was set at (3 bar) and the acetylene was pressed on (0.5 bar) of the
bottles. The gases were then controlled by the valves in the pistol. The acetylene gas was first
opened to ignite the flame and then the oxygen gas was opened.
6. The sample is heated by an oxyacetylene torch to a temperature of (350 ºC) where the
temperature is monitored by an infrared thermometer.
7. Conducting a spraying process (nickel-aluminum) from a distance of (250) mm (distance
between the spray gun hole and sample surface), It weighed 1.5 g of powder for the cylindrical
portion and 0.75 g of base
8. The thickness of the paint bond obtained is up to (0.25) mm.
And Figure (2) represents a coated sample.
Figure 2 coated sample.
3.2.2.2. Coating the second group samples
The samples of the second group included three samples with equal surfaces of surface roughness;
the sample surface was roughened by the method of roughing the sample (2). The coating process
was carried out in the same sequence as the first group samples, except for the process of changing
the surface temperature of the sample before spraying the nickel-aluminum coating. Table (5)
shows the temperature variables of the sample surface for each sample of the second group.
Table (5) the Surface temperature of the samples before coating
Sample number 1 2 3
Surface temperature of sample before coating 150 ºC 350 ºC 550 ºC
3.2.3 The third stage
Tests stage are:
3.2.3.1. Adhesion test
The adhesion of the coating layer was tested by using the tensile test device type (Microcomputer
Controlled Electronic Universal Testing Machine (WDW-50E)) was manufactured by (Time
Group Inc.) according to (ASTM A370), where adhesion samples were installed in the screw of
the tensile device.
The test was carried out according to the following steps:
1. Preparation of uncoated samples with equal number of coated samples with dimensions
(20mm*10mm).
2. Conduct chemical cleaning by using (Trichloroethylene (C2HCI3)) for both coated and
uncoated samples to remove oils and other contaminants that hinder the adhesion of both.

3. Epoxy adhesive (REP-15-0104) was used to paste the two samples together (coated and
uncoated). A layer of epoxy is placed on the surface of the coated sample. The coated and
uncoated samples are then pressed together for approximately (1 hour) and then dried for (18
hours) at (40 ºC), as shown in Figure (3).
Figure 3 shows how to install adhesion samples in tensile jaws device.
4. A vertical load of each sample was applied at a tensile rate (1 mm / min) and until the
sample failed, the highest load was recorded.
5. The value of adhesion resistance or cohesion resistance of the coating layer shall be
calculated as follows:
6. Two readings were obtained for each sample and their rate was calculated. The value
obtained from the test represents the resistance of the weakest part of the system, either in the
coating layer itself or at the boundary between the coating layer and the sample surface. The
reading value is the adhesion resistance if the failure is in the boundary area between the coating
layer and the sample surface while the resistance is the cohesion if the failure occurs within the
coating layer itself.
7. The optical microscope was used to determine the location of the failure.
3.2.3.2. Wear Test
The (pin-on-disk) adhesion wear device was used to test the wear of the coated samples as shown
in Figure (4).
Figure 4 (pin-on-disk) wear device

The rate of wear is calculated by calculating the difference in the weight of the coated sample
before and after the test by applying the following law:
W.R = ∆W/S.D 1
Where:
W.R: Weighted averages wear sliding (gm / mm)
W: Weight change is calculated from the following relationship
∆W=W1-W2 2
Where
W1: Sample weight before test (gm)
W2 Sample weight after test (gm)
S.D =S*t 3
Where:
S.D: represents the slip distance calculated from the following law:
S: Sliding speed (cm / min)
t: Sliding Time (min)
The calculated sliding speed by measuring the small diameter roller (D1) and the large
diameter roller (D2) and the radius of rotation of the sample (r) adhesion wear device user.
Where:
D1=66 mm
D2=226mm
r=70 mm
N motor=950 r.p.m.
While the reduction of the rollers ratio is calculated (the velocity) ratio of (i) through the
following law:
i=D2/D1=226/66=3.424
N1= N motor= 950 r.p.m.
Where:
N1: The rotational speed of the small reel
N2: Rotational speed of the large reel (speed of disc)
And always (N1> N2)
3.424=950/N2
N2=277.4 r.p.m.
The linear velocity of the disc which is the same as the sliding speed (S).
S=(2πN2/60)*r 4
S=(2π*277.4/60)*0.07=2 m/s=12000cm/min
The disc is made of Tool Steel and its hardness (385 HV).
Two readings were obtained for each sample and its rate was calculated.
3.2.3.2. Hardness test
The test was performed using a Brinell hardness device (hardness tester), the use of samples in
the shape of a cylindrical disc with dimensions (10mm*20mm).

The test was carried out as follows:
1. The sample is placed at a distance of 15mm between the test ball and the pressure plate.
2. Place the sample in the test place.
3. The test tool is lowered by turning the wheel manually.
4. The test force is quietly released (9.8 KN) by slowly turning the wheel,
5. As the period of increasing the force to the maximum value should take at least five
seconds.
6. Installation of pregnancy for (15s-10s) and then load is lifted.
7. The sample is then raised and the trace diameter is determined on the surface of the
coating layer using a microscope,
8. After testing and measuring the trace diameter, as shown in Figure (5), the following law
is used to calculate the hardness:
HB = 0.102F/0.5πD[D-(D2-d2)]0.5
5
Three readings were obtained for each sample and its rate was calculated.
Figure 5 measuring the trace diameter
4. RESULTS AND DISCUSSIONS
4.1 Results of adhesion tests of coating layer and discussion
These include the results of adhesion tests for all samples that were coated according to the
different variables.
4.1.1 The results of the surface roughness effect of the sample prior to coating on the adhesion
of coating layer
Table (6) shows the amount of adhesion of coating layer for each sample of the first group
samples, which were coated with varying degrees of the surface roughness of the samples before
coating.
Table 6 change of adhesion with the degree of roughness of the sample surface before coating
Sample number 1 2 3
Adhesive of coating layer 5.25 MPa 7.85 MPa 11.35 MPa
Figure (6) shows the relationship between the surface roughness of the sample before coating
and the amount of adhesion of coating layer. Where there is an increase in adhesion of the coating
layer with increased surface roughness of the sample prior to coating due to increased mechanical

bonding between the coating and the sample surface resulting from mechanical interlock between
the coating and the sample surface protrusions.
Figure 6 the relationship between the adhesive of coating layer and degree of the roughness of the
sample surface before coating
4.1.2 The results of the surface temperature of the sample effect of the sample prior to coating
on the adhesion of coating layer
Table (7) shows the amount of adhesion of coating layer for each sample of the second group
samples, which were coated with varying the surface temperatures of the samples before coating.
Table 7 change of adhesion with the surface temperature of the sample before coating
Sample number 1 2 3
Adhesive of coating layer 6.35 MPa 7.95 MPa 7.55 MPa
Figure (7) shows the relationship between the sample surface temperature before coating and
the amount of adhesion of coating layer, the curve shows that the best adhesion of the coating
layer is obtained when the sample surface is heated to a temperature of (350 ºC), The surface
heating of the surface prior to the coating process helps these grades to increase the penetration
of the coating layer inside the protrusions of the sample surface, While heating to less than (350
ºC) reduces this penetration. Heating to more than (350 ºC) leads to oxidation of the surface of
the sample before spraying the coating layer, which leads to the formation of membranes of metal
oxide on the surface of the sample, which reduces the adhesion coating layer.
0
2
4
6
8
10
12
0 1 2 3 4 5 6
Adhesiveofcoatinglayer
MPa
Surface roughness as measured by (Ra)
µm
0
2
4
6
8
10
0 100 200 300 400 500 600
Adhesiveofcoatinglayer
MPa
Surface temperature of sample before coating
ºC

Figure 7 the relationship between the adhesive of coating layer and Surface temperature of the sample
surface before coating
4.2 Results of wear tests of coating layer and discussion
These include the results of wear tests for all samples that were coated according to different
variables.
4.2.1 The results of the surface roughness effect of the sample prior to coating on the rate of
wear of coating layer
Table (8) shows the rate of wear of coating layer for each sample of the first group samples,
which were coated with varying degrees of the surface roughness of the samples before coating.
The wear of each sample of the first group was tested at a time of wear (20 minutes) and a
vertical force of (5 N).
Table 8 change of rate of wear with the degree of roughness of the sample surface before coating
Sample number 1 2 3
Rate of wear
55*10-9
(gm/min)
40*10-9
(gm/min)
25*10-9
(gm/min)
Figure (8) shows the relationship between the surface roughness of the sample before coating
and the Rate of wear of coating layer. As a result of increasing the overlap of the particles of the
coating layer with the surface of the sample composed of roots working on the installation of the
coating layer, where with increased surface roughness of the sample before coating increases
adhesion and reduce the rate of wear.
Figure 8 the relationship between the rate of wear and degree of the roughness of the sample surface
before coating
on the rate of wear of coating layer
Table (9) shows the rate of wear of coating layer for each sample of the second group samples,
which were coated with varying surface temperatures of the samples before coating.
The wear of each sample of the first group was tested at a time of wear (20 minutes) and a
vertical force of (5 N).
0
10
20
30
40
50
60
0 1 2 3 4 5 6
Rateofwear
(*10-9)(gm/min)
µm

Table (9) change of rate of wear with the surface temperature of the sample before coating
Sample number 1 2 3
Rate of wear
9-
40*10
(gm/min)
9-
35*10
(gm/min)
9-
60*10
(gm/min)
Figure (9) shows the relationship between the sample surface temperature before coating and
the rate of wear of coating layer, The curve shows that the lowest wear rate is obtained when the
sample is heated before coating to a temperature of (350 ºC), It is noted that the low surface
temperature of (350 ºC) gives a weak bond and high wear rate because the coating layer particles
cannot impregnate the surface of the sample, which reduces adhesion strength and increases the
rate of wear, A higher surface temperature of more than (350 ºC) leads to oxidation of the surface
of the sample before spraying the coating layer, which gives a high wear rate due to the formation
of metal oxide membranes on the sample surface preventing adhesion between the sample surface
and the coating layer particles.
Figure 9 the relationship between the rate of wear and surface temperature of sample before coating
4.3 Results of hardness tests of coating layer and discussion
These include the results of hardness tests for all samples that were coated according to the
different variables.
4.3.1 The results of the surface roughness effect of the sample prior to coating on the hardness
of coating layer
Table (10) shows the hardness of coating layer for each sample of the first group samples,
which were coated with varying degrees of the surface roughness of the samples before coating.
Table 10 change of hardness with the degree of roughness of the sample surface before coating
Sample number 1 2 3
Hardness of coating layer 7*10-3
HB 7.025*10-3
HB 8.055*10-3
HB
Figure (10) shows the relationship between the surface roughness of the sample before
coating and the hardness of coating layer. Where there is an increase in hardness of the coating
layer with increased surface roughness of the sample prior to coating due to increased mechanical
0
10
20
30
40
50
60
70
0 100 200 300 400 500 600
Rateofwear
(*10-9)(gm/min)
ºC

interlock between the coating and the sample surface protrusions and the coating layer takes extra
hardness from the coated sample.
Figure 10 the relationship between the hardness and degree of the roughness of the sample surface
before coating
on the hardness of coating layer
Table (11) shows the hardness of coating layer for each sample of the second group samples,
which were coated with varying surface temperatures of the samples before coating.
Table 11 change of rate of wear with the surface temperature of the sample before coating
Sample number 1 2 3
Surface temperature of sample before
coating
150 ºC 350 ºC 550 ºC
Hardness of coating layer
6.775*10-3
HB
7.035*10-3
HB
5.525*10-3
HB
Figure (11) shows the relationship between the sample surface temperature before coating
and the hardness of coating layer, The curve shows that the greatest hardness is obtained when
the sample is heated before coating to a temperature of (350 ºC), It is noted that the low surface
temperature of (350 ºC) gives a weak bond and low hardness because the coating layer particles
cannot impregnate the surface of the sample, which reduces adhesion strength and reduces the
hardness while the surface temperature higher than (350 ºC) causes oxidation of the surface of
the sample before spraying the coating layer, giving little hardness due to the formation of
metallic oxide membranes on the surface of the sample with less hardness as well as reducing the
overlap between the coating layer and the sample surface.
6.8
7
7.2
7.4
7.6
7.8
8
8.2
0 1 2 3 4 5 6
Hardnessofcoatinglayer
(*10-3)HB
µm

Figure 11 the relationship between the hardness and surface temperature of sample before coating
5. CONCLUSION
1. Increase adhesion of coating layer with increased roughness of the sample surface before
coating, it was observed that increasing the roughness of the sample surface prior to coating from
(0.95 µm) to (5.45 µm) increased the adhesion of the coating layer from (5.25 MPa) to (11.35
MPa) by about (100%) approximately due to increased mechanical bonding between the coating
layer and the sample surface.
2. The best adhesion of the coating layer is obtained when the sample surface is heated
before coating to a temperature of (350 ºC), while heating to less than (350 ºC) or more than (350
ºC) reduces the adhesion of coating layer.
3. Increase the wear resistance of the coating layer with increased surface roughness of the
sample before coating, It was observed that increasing the surface roughness of the sample prior
to coating from (0.95 μm) to (5.45 μm) reduces the rate of wear of the coating layer from (55*10-
9 (gm/min)) to (25*10-9 (gm/min)) by about more than half due to increasing the overlap of the
particles of the coating layer with the surface of the sample composed of roots working on the
installation.
4. The lowest wear rate is obtained when the sample is heated before coating to a
temperature of (350 ºC), It is noted that the low surface temperature of (350 ºC) or higher surface
temperature of more than (350 ºC) leads to gives a high rate of wear.
5. increase in hardness of the coating layer with increased surface roughness of the sample
prior to coating from (0.95 µm) to (5.45 µm) increased the hardness of the coating layer from
(7*10-3 HB) to (8.055*10-3 HB) due to increased mechanical interlock between the coating and
the sample surface protrusions and the coating layer takes extra hardness from the coated sample.
6. The greatest hardness is obtained when the sample is heated before coating to a
temperature of (350 ºC), It is noted that the low surface temperature of (350 ºC) or higher surface
temperature of more than (350 ºC) leads to gives a low hardness.
0
2
4
6
8
0 100 200 300 400 500 600
Hardnessofcoatinglayer
)HB3-10(*
ºC

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EFFECT OF THE ROUGHNESS AND TEMPERATURE OF THE SURFACE OF THE BASE MATERIAL ON THE MECHANICAL PROPERTIES OF THE COATING LAYER (NICKEL - ALUMINUM) SPRAYED THERMALLY BY FLAME

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EFFECT OF THE ROUGHNESS AND TEMPERATURE OF THE SURFACE OF THE BASE MATERIAL ON THE MECHANICAL PROPERTIES OF THE COATING LAYER (NICKEL - ALUMINUM) SPRAYED THERMALLY BY FLAME