INFLUENCE OF COATING WITH NANO PARTICLES ON FATIGUE PROPERTIES OF PLAIN LOW CARBON STEEL BEAM

Transcription

1 International Journal of Mechanical Engineering and Technology (IJMET) Volume 9, Issue 9, September 2018, pp , Article ID: IJMET_09_09_010 Available online at ISSN Print: and ISSN Online: IAEME Publication Scopus Indexed INFLUENCE OF COATING WITH NANO PARTICLES ON FATIGUE PROPERTIES OF PLAIN LOW CARBON STEEL BEAM Dr. Qasim Bader and Ali Mohammed Ali Department of Mechanical Engineering, Babylon University, Babylon, Iraq ABSTRACT This work deals with the experimental and numerical study of the effect of nano coating material type and thickness on the fatigue behavior of low carbon steel beam. The nanomaterial used are ZnO, Al 2 O 3, and a mixture of both ZnO and Al 2 O 3. The prepared of nanomaterials was done in the nanotechnology laboratory. The coating was done by using a deposited technique. The experimental work included mechanical test, the coating process and fatigue test. The coating by nanomaterial of steel was done for a three thickness of each type of the coating. The result of experimental fatigue test shows different behavior depends on coating material type and thickness of coating. The result shows that Al 2 O 3 (aluminum oxide) has more effect on the fatigue strength and life compared to the specimen coated ZnO and Mixed of both them. Also, as the thickness of coating material increase, the fatigue life increased for all types of coating material. Where the increase in fatigue life at thickness 5 micro about 5.59 %, 5.15 % and 4.04 % for Al 2 O 3, Mixed and ZnO respectively, compared to un-coated specimen for plain low carbon steel. The finite element method was used to verify the experimental work using ANSYS workbench software program of version 16, the results showed acceptable error between the numerical and experimental solutions, with maximum overall average error of 4.28%. Keyword: fatigue behavior, nano-coating technique, ZnO, Al 2 O 3 Cite this Article: Dr. Qasim Bader and Ali Mohammed Ali, Influence of coating with nano particles on fatigue properties of plain low carbon steel beam, International Journal of Mechanical Engineering and Technology, 9(9), 2018, pp INTRODUCTION Fatigue can be defined as the deterioration in mechanical properties resulting in the failure of a material or component under the effect of cyclic loading. Where it was found that 90% of service failures in metal components are subject to movement due to fatigue. In general, fatigue is a problem that affects any structural component or part that moves. Like Axel of automobiles, transmission parts, suspension systems, nuclear reactors and turbines under cyclic temperature conditions [1] editor@iaeme.com

2 Influence of coating with nano particles on fatigue properties of plain low carbon steel beam T. Roland, et al., (2006), They studied the Nano-crystalline surface layer of 316L stainless steel and its effect on fatigue behavior. And through surface treatment of mechanical corrosion (SMAT). Significant improvements in yield stress and endurance limit have been achieved. It is also shown that mechanical properties can be greatly improved by the use of short post-annealing treatment after (SMAT). The results showed a significant improvement in the fatigue strength of the low cycle fatigue region and this becomes more high cycle fatigue in addition to the improvement in the fatigue life [2]. A. Ibrahim, et al., (2007), In this work, TiO2 was sprayed thermally using air plasma spray (APS) and the process of high-speed oxygen fuel (HVOF). They showed the result of the fatigue strength of coatings deposited onto L.C.S steel (AISI 1018) that the nanostructured titanium coated specimens exhibited significantly higher fatigue strength compared to the conventionally sprayed titania [3]. X.J. Cao, et al., (2010), The ultrasonic Nanocrystal surface modification (UNSM) technique was used in 3 different vibration numbers (34,000 times / mm2, 45,000 times / mm2, 68,000 times / mm2) to improve surface and properties of steel 45C. These different numbers of vibration produced three practical conditions respectively, 2 micro,12 micro, and 30 micro Nano-crystal layers. The results showed an improvement in fatigue strength of up to 33% to steel 45C using (UNSM) at the number of vibration (68,000 times / mm2). The Nanocrystalline surface layer acts to delay the onset of fatigue cracks [4]. C. J. LEE and RI-I. MURAKAMI (2010); The fatigue characteristics of the A6061-T6 aluminum samples were obtained and compared with those samples treated with ultrasonic Nanocrystal surface treatment technology and untreated by rotating bending fatigue testing machine ( multi-spindle). The process of cracking and fatigue of the treated samples with UNSM technology has been delayed and UNSM has the effect of increasing surface hardness, reducing surface roughness. It has the effect of UNSM on fatigue strength, increasing it by about 15% [5]. X.C. Zhang et al., (2011), they studied the method of failure and the rolling contact fatigue failure mechanism of the (Ni-Cr-B-Si) by laser-melted plasma-sprayed coating in this research. The deposition coating process was carried out using a highly efficient plasma spraying system and was refilled using a (CO2) laser in continuous mode. The Weibull distribution plot was obtained which illustrates the fatigue life data after coating [6]. X. Li, et al., (2011), They were studying the fatigue properties on Nano-grained delaminated low-carbon steel sheet under different applied loads. We observed the morphology of the fatigue fracture of the sample under different applied loads by SEM. And results showed significantly enhanced the fatigue characteristics of the steel, reaching ( ), and indicating high cycle fatigue characteristics [7]. 2. EXPERIMENTAL WORK 2.1. Chemical Compositions Analysis for Low Carbon Steel In this work, a low carbon steel alloy was used for investigation. The chemical composition of the selected material was done using the spectrometer device. The purpose of the chemical composition analysis is to classify the material by knowing the percentage of carbon and finding out the percentage of each alloy element added to the material. The results obtained are recorded in Table (1) editor@iaeme.com

3 Dr. Qasim Bader and Ali Mohammed Ali Table 1 Chemical compositions for Low carbon steel material Material C% Si% Mn% P% S% Fe% LCS Bal Tensile Test The tensile test was done by using the universal testing machine type (WDW-200E - 100KN) with a speed rate of 2 mm/min as it is shown in figure (1). The specimens for a tensile test were manufactured according to the specification of ASTM (G.L =50 mm and D = 12.5) [8], the average value of the ten readings are recorded for the property. The results obtained are recorded in Table (2) Table 2 Tensile test results for sample low carbon steel Material Property value Yield Strength (MPa) 350 Ultimate Strength (MPa) 495 LCS Modula's of Elasticity E (GPa) 200 Percentage Elongation 22 Percentage Reduction of Area editor@iaeme.com

4 Influence of coating with nano particles on fatigue properties of plain low carbon steel beam Figure 1 Tensile test machine 2.3. Fatigue Test Specimens The fatigue specimens are machined in dimension (D= 12mm and L 1 = 40 mm) and (d = 8 mm and L 2 = 106 mm) as shown in the Figure (2). The specimens used in the experiments to plot the S-N curve (Basquin's equations). Figure 2 fatigue test specimens 2.4. Nano Coating In this work three types of nanomaterial are used: -Zinc oxide (ZnO) -Aluminum oxide (Al 2 O 3 ) -A mixture of (ZnO, Al 2 O 3 ) 80 editor@iaeme.com

5 Dr. Qasim Bader and Ali Mohammed Ali Spray solutions for preparation of ZnO Zinc oxide (ZnO) was prepared by Chemical Spray Pyrolysis deposit (CSPD) from the following starting chemical Zinc acetate (Zn (OAc)2.2H2O), with purity of 99.6% and molecular weight M w of g/mol. The molar concentration of the solution should be equal to be 0.1 mole/liter for (Zn (OAc)2.2H2O), dissolve (5.48g ) of (Zn (OAc)2.2H2O), in 250 ml of ethanol by the container in centrifuge for half hour to ensure the homogeneity,[9] Spray solutions for preparation of Al 2 O 3 Aluminum oxide prepared by (CSPD) from the following starting chemical Aluminium nitrate (Al (NO 3 ) 3.9H2O)), with purity of 99.5% and molecular weight M w of g/mol. The molar concentration of (Al (NO 3 ) 3.9H2O)), the solution should be equal to be 0.1 mole/liter, dissolve (9.38g ) of (Al (NO 3 ) 3.9H2O)), in 250 ml of ethanol Spray solutions for preparation of mixture (ZNO and Al 2 O 3 ) 1. Zinc acetate (Zn (OAc)2.2H2O) was used in preparation ZnO. To obtain (0.1) Molarity concentration of (Zn (OAc)2.2H2O) solution, an amount of (5.48g) of (Zn (OAc)2.2H2O) was dissolved in 250 ml of ethanol. 2. Aluminium nitrate (Al (NO 3 ) 3.9H2O) was used in preparation Al 2 O 3.To obtain (0.1) Molarity concentration of (Al (NO 3 ) 3.9H2O) solution, an amount of (9.38g) of (Al (NO 3 ) 3.9H2O) was dissolved in 250 ml of ethanol. 3. Mixing (50 of solution aluminum nitrate in ethanol and with (50 for zinc acetate solution in ethanol The Coating Prosser By Deposited In this work, three materials have been deposited on a steel sample by using chemical spraying pyrolysis technique. The nano coating was done inside the furnace at a temperature of (450 C) by using an air pump to provide compressed air mixing with nano-coat and applied the stream to steel samples. The spray rate of (2.1 ml/ min) and the compressor pressure of (1) bar. And the distance between the sample and the nozzle is (30 cm) [10]. The coating machine as shown in figure (3) Figure 3 Coating machine 81 editor@iaeme.com

6 Influence of coating with nano particles on fatigue properties of plain low carbon steel beam 2.6. Calculation of Thickness Coating A glass slide puts near the coated sample was placed to determine the thickness of the coating material [11], Dimensions glass slide is (Width = 25 mm, Length =75 mm) Mass of glass slide before coating = gm The thickness of coating (t) = Δm c : Change in the glass slide weight after and before coating (gr). A: Area of the glass slide (mm 2 ). Ρ: Density of the coating (for ZnO, Al 2 O 3 and mixture coating is 5.606gr/cm 3, 3.987g/cm 3 and gr/cm 3 ) respectively Fatigue Test Machine Rotating bending machine type (WP 140) was used in the test. This type with single cantilever beam specimen with constant amplitude and fully reversed load, as shown in figure (4) (1) Figure 4 fatigue test machine 3. NUMERICAL INVESTICATION The ANSYS Workbench software package version 16 was used to modeling numerically the fatigue tests of the different coating specimens used in the experimental work based on the stress life method. The constant amplitude loading as a fully reversed of stress ratio R= -1 was applied to determine the S-N curves and to prediction the fatigue life for each material at all tested thickness 1µ, 3µ, 5µ Life Result by Contour Plot A contour plot that shows the life variables that are used to give the analysis of fatigue. If the loading of constant amplitude load, so it represents the number of cycles until the failure event of the component due to fatigue. figure (5) shows available life for analysis of fatigue 82 editor@iaeme.com

7 Dr. Qasim Bader and Ali Mohammed Ali Figure 5 Available life for fatigue analysis 4. RESULTS There are many factors affected on the fatigue performance. In this study we stating the influence of coating type and thickness. Fatigue tests were performed for all types of coating materials are (zinc oxide, aluminum oxide, and mixed of both them) and in different thickness tested 1µ, 3µ, 5µ. For each type of coating material and thickness test, there are five samples tested with the same applied load. The results are graphically recorded in the form of S-N, curves. These curves are obtained by curve fitting of the experimental data of fatigue tests. Figures (6) to (8) express the S-N curves of ZnO, Mixed and Al 2 O 3 respectively. These figures show the behavior of fatigue for each material and thickness. We concluded that an increase the thickness of the coating a increasing the fatigue performance. For each nano coating material. Figure 6 Comparison between different thickness coatings for (ZnO) 83 editor@iaeme.com

8 Influence of coating with nano particles on fatigue properties of plain low carbon steel beam Figure 7 Comparison between different thickness coatings for (Mixed) Figure 8Comparison between different thickness coatings for (Al 2 O 3 ) Figure (9) shows the relation of the fatigue strength and thickness for ZnO, Al 2 O 3, and Mixed, and can observe that the fatigue strength increase with an increase in thickness. Also, it is concluded that a linear regression of one order can fit the experimental data to include the thickness effect on the fatigue strength. Figure 9 fatigue strength varies the nano-coating thick From table (3) to (5) we concluded that a increase the thickness of the coating a increasing the fatigue performance. For each nano-coating material editor@iaeme.com

9 Dr. Qasim Bader and Ali Mohammed Ali Table 3 Experimental S-N curve equation (Basquin's equation) and fatigue strength σe at for different thickness of (ZnO) cycles Thickness (µ) S-N equation Fatigue strength (MPa) Correlation coefficient non-coated = = = = Table 4 Experimental S-N curve equation (Basquin's equation) and fatigue strength σe at for different thickness of (mixed) cycles Thickness (µ) S-N equation Fatigue strength (MPa) Correlation coefficient non-coated = = = = editor@iaeme.com

10 Influence of coating with nano particles on fatigue properties of plain low carbon steel beam Table 5 Experimental S-N curve equation (Basquin's equation) and fatigue strength σe at for different thickness of (Al 2 O 3 ) cycles Thickness (µ) S-N equation Fatigue strength (MPa) Correlation coefficient non-coated = = = = Table (6) shows the Percentage Fatigue Life Improvement Factor for different nanocoating materials. the Percentage Fatigue Life Improvement Factor from is calculated from the following equation [12]. FLIF% = Where, N f = number of cycles to failure for coating nano material, N f ref = number of cycles to failure of reference material (un coating) Table 6 Percentage Fatigue Life Improvement Factor (FLIF%) for ZnO, Mixed and Al 2 O 3 at different test thickness (2) Thickness (µ) ZNO Mixed Al2O editor@iaeme.com

11 Dr. Qasim Bader and Ali Mohammed Ali Table 7 Percentage of Fatigue Strength Improvement Factor (FSIF%) for ZnO, Mixed and Al 2 O 3 at different thickness. Thickness ( Zno Mixed Al2O Comparison between Experimental and Numerical Results The comparison between the experimental and numerical S-N curves for each material and thickness are shown in figures (10) to (12) Figure 10 experimental and numerical for (ZnO) with thickness 5µ Figure 11 experimental and numerical for (Mixed) with thickness 5µ 87 editor@iaeme.com

12 Influence of coating with nano particles on fatigue properties of plain low carbon steel beam Figure 12 experimental and numerical for (Al2O3) with thickness 5µ From table (8) shows the overall average error Between Experimental and Numerical Results, The maximum and minimum percentage error between the experimental and numerical results is found no more than 4.28 % and 2.88 % respectively. The overall average error is calculated from following equation [12]. E %= Where, E = overall average error between experimental and numerical life data, N Exp = experimental number of cycles to failure, N Num.= numerical number of cycles to failure. Table 8 overall average error for fatigue life (3) Material Thickness (µ) Error % Un-coating ZNO Mixed Al2O editor@iaeme.com

13 Dr. Qasim Bader and Ali Mohammed Ali 5. CONCLUSION The following conclusions were obtained from this study. 1. The result of empirical testing of fatigue shows the positive effect of nano coating layers on the fatigue life of low carbon steel bars. 2. endurance limit, fatigue life, and fatigue ratio (σe/σult) increase with increasing coating thickness. 3. Coating with Al 2 O 3 gives more improvement to fatigue performance than both ZnO and Mixture of (ZnO and Al 2 O 3 ). While coating with mixed gives improvement to fatigue performance than ZnO 4. The Fatigue Life Improvement Factor (FLIF) at thickness 5 micro of zinc oxide, mixture and aluminum oxide. reaches (4.04%,5.15%,5.59%) Respectively, compared to un-coating specimen. 5. The Fatigue Strength Improvement Factor (FSIF) at thickness 5 micro of zinc oxide, mixture and aluminum oxide. reaches (7.89%,10.17%,12.61%) Respectively, compared to un-coating specimen. 6. The maximum overall average error between the experimental and numerical results is found no more than 4.28 % and the minimum percentage error is found 2.88%. REFERANCE [1] Hosford, William F. "Mechanical Behavior of Materials". Cambridge University Press, [2] Roland, Thierry, et al. "Fatigue life improvement through surface nanostructuring of stainless steel by means of surface mechanical attrition treatment." Scripta Materialia (2006): [3] Ibrahim, A., et al. "Fatigue and mechanical properties of nanostructured and conventional titania (TiO2) thermal spray coatings. "Surface and Coatings Technology (2007): [4] Cao, X. J., Y. S. Pyoun, and R. Murakami. "Fatigue properties of a S45C steel subjected to ultrasonic nanocrystal surface modification." Applied Surface Science (2010): [5] Lee, Chan Joo, Ri-Ichi Murakami, and Chang Min Suh. "Fatigue properties of aluminum alloy (A6061-T6) with ultrasonic nano-crystal surface modification." International Journal of Modern Physics B 24.15n16 (2010): [6] Zhang, X. C., et al. "Failure mode and fatigue mechanism of laser-remelted plasmasprayed Ni alloy coatings in rolling contact." Surface and Coatings Technology (2011): [7] Li, X., et al. "Fatigue property of nano-grained delaminated low-carbon steel sheet." Journal of Materials Science & Technology 27.4 (2011): [8] N. A. Alang, N. A. Razak and A. K. Miskam, "Effect of Surface Roughness on Fatigue Life of Notched Carbon Steel", International Journal of Engineering & Technology IJET- IJENS Vol.:11 No: 01, , [9] Jayanta Kumar Behera, Synthesis and Characterization of ZnO Nano-Particles, Master thesis, National Institute of Technology, India, [10] Bedia, F. Z., et al. "Electrical characterization of n-zno/p-si heterojunction prepared by spray pyrolysis technique." Physics Procedia 55 (2014): [11] Yasir, Ali S. "Improving the fatigue life of steel bars by using Nano-coating technology." International Journal of Engineering & Technology 3.4 (2014): [12] Sharp P. K., Barter S. A. and Clark G., "Localized life extension specification for the F/A- 11. Y400x11 pocket", Melbourne: DSTO-TN-0279, editor@iaeme.com