This study uses a novel thermal spray based detonation gun method to apply a hard cermet (86WC-10Co-4Cr) coating of 100 μm thickness on tool steel parts fabricated by the SLM process and evaluates its impact on tribological behaviour. The results are compared among as-fabricated, heat treated (500°C, 750°C, 1000°C) samples with air cooling for 6 h and coated samples. The coated sample exhibited 10.65% porosity and an adhesion strength of 141.14 N/mm². The pin on disc sliding wear measurement showed a lower friction coefficient and wear rate of 0.54 and 0.30 mm³/m, respectively, in the coated sample. Post wear surface analysis indicated higher surface roughness in coated sample used in sliding (20.3% Ra, 48.9% Rz) and micro abrasion (60.57% Ra, 24.96% Rz) wear studies than in the as-fabricated sample. The micro abrasion wear test indicated a low friction coefficient of 0.35 and exhibited a smaller crater diameter on the coated surface.
YapCYChuaCKDongZL, et al.Review of Selective Laser Melting: Materials and Applications. Appl. Phys. Rev2015; 2: 041101.
2.
DavidsonKSingamneniS. Selective Laser melting of Duplex stainless steel powders: an investigation. Mater. Manuf. Process2016; 31: 1543–1555.
3.
GaoBZhaoHPengL, et al.A review of research progress in selective Laser melting (SLM). Micromachines (Basel)2022; 14: 57.
4.
BouabbouAVaudreuilS. Understanding Laser-metal interaction in selective Laser melting additive manufacturing through numerical modelling and simulation: a review. Virtual Phys. Prototyping2022; 17: 543–562.
5.
MansouraAOmidiNBarkaN, et al.Selective Laser melting of stainless steels: a review of process, microstructure and properties. Metals Mater. Int2024; 30: 2343–2371.
6.
GigantoSMartínez-PelliteroSCuestaE, et al.Proposal of design rules for improving the accuracy of selective Laser melting (SLM) manufacturing using benchmark parts. Rapid Prototyp. J2022; 28: 1129–1143.
7.
JiaHSunHWangH, et al.Scanning strategy in selective Laser melting (SLM): a review. Int. J. Adv. Manuf. Technol2021; 113: 2413–2435.
8.
WuWWangXWangQ, et al.Microstructure and mechanical properties of maraging 18Ni-300 steel obtained by powder bed based selective Laser melting process. Rapid Prototyp. J2020; 26: 1379–1387.
9.
WuYZhaoXChenQ, et al.Strengthening and fracture mechanisms of a precipitation hardening high-entropy alloy fabricated by selective Laser melting. Virtual Phys. Prototyping2022; 17: 451–467.
10.
YangGXieYZhaoS, et al.Quality control: internal defects formation mechanism of selective Laser melting based on Laser-powder-melt pool interaction: a review. Chin. J. Mech. Eng.: Addit. Manuf. Front2022; 1: 100037.
11.
SimoniFHuxolAVillmerFJ. Improving surface quality in selective Laser melting based tool making. J. Intell. Manuf2021; 32: 1927–1938.
12.
HuangWZhangWChenX. Effect of SLM process parameters on relative density of maraging steel (18Ni-300) formed parts. IOP Conf. Ser.: Mater. Sci. Eng2020; 774: 012027.
13.
ZhangXXiaoZYuW, et al.Influence of erbium addition on the defects of selective Laser-melted 7075 aluminium alloy. Virtual Phys. Prototyping2022; 17: 406–418.
14.
SathishkumarNArumaikkannuG. Detonation spraying of a cermet coating to improve the surface properties of tool steel parts produced by the selective Laser melting process. J. Therm. Spray Technol2023; 32: 2439–2459.
15.
KumarMKumarSSinghPK, et al.Experimental investigation of additively manufactured MS-300 maraging steel samples: microstructure and mechanical properties. Proc. Inst. Mech. Eng., Part E: J. Process Mech. Eng2024: 09544089241295956.
16.
LiCJYangHLiH. Effect of gas conditions on HVOF flame and properties of WC-co coatings. Mater. Manuf. Process1999; 14: 383–395.
17.
XuZBXieSFengJA, et al.Laser-Assisted magnetorheological polishing of SLM-fabricated 316L stainless steel surface. Mater. Manuf. Process2024; 40: 459–465.
18.
SathishkumarNArumaikkannuGThangapandianN, et al.Exploring the impact of cryogenic treatment on detonation spray coated M2 high speed steel. Mater. Manuf. Process2024; 39: 2081–2098.
19.
TasciogluEKhanHMKaynakY, et al.Effect of aging and finish machining on the surface integrity of selective Laser melted maraging steel. Rapid Prototyp. J2021; 27: 1900–1909.
20.
ZhaoXWeiQSongB, et al.Fabrication and characterization of AISI 420 stainless steel using selective Laser melting. Mater. Manuf. Process2015; 30: 1283–1289.
21.
TanCZhouKKuangM, et al.Microstructural characterization and properties of selective Laser melted maraging steel with different build directions. Sci. Technol. Adv. Mater2018; 19: 746–758.
22.
KizhakkinanUSeetharamanSRaghavanN, et al.Laser powder bed fusion additive manufacturing of maraging steel. A Review. J. Manuf. Sci. Eng2023; 145: 110801.
23.
CampanelliSLContuzziNPosaP, et al.Study of the aging treatment on selective Laser melted maraging 300 steel. Mater Res Express2019; 6: 066580.
24.
KarlapudySPNancharaiahTRaoVS. Influence of different build orientation and Laser scan strategies on surface quality, mechanical and material characteristics of 18 Ni-300 maraging steel processed through DMLS. Aust. J. Mech. Eng2023; 21: 1381–1395.
SefeneEM. State-of-the-Art of selective Laser melting process: a comprehensive review. J. Manuf. Syst2022; 63: 250–274.
27.
ZhangBZhuLLiaoH, et al.Improvement of surface properties of SLM parts by atmospheric plasma spraying coating. Appl. Surf. Sci2012; 263: 777–782.
28.
GirnthSKoopmannJKlawitterG, et al.3D Hybrid-Material processing in selective Laser melting: implementation of a selective coating system. Prog. Addit. Manuf2019; 4: 399–409.
29.
ChengHXuBZhaoJ, et al.High-Performance nickel coating on SLM 316L stainless steel processed by jet electrochemical machining and jet electrodeposition. Proc. Inst. Mech. Eng., Part B: J. Eng. Manuf2022; 236: 462–472.
30.
MaceraLPulliniDBoschettoA, et al.Sol–gel silica coatings for corrosion protection of aluminum parts manufactured by selective Laser melting (SLM) technology. Coatings2023; 13: 1081.
31.
TillmannWHagenLSchaakC, et al.Adhesion of HVOF-sprayed WC-co coatings on 316L substrates processed by SLM. J. Therm. Spray Technol2020; 29: 1396–1409.
32.
GünenA. Micro-Abrasion wear behavior of thermal-spray-coated steel tooth drill bits. Acta Phys Pol A2016; 130: 217–222.
33.
WoodRJ. Tribology of thermal sprayed WC–co coatings. Int J Refract Met Hard Mater2010; 28: 82–94.
