Enhancement of Wear Resistance of AISI 1040 Forged Steel Roller Shaft by different Ceramic Oxide Coatings using Plasma Spray Process for Sugarcane Industries Rajarathnam D. R. P.*, Jayaraman M.** *Department of Mechanical Engineering, Paavai Engineering College, Namakkal, Tamilnadu, India **Department of Mechanical Engineering, Velalar College of Engineering and Technology, Erode, India Online published on 14 October, 2016. Abstract In this investigation, ceramic oxide powders alumina, titania, chromia, alumina-titania, alumina-chromia and titania-chromia are coated on AISI 1040 forged steel substrate with a coating thickness of 200 μm by using the plasma spraying technique. Ni-Cr is used as an intermediate bond coat material to improve the coating adhesion for a thickness of 20 μm over the substrate. By using a pin-on-disc machine, dry wear test was carried out as per ASTM-G99 standards for a constant load of 10N, at different sliding distances of 1000m, 2000m, 3000m respectively. The result showed that the wear rate depends on various attributes such as microstructure, thickness of coating, porosity, surface roughness and hardness. Surface roughness measurements were performed on the specimens before and after wear tests by using talysurf instrument and the results showed that the highest value (20.42 μm) was obtained from the coating of alumina-titania. From the above investigation, the results obtained showed that a pure chromia coated specimen is having very good wear resistance property among the tested specimens. Hence it is suggested that pure chromia can be used for surface coating on top mill roll shaft used in sugar industries to enhance wear resistance. Top Keywords Forged steel, Plasma spraying technique, Pin-on-disc machine, Microstucture, Talysurf instrument, Roll shaft. Top |