A comparative study on erosion wear behavior of bilayered high velocity oxy‐fuel ceramic coatings on aluminum alloy substrate using granite and quartz erodent

Abstract High velocity oxy‐fuel coatings have been sprayed on a novel aluminium (Al) alloy substrate with varying coating thickness and tested for their wear behavior. The air erosion wear test has been conducted on coating samples using Granite stone powder and quartz sand of size up to 75 μm as erodent. The steady state experiments indicate that the greatest specific erosion rate is at 90° for erosion by granite sand and at 60° for erosion by quartz sand. The specific erosion rate decreases with the increase in the thickness of the coatings. Surface topography of the eroded samples indicate an increase in surface roughness at 90° as compared to that at 60° impact angle. Thereafter, Taguchi (L 16 ) orthogonal array is utilized in order to optimize the input parameters. The input parameters are impact velocities, Coating thickness, Erodent feed rate and impact angle. The results from Taguchi experiments find the order of dominance of control factors as: velocity > angle > coating thickness > erodent feed rate for erosion by granite stone and velocity > coating thickness > angle > erodent feed rate for erosion by quartz sand. Coatings have exhibited a semi‐ductile wear behavior.