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<p>Agricultural-grade steels are frequently exposed to abrasive particles such as sand, stone, and quartz present in soil, leading to severe wear during service. To enhance the mechanical and tribological performance of such steels, this study focuses on the development of a ternary Al<sub>2</sub>O<sub>3</sub>-TiO<sub>2</sub>-SiO<sub>2</sub> composite coating on EN31 steel using the plasma spraying process. A comprehensive investigation into the microstructural characteristics, mechanical properties, wear resistance, and corrosion behavior of the coating was carried out. The resulting coating exhibits a heterogeneous, rough, and porous microstructure, characterized by microcracks, splats, unmelted particles, partially melted spherical droplets, and strip-like features. The porosity area fraction is approximately 10 ± 2.1%, with an average surface roughness of 5.4 ± 0.2&#xa0;µm. Phase analysis confirmed the existence of <i>α</i>-Al<sub>2</sub>O<sub>3</sub>, <i>γ</i>-Al<sub>2</sub>O<sub>3</sub>, TiO<sub>2</sub>, SiO<sub>2</sub>, and Al<sub>2</sub>O<sub>5</sub>Si in the coating, while the substrate (EN31 steel) contains ferrite, martensite (Fe<sub>1.92</sub>C<sub>0.08</sub>), and iron carbide (Fe<sub>7</sub>C<sub>3</sub>) phases. The coating also developed a compressive residual stress of –572&#xa0;MPa, which contributes to its improved mechanical integrity. Mechanically, the coating exhibited a substantial increase in hardness from 4 ± 0.4 GPa (substrate) to 7 ± 0.66 GPa, while the Young’s modulus decreased from 201 ± 4 GPa for EN31 steel to 145 ± 5 GPa for the coated surface. The enhanced hardness led to a notable reduction in the coefficient of friction, wear depth, and wear rate in comparison with the uncoated steel. The measured bond strength was found to be 15.1&#xa0;MPa, indicating a moderately strong interface between the coating and substrate. Moreover, the corrosion resistance of the coated sample was significantly improved, with the corrosion rate decreasing from 1.19 × 10<sup>−1</sup>&#xa0;mm/year for bare EN31 steel to 8.99 × 10<sup>−3</sup>&#xa0;mm/year for the composite-coated sample. Overall, the Al<sub>2</sub>O<sub>3</sub>-10 wt.% TiO<sub>2</sub>-10 wt.% SiO<sub>2</sub> plasma-sprayed coating demonstrates enhanced wear and corrosion resistance, making it a promising surface modification strategy for steels exposed to abrasive environments such as those encountered in agriculture</p>

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Protective Ternary Al2O3-TiO2-SiO2 Coating for Enhancing Durability of Agricultural-Grade Steel

  • 期刊论文

  • 发表日期：

    2025年11月25日

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  • Renu Kumari

摘要

Agricultural-grade steels are frequently exposed to abrasive particles such as sand, stone, and quartz present in soil, leading to severe wear during service. To enhance the mechanical and tribological performance of such steels, this study focuses on the development of a ternary Al2O3-TiO2-SiO2 composite coating on EN31 steel using the plasma spraying process. A comprehensive investigation into the microstructural characteristics, mechanical properties, wear resistance, and corrosion behavior of the coating was carried out. The resulting coating exhibits a heterogeneous, rough, and porous microstructure, characterized by microcracks, splats, unmelted particles, partially melted spherical droplets, and strip-like features. The porosity area fraction is approximately 10 ± 2.1%, with an average surface roughness of 5.4 ± 0.2 µm. Phase analysis confirmed the existence of α-Al2O3, γ-Al2O3, TiO2, SiO2, and Al2O5Si in the coating, while the substrate (EN31 steel) contains ferrite, martensite (Fe1.92C0.08), and iron carbide (Fe7C3) phases. The coating also developed a compressive residual stress of –572 MPa, which contributes to its improved mechanical integrity. Mechanically, the coating exhibited a substantial increase in hardness from 4 ± 0.4 GPa (substrate) to 7 ± 0.66 GPa, while the Young’s modulus decreased from 201 ± 4 GPa for EN31 steel to 145 ± 5 GPa for the coated surface. The enhanced hardness led to a notable reduction in the coefficient of friction, wear depth, and wear rate in comparison with the uncoated steel. The measured bond strength was found to be 15.1 MPa, indicating a moderately strong interface between the coating and substrate. Moreover, the corrosion resistance of the coated sample was significantly improved, with the corrosion rate decreasing from 1.19 × 10−1 mm/year for bare EN31 steel to 8.99 × 10−3 mm/year for the composite-coated sample. Overall, the Al2O3-10 wt.% TiO2-10 wt.% SiO2 plasma-sprayed coating demonstrates enhanced wear and corrosion resistance, making it a promising surface modification strategy for steels exposed to abrasive environments such as those encountered in agriculture