Role of hydrogen on adhesion of NiCr thermal sprayed coatings

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Ž.Thin Solid Films377᎐3782000675᎐680Role of hydrogen on adhesion of NiCr thermal sprayed coatings J.Lesage a,U,D.Chicot a,P.Araujo a,M.Zampronio b,P.E.V.De Miranda ca Laboratoire de Mecanique de Lille,URA CNRS1441,U.S.T.Lille,IUT A GMP,Villeneu¨e d’Ascq,France´b Departamento de Fisica,DFI r UEM,C.P.331,CEP87020-900Maringa,Brazil`c Laboratorio de Hidrogenio,COPPE r UFRJ-C.P.68505,CEP21945-970,Rio de Janeiro,BrazilˆAbstractHydrogen embrittlement was known for many years.Different theories explain how hydrogen plays the role of an accelerator for fracture when it was introduced into the material either during its elaboration or during its service as a mechanical part.In this latter case,the presence of a barrier to introduction of hydrogen into the material may delay or even impede the embrittlement process.The present study was devoted to the mechanical aspects of hydrogen contamination of this type of a NiCr thermal sprayed coating and in particular to the influence of hydrogen on the coating adhesion on a low carbon steel substrate.It was found that,besides the embrittlement of the coating,adhesion was also affected since the critical load necessary to initiate a crack at the interface was reduced in the presence of ing an apparent interface toughness concept it was also possible to point out the effect of the residual stresses in relation to the coating thickness as well as surface effects on the apparent interface toughness value.ᮊ2000Elsevier Science B.V.All rights reserved.Keywords:Adhesion;Coatings;Hardness;Hydrogen1.IntroductionTo eliminate or to delay as much as possible the hydrogen embrittlement of steels during service is a remanent industrial problem.Two different ways may be followed for that purpose.Thefirst one consists in improving hydrogen embrittlement resistance using neww xalloyed steels1,2.This solution is generally not cheapw xand has found its limits3.The second possibility is to prevent hydrogen to penetrate the steel parts using a superficial treatment in order to create a barrier tow xhydrogen contamination4᎐8.NiCr AtmosphericŽ.Plasma Sprayed APS coatings are used to resist abra-sion by particles.We proposed here to study the be-haviour of a thermally sprayed NiCr coating in order to answer the following question:How the mechanical Ž. properties hardness,adhesion of the coating are mod-U Corresponding author.Tel.:q33-3-20-67-73-26;fax:q33-320677321.Ž.E-mail address:jacky.lesage@univ-lillel.fr J.Lesage.ified after hydrogen inoculation into the substrate r coating couple?It is known that a suitable annealing treatment in-w x creases the adhesion of thermally sprayed coatings9. That is why we will study the influence of hydrogen only on the annealed specimen.The interfacial inden-tation test was developed as an alternative means tow x other,standard or not,adhesion tests10᎐13.Here, the test confirms that it is adequate to characterise the influence of hydrogen contamination on the adhesive properties.2.Materials and experimentsWe have seen that the apparent interface toughness of a given coating r substrate couple depends on thew x mechanical properties of the two materials14.It was shown also that the residual stresses generated during the thermal spraying play an important role on thew xadhesive properties of the coatings9.Keeping in mind this basic remarks and in order to study the effect of0040-6090r00r$-see front matterᮊ2000Elsevier Science B.V.All rights reserved.Ž.PII:S0040-60900001449-8()J.Lesage et al.r Thin Solid Films 377᎐3782000675᎐680676hydrogen contamination,we prepared a low carbon Ž.steel substrate 0.2%C following two heat treatments;normalised or quenched.The effect of an annealing treatment at 600ЊC during 2h in air was also examined on the sprayed samples.Ž.Ž.The thermal spraying of a Ni 80%Cr 20%powder Ž.was realised on parallelepipedic samples 30=30=2.7after that a sand blasting was performed in order to Ž.obtain a roughness R s 6␮m favourable to the a mechanical anchoring of NiCr coatings of thicknesses Ž.ranging from 200to 600␮m see Tables 1and 2.Hydrogen contamination was performed using a Ž.NaOH 0.1N electrolytical solution.Hydrogen pro-duction coming from the application of a currentTable 1Experimental and calculated results as well as hardness and Young modulus data necessary for the calculation of the apparent interface Ž.toughness normalised substrate Normalised substrateSubstrate:low carbon steel Coating:NiCrH s 1.18GPa E s 210GPa H s 2.75GPa E s 110GPaS S F F E 1r 2s 10.56ž/H iA.S.As sprayed Ž.e mm 0.240.430.53Ž.P N 8.223.648.2C Ž.a ␮m 48.081.5116.5C 1r 2Ž.K ca MPa.m 3.91 5.08 6.07Ž.b mm 0.160.260.38A.T.Annealing treatment Ž.e mm 0.240.450.56Ž.P N 44.4106.7249.1C Ž.a ␮m 111.8173.3264.8C 1r 2Ž.K ca MPa.m 5.957.419.16Ž.b mm 0.360.560.85A.t.q H A.T.q Hydrogen contamination 2Ž.e mm 0.240.430.53Ž.P N 32.285.2149C Ž.a ␮m 95.2154.9204.8C 1r 2Ž.K ca MPa.m 5.497.008.05Ž.b mm 0.310.500.66Table 2Experimental and calculated results as well as hardness and Young modulus data necessary for the calculation of the apparent interface Ž.toughness quenched substrate Quenched substrateSubstrate:low carbon steelCoating:NiCrŽ.H s 2.45GPa E s 210GPa H s 2.06GPa A.T.H s 2.75GPa E s 110GPa S S S F F E 1r 2E Ž.s 8.35A.T.and A.T.q H 1r 22ž/Ž.H s 7.83A.S.iž/iA.S.As sprayed Ž.e mm 0.260.410.53Ž.P N 2.710.615.2C Ž.a ␮m 21.943.452.0C 1r 2Ž.K ca MPa.m 3.09 4.35 4.76Ž.b mm 0.090.180.21A.T.Annealing treatment Ž.e mm 0.220.410.52Ž.P N 22.540.491.8C Ž.a ␮m 63.284.7127.7C 1r 2Ž.K ca MPa.m 5.61 6.497.97Ž.b mm 0.260.340.52A.t.q H A.T.q Hydrogen contamination 2Ž.e mm 0.230.400.52Ž.P N 12.922.229.6C Ž.a ␮m 47.962.872.5C 1r 2Ž.K ca MPa.m 4.87 5.59 6.01Ž.b mm 0.190.260.29()J.Lesage et al.r Thin Solid Films 377᎐3782000675᎐680677between the electrode and the sample.The current is w x calculated from the polarisation curves 15.Here we choose a current density of 0.1A r m 2applied during 3h.This duration time of hydrogenation was calculated from the apparent diffusion coefficient of hydrogen in w x the material 16.In these conditions all the hydrogen trapping sites are assumed to be filled.Figs.1᎐3present the results of the interfacial inden-tation tests using the following procedure:1.polishing a cross-section of the coated sample,inorder to perform Vickers indentation tests with different applied loads,for which one diagonal of the indent must be coincident with the coat-ing r substrate interface;2.for each indentation test,measuring the value ofŽ.the half diagonal of the indent a and the length of Ž.Žthe crack l ,both at the interface it was shown w x .that the crack has a semi circular shape 9;3.plotting these data as a function of the applied loadin bi-logarithmic scale;4.determining the coordinates of the criticalpointFig.1.Mean crack length as a function of the applied indentationŽ.Ž.load for the as-sprayed sample:a normalised substrate;and b quenchedsubstrate.Fig.2.Mean crack length as a function of the applied indentation Ž.Ž.load for the annealed sample:a normalised substrate;and b quenched substrate.Ž.Ž.P ,a ,intersection of the two lines a -ln P and C C Ž.l -ln P .This point,underneath no crack initiation was observed upon indentation,and used to calcu-late the apparent interface toughness of the coat-w x ing-substrate couple 14:1r 2P EC Ž.K ca s 0.015и13r 2ž/Hia C Ž.1r 2where E r H ,the interface apparent mechanical iproperties ratio,was calculated from:1r 21r 2Ž.Ž.E r H E r H 1r 2SCŽ.Ž.E r H s q2i1r 21r 2Ž.Ž.1q H r H 1q H r H S C C S where the subscripts i ,S and C stand for interface,substrate and coating respectively.Tables 1and 2give the experimental results and the calculated values as well as the hardness and Young modulus data necessary for the calculation of the ap-parent interface toughness.()J.Lesage et al.r Thin Solid Films 377᎐3782000675᎐680678Fig.3.Apparent interface toughness as a function of the thickness Ž.Ž.parameter for all the modalities:a normalised substrate;and b quenched substrate.3.Results and discussionŽ.Ž.It is seen that the relation ln a vs.ln P ,for the as Žsprayed samples,are similar for the normalised Fig..Ž.1a and quenched Fig.1b substrate although higher P values are obtained for the normalised ones.Also,C for higher loads,a change of slope was observed which was connected to the presence of a crack in the coating from the tip of the indent toward the surface in addi-tion to the crack formed at the interface.Fig.2a,b corresponds to the same quenched and normalised substrate but with an annealing treatment Ž.2h at 600ЊC performed after thermal spraying.As a consequence of this annealing treatment,it is seen that the values of P have strongly increased.The change C of slope has disappeared and it was observed that no crack was formed at the tip of the indent in the coating for the higher loads.Residual stresses in thermal sprayed coatings result from the superposition of three stresses sources.The first source was due to phase transformation during the spraying process and the second one was due to theexpansion coefficient mismatch between the substrate and the coating and the third one comes from thermal gradients which were established during the spraying w x w x and cooling process 17.It was demonstrated 18that a suitable annealing treatment reduces the major part of these residual stresses.As evidence the stresses due to thermal coefficient mismatch will persist after cooling from annealing temperature.We have demonstrated elsewhere that,when the residual stresses are elimi-nated or drastically reduced in the coating and a for-Žtiori in the substrate due to mechanical equilibrium .considerations ,the apparent interface toughness was Žindependent of the coating thickness providing that .w x the thickness was sufficient to perform the test 19.In this case,only one critical point exists and then only one corresponding value K ca which then can be called K ca .O We will now examine the relations between the values of K ca and the thickness of the coating for all i the modalities.For our results,a linear variation,for the as sprayed specimen can be obtained if the inter-face toughness is represented in function of a thickness 2Ž.w x parameter 1r e Fig.3.Following Kuroda 17,20,residual stresses should tend to zero for very high thickness values.If this notion is transposed to the relation between K ca and thickness,we should obtain the K ca value by extrapolating the results to an O infinite thickness.For the as sprayed specimen it was possible to obtain this K ca value.O For the annealed specimen,on the contrary,Fig.3shows that the K ca values are higher than K ca and O are as high as the thickness.That means that another phenomenon took place during indentation.In the Žideal case when the stresses are reduced at a maxi-.mum and has a sufficient thickness during the indenta-tion,plastic zones are developed freely each side of the interface.The extent of the plastic zone depending on the elasto-plastic properties of the materials.Gener-ally,for a material of high hardness,the plastic zones w x were very small.Works by Lawn 21have shown that the plastic zone developed in the material under the indent may be represented by a hemisphere having a radius expressed by the following relation:1r 2d E 1r 3Ž.b s ииcot g ␰3ž/2Hwhere d is the diagonal of the indent,E and H are respectively the Young modulus and the hardness and ␰is the semi-angle at the tip of the indenter measured Ž.between two edges 74Њ.If it is supposed here that the deformed zones in the coating and in the substrate under the indent have this spherical shape.The difference between the radii of each zone suggests that the motor of the crack initia-tion should be linked to the radius mismatch by the()J.Lesage et al.r Thin Solid Films 377᎐3782000675᎐680679generation of shear stresses at the interface between the coating and the substrate.The extent of this mis-match depends on the mechanical properties of the substrate,coating,and obviously,on the adhesive properties of the coating on its substrate.In some cases,and particularly when the coating has a low hardness,the plastic zone is so large that it interfers with the surface.In these conditions,the plastic zone Ž.cannot maintain its spherical shape surface effect .As a consequence of this change of shape,we may think that the radius mismatch decreases and as a corollary,the load necessary to initiate a crack increases.We can find confirmation of this assumption by considering the theoretical radius which should correspond to the criti-Ž.cal load P .Using the relation 3and the general C Ž.expression of the hardness H in MPa :P C Ž.H s 1.8544и42d Ž.where P is the critical load in N and d the diagonal C Ž.of the indent in mm.Fig.4.Mean crack length as a function of the applied indentation Ž.load for the annealed and hydrogen contaminated sample:a nor-Ž.malised substrate;and b quenched substrate.It was possible to calculate the radius of the plastic zone in function of the critical load as follow:E 1r 2Ž.b s 0.0142ииP 5CHTables 1and 2give the results of the calculation for each situation.It can be seen that when K ca is higher than K ca the radius which was calculated using this O methodology was always higher than the thickness in-dependently of the treatment.Some values of K ca,nevertheless,are lower than K ca and particularly for O the small thicknesses.This suggests that the residual stresses have not been completely removed by the annealing treatment.If it is considered the effect of hydrogen,our hy-pothesis is reinforced since it is clear that hydrogen trapping generates residual stresses in the material w x 22.As a consequence,the K ca for the hydrogen-con-taminated samples were reduced compared to the only Ž.annealed ones Fig.3.Moreover,Fig.4shows the reappearance of the change of slope,at least for some of the thicknesses,indicating the presence of a signifi-cant residual stress state.4.ConclusionIn this paper,we confirmed that the residual stresses,generated during thermal spraying,have a detrimental effect on the adhesive properties of a NiCr thermal sprayed coating.A suitable annealing performed after spraying improves by a factor of 5the critical load necessary to initiate a crack at the interface by indenta-tion.Due to the fact that the hardness of the coating was low compared to that of other types of coatings,a new phenomenon-related to the extension of the plas-tic zone under the indent in the coating,has been observed.Analysis of this phenomenon,joined to the known residual stresses effect,allowed us to propose a new interpretation for the relations between the 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