FACTA UNIVERSITATIS Series: Mechanical Engineering Vol. 18, N o 1, 2020, pp. 31 - 42 https://doi.org/10.22190/FUME190623005B © 2020 by University of Niš, Serbia | Creative Commons License: CC BY-NC-ND Original scientific paper  SURFACE MODIFICATION OF RING-TRAVELER OF TEXTILE SPINNING MACHINE FOR SUBSTANTIALITY Preetkanwal Singh Bains 1 , Jasmaninder Singh Grewal 2 , Sarabjeet Singh Sidhu 1 , Sandeep Kaur 3 , Gurpreet Singh 1 1 Department of Mechanical Engineering, BCET, Gurdaspur, Punjab, India 2 GNDEC, Gill Road, Ludhiana, Punjab, India 3 GNDU (RC), Gurdaspur, Punjab, India Abstract. In this report, a study of the wear mechanisms involved in the spinning ring and the traveler of textile industry are presented. These components, after surface processing with various coatings techniques, were analyzed on the test rig so as to analyze the wear mechanism. The objective was accomplished by comparing various plasma sprayed coatings on E52100 steel pins using a pin-on-disc machine. The surface morphology as well as mechanical properties of the deposited coatings, namely WC-Co- Cr, Al2O3+TiO2 (Alumina-Titania) and Cr3C2NiCr, as well as uncoated E52100, were comparatively studied. This study elucidates towards improving the working life of the ring in a textile mill in the spinning operation. An x-ray diffractometer (XRD) and scanning electron microscope (SEM) were employed to characterize the unworn and worn surfaces of the specimens. The study revealed that the wear rate of plasma sprayed thermal coatings enhanced with augmenting load. The plasma sprayed WC-Co-Cr, Cr3C2NiCr, Al2O3+13TiO2 coatings developed on workpiece pins exhibited a notable decrease in volume loss of the material as compared to uncoated E52100 substrate. WC- Co-Cr coating turned out to be the best performer in terms of the lowest cumulative volume loss among all the variants of coatings. Key Words: Pin-on-disc, Thermal, Al2O3, Coatings, SEM, Traveler, XRD, Ring 1. INTRODUCTION The wear mechanisms amongst various parts of the spinning machine have been extensively studied and analyzed by myriad researchers over the past few years. For the efficient working of a textile mill, a ring and a traveler play a crucial role; the later impart twisting to yarn (thread), around the inner periphery of the ring, facilitating the winding Received June 23, 2019 / Accepted January 11, 2020 Corresponding author: Sarabjeet Singh Sidhu Department of Mechanical Engineering, Beant College of Engineering & Technology, Gurdaspur – 143521, Punjab, India E-mail: sarabjeetsidhu@yahoo.com 32 P.S. BAINS, J.S. GREWAL, S.S. SIDHU, S. KAUR, G. SINGH of the yarn on the bobbin. The centrifugal force between the two generates a high pressure during winding when the traveler glides around the ring along with the yarn (Fig. 1). As a consequence, the inner surface of the ring deteriorates in the form of waviness depicting abnormal wear pattern. This problem, however, mushrooms in by the recurring high-temperature cycles in addition to the usual tribological contact between them. The waviness formation on the internal face of the ring interrupts the free sliding of the traveler along the ring, resulting in an irregular winding of the thread. The obstructed sliding motion is usually associated with abrasion and wears causing the uneven and rough internal surface of the ring. Owing to abrasive wear, this causes the affected part to fail prematurely and demands regular replacements and reinstating of the rings. Moreover, this causes a considerable breakage of the thread and hence results in reduction in production efficiency [1, 2]. In the light of this, the surface modification of this component was carried out in this study, to enhance the compatibility, durability and performance with the help of suitable surface coatings. Fig. 1 New spinning Ring (left) and damaged Ring surface (right) Ceramics possess infinite merits over metallic as well as polymeric materials and are known for high hardness and effective resistance to the thermal and corrosive environment [3, 4]. Numerous oxide ceramics like alumina, silica, zirconia, titania, and chromium find widespread applications as potential materials for surface coatings and thermal barriers and for enhancing erosion, wear, abrasion, and corrosion resistance [5, 6]. Plasma spraying has been the prominent thermal deposition method in this regard [7- 9]. When spraying for coating, the molten particles collide to build a layer of coating with superior thermo-mechanical properties. The coating is generated high energy collision of particles to form solidified layer. Al2O3 and Cr2O3 coatings have been a point of interest for several industrial applications like turbines and pumps [10]. Al2O3 is a ceramic material known to have exceptional resistance to wear along with exhibiting high Surface waviness Traveler Ring Surface Modification of Ring-Traveler of Textile Spinning Machine for Substantiality 33 hardness at elevated temperatures [11, 12]. It has been witnessed from literature study that Cr2O3 coating is a better candidate for a wear and erosion resistant coating in a gentle sliding condition, under the normal load and it may exhibit typical tribological behavior. Rickerby and Winstone [13] put forward that the surface coatings help to deal with the physical and chemical degradation of the surface. The fracture toughness of Al2O3 coatings can be enhanced by the addition of TiO2 particles clad in the form of layers [14]. Thermal spraying is an effective and economical route to develop thick and uniform coatings for the surface modification of a part [15]. These spray coatings techniques are extensively used in automobile, textile, turbines, and aircraft industry [16]. The investigations revealed that the properties of the coatings primarily depend on the cohesion/bonding of particles which varies steeply with the temperature of sprayed particles [17]. Although copious research work [18-21] associated with the wear resistant coatings developed by plasma spray and HVOF techniques could be witnessed, much less work towards improving the wear resistance of distinct components of the textile industry has been traced. In Cr3C2NiCr coating, the NiCr phase is responsible for the required corrosion resistance whereas the carbide ceramic phase provides the necessary abrasive wear resistance [22, 23]. This study, thus, aims at exploring the characteristics and wear behavior of plasma sprayed coated E52100 pins using WC-Co-Cr, Al2O3+TiO2 and Cr3C2NiCr ceramics. The wear trends of coating observed from these tests were used to envisage the working life of the actual rings in the textile mill. 2. MATERIALS AND METHODS 2.1. Preparation of substrate and coating deposition Usually, the rings in the spinning machine are mainly subjected to friction and abrasive wear [24]; thus, to overcome such problems, WC-Co-Cr, Al2O3+13TiO2 and Cr3C2NiCr [25] opt as coating materials. The detail of the coating powders utilized in the present work is enlisted (Table 1) as below. Sulzer-Metco F4 plasma gun for atmospheric plasma spraying is employed to deposit three coating variants. Argon as carrier gas acts as a medium for both plasma-operation and coating powders. Table 1 Detail of the plasma sprayed powders Powder Preparation Route Powder size (µm) Density (mg/mm 3 ) Shape of particles Composition (wt. %) WC-Co-Cr Sintering/Agglomerated -45/ +10 5.8 Spherical 86 WC, 10 Co, 4 Cr Al2O3+13TiO2 Blending -45/ +11 3.43 Angular 87 Al2O3, 13 TiO2 Cr3C2NiCr Cladding -45/ +15 3.0 Irregular 85 Cr3C2, 15 NiCr A high-carbon iron alloy, E52100, in the form of pins (50mm x 5mm) was used as a substrate material owing to its hardenability and resistance towards wear, making it suitable for industrial applications. Al2O3+13TiO2, WC-Co-Cr and Cr3C2NiCr powders were deposited with a thickness in the range of 100-150 µm on the end-faces of the E52100 substrate (Fig. 2) material by the plasma spray. Nine circular specimens (50mm of length, 5mm diameter) were grit blasted using alumina grits at 3 kg/cm 2 pressure. The stand-off distance in shot blasting was kept between 150-200 mm. The average roughness of the surface to be coated was fixed as 6.8 μm (approx.) facilitating suitable adhesion of 34 P.S. BAINS, J.S. GREWAL, S.S. SIDHU, S. KAUR, G. SINGH the sprayed particles. The grit blasted specimens were cleaned with acetone in an ultrasonic cleaning unit followed by spraying. The chemical composition of the material used for testing (E52100) has been represented in Table 2. Fig. 2 Pictorial view of (a) Pins; (b) As-coated pin ends Table 2 Chemical composition of E52100 pins Grade Elements (%) E52100 Cr C Ni Si Cu P Mn S 1.580 0.996 0.107 0.236 0.11 0.054 0.468 0.005 2.2. Characterization of microstructure The microstructures and surface morphologies of the coating powder were examined using (JSM 6610LV, JEOL) field emission scanning electron microscopy (FE-SEM). In order to obtain coatings of uniform thickness, the same was noted precisely during the procedure of plasma spraying using a thin film thickness gauge (Minitest-600B, precision ± 1µm) at six distinct points, considering the average thickness of the coating. To identify distinct phases, XRD analysis for coated specimens was carried out using the X’Pert PRO, Panalytical Advance Diffractometer (Netherland) with CuKα radiation and nickel filter at 40 mA. The SEM examination of the coated samples before the wear test was carried out showing the dense, even with few pores and proper deposition of coatings without unmelted particles, as shown in Fig. 3. Surface Modification of Ring-Traveler of Textile Spinning Machine for Substantiality 35 Fig. 3 Morphology of as-coated specimens: (a) WC-Co-Cr; (b) Al2O3 +13TiO2; (c) Cr3C2NiCr 2.3. Experimental procedure To examine the controlled wear, the comparative tests were carried out for uncoated and plasma sprayed cylindrical pins (E52100) by employing a pin-on-disc apparatus (wear and friction monitor, TR-201) (Fig. 4) that incorporates a rotating disc and a sample holder loaded with dead weights. The weights (30N, 40N, 50N) were applied as a normal force on the sample for 30 minutes. The specimen pin was fixed in the holder at 80mm track diameter with the coated end facing the carbon steel (EN-31) rotating disc of a hardness of 64 HRC. The parameters of wear test are presented in the Table 3. The specimens were cleaned and degreased and weighed using a precision electronic balance (Citizen, CY220). The loss of weight for each specimen was noted at a gap of 30 minutes. After each trial, the sample pin was allowed to cool at room temperature after removing from the test rig. The wear debris was removed with the help of brushing, the sample was re-weighed to determine the material loss and then fixed back in the holder in the same position. (a) (b) (c) 36 P.S. BAINS, J.S. GREWAL, S.S. SIDHU, S. KAUR, G. SINGH Fig. 4 Pin-on-disc wear apparatus Table 3 Parameters of the sliding wear test Nomenclature Value Pin diameter (mm) 5.0 Pin material E52100 Bearing alloy steel Disc material Carbon steel (EN 31) Track diameter (mm) 80 Velocity (m/s) 5.50 Sliding distance (m) 5400 Weight (N) 30, 40, 50 Additionally, the volume loss represented in Table 4 indicates the amount of wear encountered by each sample calculated according to below Eq. (1), 3 3 weight loss (mg) CVL(mm )= density of coating material (mg/mm ) (1) The density of the coating material was measured by the gravimetric method. Moreover, the average porosity of as-sprayed coatings was less than 1%. The average thickness of selected coatings was recorded as 125 microns (approx) as measured using Minitest-600B. Fig. 6 shows the microstructure of the worn out surfaces of the coated specimens. Typical X-ray diffractograms (Fig. 7) for plasma sprayed coatings on E52100 specimens were carried out for phase identification with a rate of scanning ranging from 1º to 100º/min (2Theta) with Cu-Kα radiation equals to 1.5418Å. Surface Modification of Ring-Traveler of Textile Spinning Machine for Substantiality 37 Table 4 Experimentation design and results Trials Coatings Load CVL (mm 3 ) S/N Ratio (dB) R1 R2 1 WC-Co-Cr 30 0.059 0.061 24.4358 2 WC-Co-Cr 40 0.048 0.052 26.0137 3 WC-Co-Cr 50 0.090 0.101 20.3856 4 Al2O3 +13TiO2 30 0.084 0.084 21.5144 5 Al2O3 +13TiO2 40 0.083 0.086 21.4615 6 Al2O3 +13TiO2 50 0.099 0.111 19.5621 7 Cr3C2NiCr 30 0.300 0.299 10.4721 8 Cr3C2NiCr 40 0.665 0.665 3.5436 9 Cr3C2NiCr 50 0.528 0.531 5.5226 In order to draw valid conclusions, the prominent process factors, for instance, coating type and load (Table 4) selected by screening trials were changed at three levels. The limited numbers of runs were achieved as the optimum conditions using the full factorial design. In this experiment, two different repetitions at random order were carried out to obtain the S/N ratio for more precise results. The S/N ratio is considered as a performance measure in terms of ratio of magnitude of the signal strength to the noise. 3. RESULTS AND DISCUSSION The input variables chosen according to the control log of the standard full factorial method, and the recorded cumulative volume loss (CVL) values for wear of coatings along with their respective S/N ratio are arranged in Table 4. It is noteworthy from Fig. 5 that the coating is the most significant parameter affecting the volume loss of the coated samples; wherein, WC-Co-Cr coated pin (sample) exhibited very less wear damage. However, the severe abrasive wear was witnessed for Cr3C2NiCr variant of coating sample and was severe amid all the selected variants of coatings. Moreover, the load applied during the pin-on-disc testing was observed as an insignificant factor affecting the wear of the coated surface (Table 5). Hence, the wear resistance of plasma sprayed coatings generated on E52100 substrate was recorded as WC-Co-Cr > Al2O3 +13TiO2 > Cr3C2NiCr in their decreasing order. Fig. 5 Main effects plot of S/N ratios for CVL 38 P.S. BAINS, J.S. GREWAL, S.S. SIDHU, S. KAUR, G. SINGH Table 5 Analysis of variance for CVL Source DF Seq SS Adj SS Adj MS F-value p-value Coatings 2 505.46 505.46 252.736 40.75 0.002* Load (N) 2 19.99 19.99 9.996 1.61 0.307 Residual Error 4 24.81 24.81 6.203 Total 8 550.27 *significant The post-wear characterization of SEM micrographs of worn samples in Fig. 6 shows that the surface deposition remained uniform, homogeneous entailing no visible cracks. Fig. 6(a) illustrates that mostly spherical shaped particles were present with an elongated profile in few particulates resulting in denser coatings. The traces of carbide fragmentation followed by spalling were observed from Fig. 6(a). Some debris containing partially molten particles of the agglomerated and sintered alumina-titania had been noticed, as shown in Fig. 6(b). Also, SEM Fig. 6 SEM of worn samples (a) WC-Co-Cr (b) Al2O3 +13TiO2 (c) Cr3C2NiCr (at 30N) (c) (b) (a) molten metal Dense coating Uneven pits Spherical particles Surface Modification of Ring-Traveler of Textile Spinning Machine for Substantiality 39 micrographs revealed that oxidation might have occurred due to the presence of γ-Al2O3, as disclosed in XRD analysis (Fig. 7). However, in Fig. 6(c) white layers revealing that stress concentration were more prominent in the Cr3C2NiCr variant of coating, exhibiting minimum resistance for abrasive wear amid all coatings. The wear mechanism has impacted the Cr3C2NiCr coating surface in form of uneven pits as a sign of brittle fracture accompanied by small and non-uniform plastically deformed region. A significant grain fracture and sub- surface damage were witnessed in WC-Co-Cr coated specimen. The assessment of worn surface using X-ray diffraction measurements was carried out to analyze the surface modification of specimens. The XRD images depicted a notable quantity of WC as the major constituent phase which resulted in increased hardness of the coating, besides Cr and Co as a minor fraction in WC-Co-Cr coating. This ruled out any possibility of decarburization of WC as a result of Cr addition during coating procedure as no other phase, as expected, was spotted, which could be attributed to the chromium addition [26, 27]. Additionally, certain spectrum peaks showed an evident quantity of retained cobalt as a binder phase. X-ray diffractogram of Al2O3+13TiO2 coating specified the occurrence of the broad bulge between 45° and 65° in the concerned pattern that promoted the development of an amorphous phase. Few peaks for rutile-TiO2 (6% wt. fraction) could also be witnessed in X-ray analysis (Fig. 7). The X-ray diffractogram in Fig. 7 signified a high content of γ-Al2O3 accompanied by almost equal amounts of TiO2 along with a small amount of amorphous; Al2O3 attributed to the rapid solidification of molten particles of alumina [28, 29]. The X-ray diffractogram for Cr3C2NiCr advocated a higher amount of chromium carbide as the major phase. NiCr compound has been detected as a minor phase in the form of a small one. Fig. 7 XRD spectra for coated E52100 samples after wear 40 P.S. BAINS, J.S. GREWAL, S.S. SIDHU, S. KAUR, G. SINGH Three coated specimens with each coating were analyzed against wear on pin-on-disc apparatus with normal acting loads ranging between 30N, 40N and 50N, respectively (Table 4) along with uncoated specimen of E52100 substrate. Fig. 8 depicts the wear resistance of all the three variants of plasma sprayed coatings. Furthermore, the rate of wear for Cr3C2NiCr coating augmented with normal load whereas WC-Co-Cr coating showed a negligible effect. The uncoated pins of E52100 exhibited CVL of 5.660, 7.245 and 6.904 mm 3 at load of 30, 40 and 50 N, respectively. The wear resistance of coating with tungsten carbide powder is recorded to be higher amid all coatings. This is due to a relatively high amount of wear resistant fused carbide powder in this variant of coatings [30, 31]. This is also attributed to the finer carbide particles and a less carbon loss during abrasive wear. The percentage decrease in CVL for WC-Co-Cr coating has been recorded as 98.94% at 30 N, 99.3% at 40 N and 99.3% at 50 N as compared to the base metal. The reduction in the volume loss for Al2O3+13TiO2 coated pins was recorded as 98.58% at 30 N, 98.89% at 40 N and 99.3% at 50 N against E52100 material. This is related to lower hardness and lower cohesion due to high porosity in alumina-titania coatings [32]. Finally, Cr3C2NiCr coating variant experienced 94.7% at 30 N, 90.75% at 40 N and 96.5% at 50 N as wear reduction, comparatively. This higher erosion is expected as the material removal occurred mainly by carbide particles fracture that involved crack initiation at a particle- matrix interface which propagated to the surface of the coating. This phenomenon amplified with a higher porosity of the coating material being brittle in nature. Better wear resistance of WC-Co-Cr coating over other counterparts may be due to the better fracture as well as adhesive strength of the Co-Cr matrix with the carbides. Fig. 8 Cumulative volume wear rate (mm 3 ) for coatings and uncoated E52100 at 30N, 40N, and 50N Surface Modification of Ring-Traveler of Textile Spinning Machine for Substantiality 41 4. CONCLUSIONS This study aimed at investigating the effect of various plasma sprayed coatings on wear behavior of E52100 alloy steel under different loading conditions. SEM and XRD examinations were carried out to examine the wear mechanism that was witnessed to be influenced by various optimized coating and loading conditions. 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