Effect Of Deposition Process On Properties Of Nickel-Based Aloy Clad On Cast Iron Trim Cutter Mould

Hussein, Nur Izan Syahriah and Ayof, Mohd Nizam and Abdullah, Abu and Abu Bakar, Mohd Hadzley and Shamsuri, Siti Rahmah and Othman, Md Nazri (2017) Effect Of Deposition Process On Properties Of Nickel-Based Aloy Clad On Cast Iron Trim Cutter Mould. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Hardfacing process of nickel-tungsten carbide (Ni-WC) overlay using gas metal arc welding (GMAW) method has been applied on gray cast iron substrate and the effect on microstructure and hardness property of the deposited overlay clad has been investigated. The thermal cycle of the process was also studied and the optimum set of process parameters as to improve the overlay hardness as well as bead height and width has been suggested. In the automotive industry, burr formation defect is continuously occurred on the produced blanks of sheet metal shearing process caused by the wear of the trim cutter die. The problem is more profound when using die with lower hardness and hardfacing process of Ni-WC overlay could be utilized as the hardfacing material is already prominent for wear resistant purpose in oil sands applications. The gray cast iron material was chose for the substrate in this study as it is the one the die materials for the sheet metal shearing process in the automotive industry. The GMAW method is preferred compared to other methods such as laser beam welding or plasma arc welding because the GMAW method is much lower in cost and more flexible. Response surface methodology (RSM) was applied for the design of experiment (DOE) in this study and a set of parameters in the DOE has produced overlay with hardness value of 644 HV which is in the targeted hardness value ranging from 610 to 810 HV. The WC particles content is not significant in affecting the hardness value of the overlay at macro level. Heat input of the process has direct correlation to the bead height and width of the overlay but indirect correlates to the hardness of the overlay. The temperature reading of the hardfacing process as high as 1351°C was recorded in the thermal cycle investigation and based on the temperature reading, such phases like borides and silicides could have formed in the overlay and dictating the overlay hardness value. Process optimization was done and the top ten of optimized sets of parameters having reliability value close to 1 were suggested. The suggested set of parameters can be employed for improving the hardness of the gray cast iron substrate surface.

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