Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method

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, macrostructure and hardness property of the deposited overlay has been investigated. In the automotive industry, burr...

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Main Author:	Rasidi, Mohd Kamarul Shaufi
Format:	Thesis
Language:	English English
Published:	2017
Subjects:	T Technology (General)
Online Access:	http://eprints.utem.edu.my/id/eprint/20710/1/Hardfacing%20Process%20Of%20Ni-WC%20On%20Gray%20Cast%20Iron%20Substrate%20Using%20GMAW%20Method%20-%20Mohd%20Kamarul%20Shaufi%20Rasidi%20-%2024%20Pages.pdf http://eprints.utem.edu.my/id/eprint/20710/2/Hardfacing%20process%20of%20Ni-WC%20on%20gray%20cast%20iron%20substrate%20using%20GMAW%20method.pdf
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id	my-utem-ep.20710
record_format	uketd_dc
institution	Universiti Teknikal Malaysia Melaka
collection	UTeM Repository
language	English English
advisor	Hussein, Nur Izan Syahriah
topic	T Technology (General) T Technology (General)
spellingShingle	T Technology (General) T Technology (General) Rasidi, Mohd Kamarul Shaufi Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method
description	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, macrostructure and hardness property of the deposited overlay has been investigated. 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 gray cast iron die which possess low hardness property. Ni-WC is a very hard hardfacing material and has potential to be utilized as the hardfacing material on the gray cast iron die. The use of GMAW method for the purpose of the hardfacing process needs to be done attentively in the aspect of the heat input because the produced heat input of the process affects the microstructure of the overlay thus affecting the hardness property of the hardfacing overlay. The effect of process parameters on the hardness and microstructure of the overlay was studied because the parameters are related to the heat input of the process. The effect of process parameters on the overlay bead width and height was also studied because bead width and height are two of important aspects of a hardfacing overlay. Thermal cycle of the process was also studied as to understand the thermal cycle effect on the hardness and microstructure of the overlay. The effect of overlay beads overlapping percentage on the microstructure and hardness was studied as well as the overlapped region undergoes more thermal effect of the process. The process parameters were optimized for improving the overlay hardness as well as bead width and height. Response surface methodology (RSM) using Design Expert software was applied for the design of experiment (DOE) and process parameters optimization in this study. The proposed optimized parameters focusing on maximizing the hardfacing overlay hardness are having hardness values within the targeted range from 610 HV60 to 810 HV60. The WC particles content was concluded as 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 correlation 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 the temperature reading implies that such phases like borides and silicides could have formed in the overlay and dictating the overlay hardness value. Process optimization was done and the optimization focusing on maximizing the hardness value by the software suggested sets of parameters having reliability value close to 1. The suggested sets of parameters have potential to be employed for improving the hardness of the gray cast iron substrate surface.
format	Thesis
qualification_name	Master of Philosophy (M.Phil.)
qualification_level	Master's degree
author	Rasidi, Mohd Kamarul Shaufi
author_facet	Rasidi, Mohd Kamarul Shaufi
author_sort	Rasidi, Mohd Kamarul Shaufi
title	Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method
title_short	Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method
title_full	Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method
title_fullStr	Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method
title_full_unstemmed	Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method
title_sort	hardfacing process of ni-wc on gray cast iron substrate using gmaw method
granting_institution	Universiti Teknikal Malaysia Melaka
granting_department	Faculty Of Manufacturing Engineering
publishDate	2017
url	http://eprints.utem.edu.my/id/eprint/20710/1/Hardfacing%20Process%20Of%20Ni-WC%20On%20Gray%20Cast%20Iron%20Substrate%20Using%20GMAW%20Method%20-%20Mohd%20Kamarul%20Shaufi%20Rasidi%20-%2024%20Pages.pdf http://eprints.utem.edu.my/id/eprint/20710/2/Hardfacing%20process%20of%20Ni-WC%20on%20gray%20cast%20iron%20substrate%20using%20GMAW%20method.pdf
_version_	1747833991561478144
spelling	my-utem-ep.207102022-06-13T09:20:08Z Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method 2017 Rasidi, Mohd Kamarul Shaufi T Technology (General) TK Electrical engineering. Electronics Nuclear engineering 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, macrostructure and hardness property of the deposited overlay has been investigated. 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 gray cast iron die which possess low hardness property. Ni-WC is a very hard hardfacing material and has potential to be utilized as the hardfacing material on the gray cast iron die. The use of GMAW method for the purpose of the hardfacing process needs to be done attentively in the aspect of the heat input because the produced heat input of the process affects the microstructure of the overlay thus affecting the hardness property of the hardfacing overlay. The effect of process parameters on the hardness and microstructure of the overlay was studied because the parameters are related to the heat input of the process. The effect of process parameters on the overlay bead width and height was also studied because bead width and height are two of important aspects of a hardfacing overlay. Thermal cycle of the process was also studied as to understand the thermal cycle effect on the hardness and microstructure of the overlay. The effect of overlay beads overlapping percentage on the microstructure and hardness was studied as well as the overlapped region undergoes more thermal effect of the process. The process parameters were optimized for improving the overlay hardness as well as bead width and height. Response surface methodology (RSM) using Design Expert software was applied for the design of experiment (DOE) and process parameters optimization in this study. The proposed optimized parameters focusing on maximizing the hardfacing overlay hardness are having hardness values within the targeted range from 610 HV60 to 810 HV60. The WC particles content was concluded as 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 correlation 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 the temperature reading implies that such phases like borides and silicides could have formed in the overlay and dictating the overlay hardness value. Process optimization was done and the optimization focusing on maximizing the hardness value by the software suggested sets of parameters having reliability value close to 1. The suggested sets of parameters have potential to be employed for improving the hardness of the gray cast iron substrate surface. 2017 Thesis http://eprints.utem.edu.my/id/eprint/20710/ http://eprints.utem.edu.my/id/eprint/20710/1/Hardfacing%20Process%20Of%20Ni-WC%20On%20Gray%20Cast%20Iron%20Substrate%20Using%20GMAW%20Method%20-%20Mohd%20Kamarul%20Shaufi%20Rasidi%20-%2024%20Pages.pdf text en public http://eprints.utem.edu.my/id/eprint/20710/2/Hardfacing%20process%20of%20Ni-WC%20on%20gray%20cast%20iron%20substrate%20using%20GMAW%20method.pdf text en validuser https://plh.utem.edu.my/cgi-bin/koha/opac-detail.pl?biblionumber=106156 mphil masters Universiti Teknikal Malaysia Melaka Faculty Of Manufacturing Engineering Hussein, Nur Izan Syahriah 1. Abioye, T. E., Folkes, J., McCartney, D.G. and Clare A.T., 2012. 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Hardfacing process of Ni-WC on gray cast iron substrate using GMAW method

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