Experimental and numerical assessment of impact wear resistant coatings: mechanical characterization and surface optimization

Resumo

The failure process of the protective structures, such as the frame of a flail mower, is mainly caused
by the impact of particles with varied geometries and weights. Moreover, the continuous and cyclic nature of
the loading conditions affecting protective systems often responsible for the development of erosive wear. This
work presents impact wear resistance assessment of the SAE 1045 steel in two surface conditions: uncoated and
with an electrode surface treatment. The goal is to evaluate the influence of coating’s mechanical properties, such
as resilience, elastic modulus, hardness and roughness, on the failure mechanics of the substrate. Sphere-to-flat
compression tests are performed on samples of each surface configuration. Both monotonic and cyclic tests are
carried-out. Results are used for the calibration of a finite element model of the problem. Simulation of various
surface configurations and loading conditions are presented and a solution for the life enhancement of a specific
protective system is proposed.