Journal
ENGINEERING FAILURE ANALYSIS
Volume 66, Issue -, Pages 130-140Publisher
PERGAMON-ELSEVIER SCIENCE LTD
DOI: 10.1016/j.engfailanal.2016.04.011
Keywords
Coating failures; Crack formation; Indentation damage; Residual stress; Hard chromium
Funding
- Saudi Cultural Bureau in Canada
- Atlantic Hardchrome Limited
- Natural Science and Engineering Research Council (NSERC) [RGPIN/217203-2013, RGPIN/327449-2012]
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Hard chromium coatings are widely used for high performance components due to their superior wear and corrosion resistance. In this study, 416 stainless steel bars were chromium electroplated commercially with different thickness. Mechanical properties and residual stress were measured using a nano-indentation system and X-ray diffraction, respectively. Image analysis technique was used to measure inherent crack density. Residual stress in the coating increases with increasing thickness leading to an increase in inherent crack density. An indentation study was carried out to investigate the mechanical damage of hard chromium coating as a function of thickness. Different failure modes were observed when hard chromium coatings were indented with a spherical indenter including Hertzian cone cracks, radial cracks, bend cracks, lateral cracks and coating delamination. Three thickness regions of distinctive cracking modes were identified. Thin coating region exhibited through-thickness Hertzian cracks. Hertzian and coating-bend rings, cone, surface radial cracks and coating bottom surface radial cracks were observed in intermediate coating region. This region exhibited highest cracking damage density. In thick coatings Hertzian cracks were observed. It was found that two factors affect the cracking damage: residual stress that increaseswith increasing thickness and bending stresses that decrease with increasing thickness. The resultant effect was maximized at intermediate coating thickness. (C) 2016 Elsevier Ltd. All rights reserved.
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