Investigations on the Effect of Oxide Coatings on Wear Resistance Behaviour of 3D Printed 17-4 PH Stainless Steel

Abstract

Manufacturing is important for obtaining key components and products on time, enhancing wealth and quality of life. 3D printing also called additive manufacturing (AM) is a unique process that builds products layer by layer, unlike traditional methods that remove material. Recently, AM has gained attention for its creative flexibility and faster production times. This research draws comparisons between samples made via additive manufacturing technique and how Cr2O3 and TiO2 coatings affect these samples. SEM analysis is utilized to assess how the coatings influence the performance of these stainless-steel components. The focus of the study is on the microstructure and wear characteristics of Cr2O3 and TiO2 coatings on 17-4 PH Stainless Steel. Macro Hardness test is also conducted on Cr2O3 and TiO2 coatings, comparing the results with uncoated samples. Wear tests were performed using a pin-on-disc tribometer, with pins that featured various coatings SEM techniques were applied to examine the microstructure of the material and the mechanisms behind wear. The application of Cr2O3 and TiO2 coatings has demonstrated a notable improvement in these properties. The observed wear resistance showed significant differences due to the varied coatings on the pins. This study offers valuable insights into enhancing the durability of stainless-steel components for challenging environments.

Introduction

1. Modern Manufacturing Trends

• Manufacturing is evolving from traditional material processing to machine-based and smart systems operations.

• Key features: customization, complexity, and volume.

• 3D printing (Additive Manufacturing - AM) enhances efficiency, reduces material waste, and is ideal for custom, low-volume production.

2. Additive Manufacturing Techniques

Different AM techniques (e.g., SLM, FDM, DED, Inkjet) use materials like metals, polymers, and ceramics for industries such as aerospace, biomedical, and construction. Benefits include:

• High-quality resolution

• Reduced tooling and manufacturing time

• Capability to print complex and large structures

3. Material Focus: 17-4 PH Stainless Steel

• A martensitic precipitation-hardened steel with 17% Cr, 4% Ni, and copper (hardener).

• Transforms from austenite to martensite at around 300°F.

• Used in high-performance applications for its strength and corrosion resistance.

4. Protective Coatings

• Thermal spray coatings, such as plasma spraying, improve wear resistance, oxidation, and corrosion protection.

• Coatings like TiO? (titanium oxide) and Cr?O? (chromium oxide) are applied using high-temperature plasma jets.

• These coatings enhance mechanical, thermal, and chemical performance.

5. Experimentation Methods

• Sample preparation: 17-4PH stainless steel specimens were produced using Selective Laser Melting (SLM).

• Coating deposition: Plasma-sprayed TiO? and Cr?O? coatings applied after grit blasting and cleaning.

• Testing methods:

  • SEM + EDS: Analyzed surface and composition.

  • Hardness Test: Rockwell scale.

  • Wear Test: Assessed durability under friction.

6. Process Parameters

• SLM process used:

  • Laser Power: 105 W

  • Scan Speed: 2500 mm/s

  • Layer Thickness: 30 µm

  • Hatch Spacing: 50 µm

• Plasma spray coating settings included:

  • Power: 35.6 kW

  • Argon/H?/N? gas flow, 110 mm standoff distance

7. Results

• Hardness (Rockwell HRC):

  • Uncoated: 68.8 HRC

  • Cr?O?-coated: 75.4 HRC

  • TiO?-coated: 72.1 HRC

• SEM/EDS revealed proper coating adhesion and composition. "Splats" typical of plasma-sprayed coatings were visible.

• Coatings significantly improved surface hardness and wear resistance.

Conclusion

1) 17-4 PH stainless steel fabricated through Additive Manufacturing show considerable promise as substitutes for wrought materials concerning friction and wear characteristics. 2) Both the coated steels showed higher wear resistance in comparison to the uncoated steel. Plasma-sprayed Cr2O3 coatings showed a reduced coefficient of friction (COF), lesser wear loss, and a heightened wear resistance compared to TiO2 coating. 3) Elements like material hardness, surface finish, and lubrication play a crucial role in determining wear rates, emphasizing the need to comprehend these dynamics for material choice and component design in applications where wear is a significant factor.

References

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Copyright

Copyright © 2025 Ms. Kanta Chaudhary, Dr. Niraj Bala, Dr. Amandeep Kaur. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.