Deni Fajar Fitriyana, Windy Desti Puspitasari, Sivasubramanian Palanisamy, Mufti Muhadzdzib, Samsudin Anis, Januar Parlaungan Siregar, Tezara Cionita, Aravindhan Alagarsamy, Sarath K. S, Saleh A. Al-Farraj, Mansour I. Almansour, Quanjin Ma
The purpose of this study is to evaluate the effects of substrate surface roughness (35 μm and 40 μm) and preheat temperature (50 °C, 100 °C, 150 °C) on the properties of the FeCrBMnSi coating layer applied to 304 stainless steels using the TWAS (Twin Wire Arc Spray) method. Surface preparation involved sandblasting and preheat treatment, followed by coating application with TWAS, and subsequent characterization using pull-off bonding, hardness, corrosion rate, Light Optical Microscope (LOM), and scanning electron microscopy (SEM) test. The current study’s findings indicate that increasing preheat temperature and surface roughness consistently reduces the percentage of porosity, unmelted material, and coating layer thickness. This enhances the hardness and adhesive strength of the coating layers. The hardness of the coating layer obtained in the present study was improved by 360–439% compared to the uncoated material. The best specimen in this study was found on a substrate with a surface roughness of 40 μm and performed a preheating treatment at a temperature of 150 °C. The thickness of the coating layer for this specimen was 150.58 × 10⁻³ mm, with a porosity and unmelted materials of 7.233%, a hardness of 1114.6 HV, an adhesive strength of 20.29 MPa, and a corrosion rate of 1.0640 × 10⁻² mmpy. However, the corrosion resistance of the coated specimens remains lower than that of the uncoated 304 stainless steel. © The Author(s) 2025.
Department of Mechanical Engineering, Universitas Negeri Semarang, Semarang, 50229, Indonesia; Department of Mechanical Engineering, P T R College of Engineering & Technology, Thanapandiyan Nagar, Austinpatti, Madurai-Tirumangalam Road, Tamilnadu, Madurai, 625008, India; Faculty of Mechanical & Automotive Engineering Technology, Universiti Malaysia Pahang, Pekan, 26600, Malaysia; Centre for Automotive Engineering, Universiti Malaysia Pahang Al-Sultan Abdullah (UMPSA), Pekan, Pahang, 26600, Malaysia; Faculty of Engineering, Built Environment & Information Technology, SEGi University, Selangor, 47810, Malaysia; Department of Electronics and Communication Engineering, Koneru Lakshmaiah Education Foundation, Andhra Pradesh, Vaddeswaram, 522501, India; Department of Electrical and Electronics Engineering, Carmel College of Engineering & Technology, Kerala, Punnapra, Alappuzha, 688004, India; Department of Zoology, College of Science, King Saud university, P. O. Box 2455, Riyadh, 11451, Saudi Arabia; School of Automation and Intelligent Manufacturing, Southern University of Science and Technology, Shenzhen, 518055, China
