Fe-24 wt.%Cr-4.1 wt.%C hardfacing alloy: Microstructure and carbide refinement mechanisms with ceria additive
The microstructure and carbide refinement mechanisms of Fe-24 wt.%Cr-4.1 wt.%C hardfacing alloys with 0 wt.%, 0.5 wt.%, 1.0 wt.%, 2 wt.%, and 4 wt.% ceria additives have been systematically investigated in this work. Optical microscopy, field emission scanning electron microscopy with energy dispersive spectrometer, and X-ray diffraction were collectively used to study the microstructure, the phase components, and the chemical formation of inclusion formed in the welding process. Wear-resistance of the alloys was comparatively studied using an abrasive wear testing machine. The structure analysis results show that the Fe-Cr-C hardfacing alloy mainly consists of martensite, retained austenite, MC carbide and M{sub 7}C{sub 3} carbide. With increasing ceria additive contents, the average size of the primary M{sub 7}C{sub 3} carbide decreases and reaches a most refined state in the alloy with 2 wt.% ceria additives. Comparative wear tests data shows that the wear resistance of the hardfacing alloys with ceria additives is better than that without ceria additive. In a good agreement with the carbide refinement results, the wear resistance of the alloy reaches an optimum level in the sample with 2 wt.% ceria additive. The main RE inclusion type identified with in-situ XRD analysis is RE inclusion Ce{sub 2}O{sub 2}S. Thermodynamics calculation confirms that this type of RE inclusion could precipitate prior to M{sub 7}C{sub 3} carbides, and act as a heterogeneous nucleus for M{sub 7}C{sub 3} in the welding process, which effectively provides a mechanism for significant refinement of the M{sub 7}C{sub 3} carbide and improves its wear resistance. - Graphical Abstract: Rare Earth inclusion (Ce{sub 2}O{sub 2}S) distributes in the primary M{sub 7}C{sub 3} carbide. Moreover, Ce{sub 2}O{sub 2}S, which acts as heterogeneous nuclei of the primary M{sub 7}C{sub 3} carbide, is medium effective. Therefore, the primary M{sub 7}C{sub 3} carbide has been refined. Highlights: Black-Right-Pointing-Pointer Micro-hardness of primary M{sub 7}C{sub 3} carbide in Fe-Cr-C hardfacing alloy is 1594 HV. Black-Right-Pointing-Pointer RE inclusion Ce{sub 2}O{sub 2}S can be observed in the primary M{sub 7}C{sub 3} carbide. Black-Right-Pointing-Pointer Ce{sub 2}O{sub 2}S as heterogeneous nuclei of the Cr{sub 7}C{sub 3} is medium effective. Black-Right-Pointing-Pointer Primary carbide is most refined with 2 wt.% ceria additive.