الفهرس 
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Abstract
Ain Shams University
Faculty of Engineering
Design and Production Engineering Department
Effect of adding different materials on properties of Plasma sprayed coating
A Thesis submitted in partial fulfilment of the requirements of the degree of
master of Science in Mechanical Engineering
(Design and Production Engineering)
submitted by
Kareem Hamed Ibrahim
Bachelor of Science in Mechanical Engineering
Military Technical College, 2012
supervised by
Prof. Nahed Abd El-Hamid El-Mahallawy
Emeritus Professor, Design and Production Engineering Department, Faculty of Engineering, Ain Shams University
Prof. Mokhtar Omar Abass Mokhtar
Emeritus Professor, Mechanical Design and Production Department, Faculty of Engineering, Cairo University
Cairo – (2022)
Ain Shams University
Faculty of Engineering
Design and Production Engineering Department
Effect of adding different materials on properties of Plasma sprayed coating
submitted by
Kareem Hamed Ibrahim
Bachelor of Science in Mechanical Engineering
Military Technical College, 2012
Supervising Committee
Name Signature
Prof. Nahed Abd El-Hamid El-Mahallawy ..............................
Prof. Mokhtar Omar Abass Mokhtar ..............................
Date: 12 / 5 / 2022
Ain Shams University
Faculty of Engineering
Design and Production Engineering Department
Effect of adding different materials on properties of Plasma sprayed coating
submitted by
Kareem Hamed Ibrahim
Bachelor of Science in Mechanical Engineering
Military Technical College 2012
Examiners’ Committee
Name Signature
Prof. Nahed Abd El-Hamid El-Mahallawy ..............................
Prof. Mokhtar Omar Abass Mokhtar ..............................
Prof. Nabil Kamal Fatah-Allah ..............................
Prof. Waheed Yosry Aly ..............................
Date: 12 / 5 / 2022
Statement
This thesis is submitted as partial fulfilment of master of Science in Mechanical Engineering, Faculty of Engineering, Ain Shams University.
The researcher carried out the work included in this thesis, and no part of it has been submitted for a degree or a qualification at any other scientific entity.
Signature
..............................
Kareem Hamed Ibrahim
Date: 12 / 5 / 2022
Researcher Data
Name : Kareem Hamed Ibrahim
Date of birth : 09 / 12 / 1989
Place of birth : Cairo
Last academic degree : Bachelor of Science in Mechanical Engineering
Field of specialization : Aircraft Mechanical Engineering
University issued the degree : Military Technical College
Date of issued degree : 07-2012
Current job : Aviation Technical Support Engineer
Acknowledgement
In the name of God, this research would not have been possible without the support of my family, colleagues, interdisciplinary technicians, and last but not least, my beloved family, for their tremendous support.
Prof. N. El-Mahallawy and Prof. M.O.A. Mokhtar have been ideal teachers, and thesis supervisors, offering advice and encouragement with a perfect blend of insight and professionalism. I’m proud of, and grateful for, my time working with them.
Many thanks to my colleagues, and their encouragement to write this thesis made me confident that the topic was worthy of my investigation—and that my investigation was worthy of the topic.
I do appreciate all the efforts that have been made by each knowledgeable person I met in the journey of this research, and all organizations that permitted utilizing their facilities to accomplish the whole experiment.
Thesis Summary
Atmospheric Plasma Spraying (APS) could be considered the most leading industrial technique among a wide range of protective coating techniques for surfaces of metals and mechanical parts, especially for enhancing the behavior of the wear resistance and thermal barrier coating.
Accordingly, this thesis subjects the study of mixing pure Aluminum powder separately with two different powders of Nickel-based alloys to create six types of Aluminum-Nickel compositions to be deposited with three thicknesses (300, 600, 900 μm) on Stainless steel (304) substrate using APS technique, then performs a Pin-on-Disc experiment for all samples.
A comprehensive analysis for all samples with thickness 600 μm and their characterization is presented using X-ray Diffraction (XRD), Scanning Electron Microscope (SEM), porosity, surface roughness, and microhardness measurements. In addition, investigations have been performed to study the effect of different compositions and thicknesses on the wear resistance patterns.
The findings of this research illustrate the existence of two intermetallic compounds, namely: NiAl and Ni3Al, where the formation of NiAl is unavoidable in all samples with any amount of the Ni-based alloys or even the Nickel’s atomic percentage. Whereas the formation of Ni3Al depends on the percentage of Ni-based alloys in Ni5Al samples only. As regards the substrate, results have shown that the microhardness in the interdiffusion zone has been considerably improved.
On the subject of wear testing, samples with Ni/Al alloys provide more promising patterns of wear resistance rather than samples with Ni 5Al powders, due to the existence of intermetallic compound Ni3Al. And the thickness of samples has an explicit impact on the wear rate behavior, where it was inversely proportional with the wear rate for all samples B (Ni 5Al – Al), despite its positive effect on samples A (Ni/Al – Al).