Mubassyir, Haniif (2026) Pengaruh Variasi Tekanan Gas Dan Jarak Penyemprotan Pelapisan FeCrMnNiCSi Metode Arc Spray Terhadap Struktur Mikro Dan Sifat Mekanik Pada Material Baja S45C. Other thesis, Institut Teknologi Sepuluh Nopember.
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Abstract
Remanufacturing melalui metode Twin Wire Arc Spray (TWAS) dapat digunakan untuk memulihkan dimensi sekaligus meningkatkan kualitas permukaan komponen yang mengalami keausan. Namun, parameter standar perusahaan berupa tekanan gas 3,8 bar dan jarak penyemprotan 150 mm masih menghasilkan kekerasan coating yang perlu ditingkatkan. Penelitian ini bertujuan menganalisis pengaruh variasi tekanan gas dan jarak penyemprotan terhadap struktur mikro, porositas, dan microhardness coating FeCrMnNiCSi pada substrat baja S45C. Sistem pelapisan terdiri atas Ni-5Al sebagai bond coat dan FeCrMnNiCSi sebagai top coat. Variasi tekanan gas yang digunakan adalah 2,4; 3,8; dan 5 bar, sedangkan jarak penyemprotan divariasikan sebesar 100, 150, dan 200 mm. Karakterisasi dilakukan menggunakan optical metallography, analisis porositas berbasis ImageJ, pengujian microhardness Vickers, Scanning Electron Microscopy-Energy Dispersive X-ray Spectroscopy (SEM-EDX), elemental mapping, dan X-Ray Diffraction (XRD). Hasil penelitian menunjukkan bahwa pengaruh tekanan gas terhadap kualitas coating bergantung pada jarak penyemprotan sehingga perubahan porositas dan kekerasan tidak selalu menunjukkan kecenderungan linier. Kombinasi tekanan gas 5 bar dan jarak penyemprotan 150 mm pada spesimen F menghasilkan kondisi terbaik dalam rentang penelitian, dengan porositas rata-rata terendah sebesar 1,573% dan microhardness tertinggi sebesar 445,20 ± 29,51 HV atau sekitar 48 HRC. Dibandingkan parameter standar perusahaan pada spesimen E yang menghasilkan porositas 2,902% dan microhardness 382,30 ± 46,64 HV atau sekitar 46 HRC, parameter tersebut menurunkan porositas sebesar 45,8% dan meningkatkan microhardness sebesar 16,45%. Pengamatan struktur mikro dan SEM menunjukkan bahwa spesimen F memiliki susunan lamella yang lebih kontinu, celah antarlamella yang lebih sedikit, dan struktur lapisan yang relatif lebih rapat. Hasil phase matching XRD pada spesimen E dan F mengindikasikan jenis fasa yang relatif sama, yaitu γ-(Fe,Ni), Cr₇C₃, Fe₂O₃, dan Fe₃O₄, sehingga peningkatan kekerasan spesimen F lebih rasional dikaitkan dengan penurunan porositas dan perbaikan struktur fisik lapisan daripada pembentukan jenis fasa baru. Hasil EDX dan elemental mapping menunjukkan bahwa Fe dan Cr lebih dominan pada top coat, sedangkan Ni dan Al lebih terkonsentrasi pada bond coat. Dengan demikian, kombinasi tekanan gas 5 bar dan jarak penyemprotan 150 mm ditetapkan sebagai parameter terbaik dalam rentang yang diuji untuk menghasilkan coating FeCrMnNiCSi dengan porositas rendah dan kekerasan tinggi.
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Remanufacturing using the Twin Wire Arc Spray (TWAS) method can restore component dimensions while improving the surface quality of worn components. However, the company’s standard parameters, consisting of a gas pressure of 3.8 bar and a spraying distance of 150 mm, still produce a coating hardness that requires further improvement. This study aimed to analyze the effects of gas pressure and spraying distance on the microstructure, porosity, and microhardness of FeCrMnNiCSi coatings deposited on S45C steel substrates. The coating system consisted of Ni-5Al as the bond coat and FeCrMnNiCSi as the top coat. Gas pressures of 2.4, 3.8, and 5 bar were applied at spraying distances of 100, 150, and 200 mm. Characterization was conducted using optical metallography, ImageJ-based porosity analysis, Vickers microhardness testing, Scanning Electron Microscopy-Energy Dispersive X-ray Spectroscopy (SEM-EDX), elemental mapping, and X-ray Diffraction (XRD). The results showed that the effect of gas pressure on coating quality depended on the spraying distance, resulting in non-linear changes in porosity and hardness. The combination of a gas pressure of 5 bar and a spraying distance of 150 mm in specimen F produced the best result within the investigated parameter range, with the lowest average porosity of 1.573% and the highest microhardness of 445.20 ± 29.51 HV, equivalent to approximately 48 HRC. Compared with the company’s standard parameters applied to specimen E, which produced a porosity of 2.902% and a microhardness of 382.30 ± 46.64 HV, equivalent to approximately 46 HRC, the optimized parameters reduced porosity by 45.8% and increased microhardness by 16.45%. Microstructural and SEM observations showed that specimen F exhibited a more continuous lamellar structure, fewer interlamellar gaps, and a relatively denser coating structure. XRD phase matching of specimens E and F indicated similar phases, namely γ-(Fe,Ni), Cr₇C₃, Fe₂O₃, and Fe₃O₄. Therefore, the increase in hardness of specimen F was more reasonably associated with reduced porosity and improved physical coating structure rather than the formation of new phases. EDX and elemental mapping showed that Fe and Cr were more dominant in the top coat, whereas Ni and Al were more concentrated in the bond coat. Therefore, a gas pressure of 5 bar and a spraying distance of 150 mm were determined as the best parameters within the investigated range for producing an FeCrMnNiCSi coating with low porosity and high hardness.
| Item Type: | Thesis (Other) |
|---|---|
| Uncontrolled Keywords: | FeCrMnNiCSi, Twin Wire Arc Spray, parameter proses, porositas, microhardness,FeCrMnNiCSi, Twin Wire Arc Spray, process parameters, porosity, microhardness. |
| Subjects: | Q Science Q Science > QC Physics > QC100 Crystals. Q Science > QD Chemistry > QD471 Chemical compounds - Structure and formulas Q Science > QD Chemistry > QD79.T38 Thermal analysis Q Science > QD Chemistry > QD905.2 Crystals. |
| Divisions: | Faculty of Industrial Technology > Material & Metallurgical Engineering > 28201-(S1) Undergraduate Thesis |
| Depositing User: | Haniif Mubassyir |
| Date Deposited: | 03 Aug 2026 04:03 |
| Last Modified: | 03 Aug 2026 04:03 |
| URI: | http://repository.its.ac.id/id/eprint/139500 |
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