Enhancement of Three-Body Wear Resistance of Steel Substrate
using Molybdenum Coating for Steel Roller Conveyor
Arunadevi M
1 a
and Vivek Bhandarkar V N
1 b
1
Department of Mechanical Engineering, Dayananda Sagar College of Engineering, Bangalore, India
Keywords: Wear, Resistance, Steel, Molybdenum Coating.
Abstract: The main focus of this work is enhancing the steel rollers wear resistance which is used in mining industry
conveyor systems. Wear and efficiency of steel conveyor system is affected by the presence of sand, dust and
grit (abrasive particles) and by the continuous contact between metal surface with steel roller. To overcome
the above issue, application of molybdenum powder coating for the steel is suggested using plasma thermal
spray coating. As per the ASTM (American Society for Testing and Materials) standards the experiments are
conducted and the performance enhancement analyzed for the coated samples by comparing with uncoated
samples. ASTM G65 is a test method developed by ASTM International to evaluate the abrasive wear
resistance of materials using a dry sand/rubber wheel abrasion test. This test method is commonly used to
assess the durability and wear performance of various materials, coatings, and surface treatments. SEM
(Scanning Electron Microscope), EDAX (Energy Dispersive X-Ray analysis) and hardness tests are
performed to measure the wear resistance and wear surface properties. It is proven that the molybdenum
coating plays very important role in improving the three-body wear resistance of steel conveyor rollers. SEM
analysis confirmed a smooth and well-adhered coating, while EDAX revealed the presence of molybdenum
on the coated surface. Hardness tests indicates a notable increase in hardness, further supporting the enhanced
wear resistance. This research highlights the potential of molybdenum powder coatings to enhance the
durability and lifespan of steel rollers in conveyor systems operating in harsh environments. The findings
contribute to the development of effective strategies for reducing wear and optimizing the performance of
mining and construction equipment.
1 INTRODUCTION
Abrasive wear is observed in manufacturing,
transportation, mining and construction industries,
also in day-to-day life. It has very significant effect
on the life span and efficiency of the components or
parts subjected to abrasive wear. It may lead to
material loss, decrease in dimensional accuracy,
higher surface roughness and reduction in efficiency.
In industries it may occurs in parts or components
exposed to harsh environments such as grinding tools,
engine components, conveyor belts and also in
cutting machinery. To overcome the above issue,
application of molybdenum powder coating for the
steel is suggested using plasma thermal spray coating.
C S Ramesh (2018) et.al highlighted the effect of
molybdenum and molybdenum silicon carbide
a
https://orcid.org/0000-0002-2831-8198
b
https://orcid.org/0000-0003-2706-3848
coatings on mild steel to improve the wear resistance,
to improve the tribological properties and also to
reduce the friction. High-velocity oxy-fuel (HVOF)
technique is used for the coating to achieve less
porosity, higher coating density and good bonding
with the material and microstructure, composition,
phase change and mechanical properties are
evaluated using microhardness testing, EDX, XRD,
and SEM. The tests were conducted as per ASTM
standards and the improved wear resistance and
reduction in friction are demonstrated by the ASTM
G65 abrasion tests (C.S. , et al. 2018).
Patel G C (2022) et.al studied the wear loss and
microhardness of Mo-Ni-Cr coated super duplex
stainless steel to optimize and analyze the plasma
spray parameters effect on experimentation. The
parameters such as current, voltage, spray distance
116
M., A. and N., V.
Enhancement of Three-Body Wear Resistance of Steel Substrate Using Molybdenum Coating for Steel Roller Conveyor.
DOI: 10.5220/0012525700003808
Paper published under CC license (CC BY-NC-ND 4.0)
In Proceedings of the 1st International Conference on Intelligent and Sustainable Power and Energy Systems (ISPES 2023), pages 116-124
ISBN: 978-989-758-689-7
Proceedings Copyright © 2024 by SCITEPRESS – Science and Technology Publications, Lda.

and powder feed rate are influencing factors to
achieve required coating properties. The wear
behavior, hardness and microstructure were evaluated
using wear testing, microhardness testing and surface
roughness analysis. It is discovered that proper
optimization of plasma spray variables on
microhardness and wear loss is needed to achieve the
better quality and performance of coatings. Han. Ya-
guang (2017) et.al focused on the correlation between
wear resistance and micro structural properties of
molybdenum coatings on different substrates using
APS (Atmospheric Plasma Spraying). The authors
discussed the importance of process parameters of
plasma spray coating such as gas flow rate, powder
flow rate and spray distance in controlling properties
and microstructure of coatings using EDX, SEM and
microhardness testing.
Cristian Puscasu et.al investigated the thermal
spray molybdenum coating properties to increase the
durability and enhance the wear resistance of railway
axles. It is proved that wear related damages are
reduced, performance of axles are improved and
service life is also extended using molybdenum
coatings. The main challenges of railway axles such
as cyclic loading, harsh operating conditions and high
loads are handled using protective coatings using
molybdenum. This study discussed the coating
properties such as microstructure, mechanical
strength, hardness and adhesion and also their
significant importance on performance of railway
axle applications. H Adarsha (2018) et.al highlighted
the influence of HVOF(High-Velocity Oxy-Fuel)
technique on manufacturing well-bonded and dense
coatings with better mechanical properties such as
less friction coefficient, higher hardness value and
better adhesion to the substrate material( SS304 and
A36). These materials are mainly used in the mining
and construction industries under abrasive
environment, which required the wear enhancement
and extended life span. Huang Long (2018) et.al
studied the wear resistance comparison of the steel
with and without (Ti,Mo)C particles. This study
explores the influence of parameters such as
concentration, particle size and distribution of
particles on the improvement of wear resistance
performance and also characterization of materials is
performed using harness testing, SEM and EDX to
analyze the composition, the microstructure and
mechanical properties of coatings on steel.
R Riastuti (2018) et.al focused the study on
corrosion behavior improvement of 316L stainless
steel by molybdenum and aluminum coatings.
Coating thickness is varied to analyze the good
adhesion property and characterization is done using
SEM, EDX, and microhardness testing. It is
recommended by the authors to optimize the coating
parameters which will increase the durability and
performance of the component which is subjected to
corrosive environments. S Ilaiyavel (2012) et.al
studied the behavior of manganese phosphate-
coatings on AISI D2 steel which is used in tool and
die material. The manganese phosphate coating is
achieved by forming a layer of manganese phosphate
compound which involves chemical conversion of
steel surface and different influencing parameters
such as surface preparation, coating parameters and
post treatment processes are analyzed to obtain
uniform and adherent coatings. The wear resistance
of the coated steel is evaluated using pin-on-disk and
abrasive wear test. Chávez (2018) et.al investigated
the microstructural and tribological behavior of
coatings on AISI/SAE D2 grade tool steels using
HVOF (High-Velocity Oxy-Fuel) thermal spraying
process and GTAW (Gas Tungsten Arc Welding)
process. The performance and wear resistance are
enhanced and desired properties such as low porosity,
high adhesion and improved mechanical properties
are also achieved. It explored tribological behavior of
the coatings such as surface damage resistance, wear
and friction and the microstructural changes also
examined.
L Bourithis (2005) et.al explored the various
surface treatment methods such as heat treatments,
surface engineering methods and coatings to enhance
the wear behavior of low carbon steel. The authors
introduced the modified strategies to enhance the
wear resistance of low carbon steel surfaces.
S. Piçarra (2019) et.al proved in their studies that the
molybdenum coating improved the adhesion, stability
and durability of staphylococcus aureus which is a
common bacterium with nosocomial infections.
N González (2020) et.al studied the effect of alumina
coatings on steel using automated image processing
techniques applied on isolated splat samples.
Excellent thermal properties and wear resistance can
be achieved by these coatings, but achieving defect
free and uniform coating is challenging due to
complexity involved in bonding between coating and
substrate material during thermal spray process.
Spray distance, powder feed rate and spray angle are
identified the influencing parameters on thermal
spray process using statistical techniques.
M.M.A. Bepari and Shorowordi K.M (2004)
studied the effect of nickel and molybdenum coating
on carburized and hardened low carbon steels to
improve the wear resistance and also further addition
of coating leads to improve the mechanical properties
such as yield strength, tensile strength and impact
Enhancement of Three-Body Wear Resistance of Steel Substrate Using Molybdenum Coating for Steel Roller Conveyor
117

toughness. Hwang (2004) et.al demonstrated that the
MoO3-Al coating using plasma spray on the substrate
exhibit a dense and well bonded structure with less
porosity. Compared to pure Al coating, MoO3-Al
gives better wear resistance and hardness. G. Bruno
(2006) et.al presented the study on residual stress
analysis of steel gear wheels with molybdenum
coating using thermal spray coating process to find
the influence of coating in wear resistance
enhancement. The stress distribution of coating may
affect the performance which is analyzed using
residual stress analysis. Zhongsheng (2023) et.al
investigated the effect of multilayer coating of
MSZ(mullite-stabilized zirconia) and molybdenum
using plasma spray and hot isostatic pressing to
enhance the resistance which is able to withstand high
temperature ablation in extreme conditions. Good
bonding and less cracking are exhibited between the
layers which leads to efficient stress transfer and good
mechanical integrity.
It is observed that three-body abrasive wear
research is lagging and less papers on abrasive
particles impact on coatings. Therefore, this paper is
aiming to assess and compare the effectiveness of
molybdenum thermal sprayed coating system with
the uncoated system in order to address the issue of
wear rate in steel conveyor rollers. Based on the
observations made from literature, stainless steel is
the predominant choice of material for the rollers and
the main dis advantage of the steel rollers is abrasion
wear. To overcome this, among various techniques
the plasma spray process is identified as effective
technique to achieve effective bonding and less wear
rate. A molybdenum coating is selected to enhance
the wear characteristics in this study.
The main objective of this study is to find the
coating influence on steel in wear environment and
enhancing wear resistance by various grain size and
by achieving the following objectives
To provide molybdenum coating on
stainless steel SS304 using plasma spray coating
process and asses the coating properties
To compare the performance of a
Molybdenum coated steel with uncoated steel when
exposed to a wear environment.
To determine the optimal range of
Molybdenum coating thickness on the substrate.
2 EXPERIMENTATION
The experimentation process is explained in the
below sections.
2.1 Methodology
1. A comprehensive review of the literature is
conducted to gain insights into various
materials, their applications, coating
substrates, and their characteristic properties.
2. Based on the findings from the literature
survey and considering the desired properties,
appropriate materials are selected and
procured for the specific application.
3. Initially uncoated stainless steel SS304
characterized to assess the performance
without coating using SEM, EDAX and
hardness test.
4. Stainless steel SS304 is coated by
Molybdenum using plasma spray technique.
5. Characterization of Molybdenum coated
stainless steel SS304 samples using SEM,
EDAX and hardness test.
6. Comparison of performance characteristics of
coated and uncoated stainless steel SS304 in
terms of microstructure, composition and
hardness.
SS304 is austenitic steel of T300 series is selected as
base material for this research which is widely used
in different industrial applications because of its high
corrosion resistance, high tensile strength and higher
temperature resistance. It consists of minimum 18 %
of chromium and maximum 0.08 % of carbon. The
material is obtained from Sri Durga sales in
Bengaluru. The purchased material had dimensions of
75 mm by 25 mm with a thickness of 8 mm which is
shown in figure 1.
A steel strip measuring 25 mm by 8 mm was cut
from the obtained material using a Bandsaw-Double
column machine, with each piece being cut to a length
of 75 mm. Subsequently, the cut specimens
underwent hand grinding to achieve a flat surface
along the edges, ensuring proper fitting into the
specimen holder which is shown in figure 2. In this
research, ASTM G65 standard test is used to evaluate
the three-body abrasion. In this test, a dry sand/rubber
wheel abrasion test is conducted using rubber wheel
abrasion tester which is shown in figure 3.
The standard test specimen, with dimensions of
75*25*8, is securely mounted on a clamp, while the
rubber wheel is pressed against it with a specified
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118

force using a lever arm. The setup configuration and
details are shown in table 1.
Figure 1: Stainless steel-304.
Figure 2: Grinding.
Figure 3: Rubber wheel abrasion tester.
Table 1: Rubber wheel abrasion test rig specifications.
Test parameter
Details
Wheel
Chlorobutyl rubber A-60, dia
228.6*32.7mm
Sand
AFS50/70, Quartz sand
Sand Flow rate
350 gms/min
Pre-load on rubber
wheel
2.62 kg
Loading lever ratio
1:2.42
Happer capacity
15 kg
The abrasion wear of the test surface of the sample
is regulated by the flow of grain in terms of grain size,
speed or sliding distance and load. Grain size is varied
from fine sand to coarse sand (200um, 300um and
600um), speed varies from 50rpm t0 150rpm (50 rpm,
100rpm and 150 rpm) and load varies from 25.702N
to 72.986N(25.702N, 49.344N and 72.986N).
Figure 4: Dry Sand of different grain size (200,
300,600micron).
Mass loss is calculated by measuring the weight
before and after the test using electro weighing scale
which has 0,01 precision. The formula used to
calculate the Mass loss is given below
Mass loss = Initial weight – Final weight
Then the volume loss is converted from Mass loss in
cubic millimeters.
Volume loss = [Mass loss * 1000 / Density]
Then the Specific wear is calculated using
Specific wear rate = [ (Volume loss) / (Load *
Abrading distance)]
The obtained data from the test procedure for both the
uncoated and coated specimens undergoes a series of
Enhancement of Three-Body Wear Resistance of Steel Substrate Using Molybdenum Coating for Steel Roller Conveyor
119

calculation procedures, and their respective
characteristics are considered for comparison.
3 RESULTS AND DISCUSSIONS
Figure 5a: SEM image of coated sample at 500X.
Figure 5b: SEM image of coated sample at1000X.
Figure 6: EDAX spectrum of coated sample.
SEM images of coated sample at different
magnification such as 500X and 1000X are shown in
figure 5 and EDAX analysis is performed to find the
composition of coated sample which is shown in
Figure 6. The spectrum obtained from EDAX
provides confirmation of Molybdenum presence in
coated sample. The atomic and weight percentage of
the elements obtained through EDAX analysis is as
shown in table 2.
Table 2: Atomic and Weight Percentage of Elements in
Coated Sample.
Element
Weight %
Atomic %
MoL
89.28
58.13
OK
10.72
41.87
There are five different coating thicknesses along
the length from SEM image are considered for the
thickness measurement. The average thickness
measured from the image is 110 microns from the
Figure 7.
Figure 7: Coating thickness measured using SEM.
The uncoated specimen is clamped in specimen
holder of rubber wheel abrasive tester and surface
contact with rubber wheel is ensured. Sand hopper is
filled with sand and the speed in terms of number of
revolutions of wheel is fixed accordingly load is also
placed on the lever arm. The results of 200, 300, 600
microns are tabulated in table 3, table 4 and table 5
which is shown below.
Table 3: Abrasion wear test results of uncoated specimen
(200 microns).
Sl.
no
Load
(N)
Spe
ed
(rp
m)
Initial
weight
(g)
Final
weight
(g)
Mass
Loss
(g)
Volum
e loss
(mmt)
1
25.70
2
50
121.37
2
121.35
9
0.013
1.639
2
49.34
4
100
122.70
9
122.69
1
0.018
2.269
3
72.98
6
150
121.62
4
121.59
7
0.027
5.170
The table shows that least value of volume loss
(1.639) was found for 50rpm and 25.072N load. the
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120

volume loss increased linearly for increased speed
and load conditions.
Table 4: Abrasion wear test results of uncoated specimen
(300 microns).
S
l
.
n
o
Load
(N)
Speed
(rpm)
Initial
weight
(g)
Final
weight
(g)
Mass
Loss
(g)
Volume
loss
(mmt)
1
25.702
50
122.534
122.519
0.015
1.891
2
49.344
100
121.156
121.134
0.022
2.774
3
72.986
150
122.262
122.218
0.044
5.548
The table shows that least value of volume loss
(1.891) was found for 50rpm and 25.072N load. the
volume loss increased linearly for increased speed
and load conditions.
Table 5: Abrasion wear test results of uncoated specimen
(600 microns).
S
l
.
n
o
Load
(N)
Speed
(rpm)
Initial
weight
(g)
Final
weight
(g)
Mass
Loss (g)
Volu
me
Loss
(mmt
)
1
25.702
50
120.388
120.370
0.016
2.017
2
49.344
100
118.839
118.184
0.025
3.152
3
72.986
150
121.717
121.669
0.048
6.052
The table shows that least value of volume loss
(2.017) was found for 50rpm and 25.072N load. the
volume loss increased linearly for increased speed
and load conditions.
The coated specimen is clamped in specimen
holder of rubber wheel abrasive tester and surface
contact with rubber wheel is ensured. Sand hopper is
filled with sand and the speed in terms of number of
revolutions of wheel is fixed accordingly load is also
placed on the lever arm. The results of 200, 300, 600
microns are tabulated in table 6, table 7 and table 8
which is shown below.
Table 6: Abrasion wear test results of coated specimen (200
microns).
Sl.
no
Load
(N)
Speed
(rpm)
Initial
weight
(g)
Final
weight
(g)
Mass
Loss
(g)
V
ol
u
m
e
lo
ss(
m
mt
)
1
25.702
50
123.043
123.032
0.011
1.
38
7
2
49.344
100
123.118
123.104
0.014
1.
76
5
3
72.986
150
124.171
124.154
0.017
2.
14
3
The table shows that least value of volume loss
(1.387) was found for 50rpm and 25.072N load. the
volume loss increased linearly for increased speed
and load conditions.
Table 7: Abrasion wear test results of coated specimen (300
microns).
Sl.
no
Load
(N)
Speed
(rpm)
Initial
weight
(g)
Final
weight
(g)
Mass
Loss
(g)
Volu
me
Loss
(mmt
)
1
25.702
50
123.877
123.864
0.013
1.639
2
49.344
100
123.638
123.621
0.017
2.143
3
72.986
150
124.051
124.026
0.025
3.404
The table shows that least value of volume loss
(1.639) was found for 50rpm and 25.072N load. the
volume loss increased linearly for increased speed
and load conditions.
Table 8: Abrasion wear test results of coated specimen (600
microns).
Sl.
no
Load
(N)
Speed
(rpm)
Initial
weight
(g)
Final
weight
(g)
Mass
Loss
(g)
Volu
me
loss(
mmt
)
1
25.702
50
124.670
124.654
0.016
2.01
7
2
49.344
100
124.353
124.334
0.019
2.39
5
3
72.986
150
124.469
124.420
0.027
3.40
4
Enhancement of Three-Body Wear Resistance of Steel Substrate Using Molybdenum Coating for Steel Roller Conveyor
121

Figure 8: Load Vs Mass (200 microns).
Figure 9: Load Vs Mass (300 microns).
The table shows that least value of volume loss
(2.017) was found for 50rpm and 25.072N load. the
volume loss increased linearly for increased speed
and load conditions.
Load versus Mass loss graphs of both coated and
uncoated samples are plotted for different grain size
and shown in Figure 8-10.
Figure 10: Load Vs Mass (600 microns).
Linear relationship between load and Mass loss is
proved by all three graphs. Irrespective of Load and
grain size, coated samples mass loss is less compared
to uncoated steel samples which is proved by graphs.
From figure 9, it is observed that mass loss for both
coated and uncoated steel substrate are same for
minimum load value. At minimum load, with higher
grain size (600 micron) coating does not enhance the
abrasive wear resistance.
Speed versus Mass loss graphs of both coated and
uncoated samples are plotted for different grain size
and shown in Figure 10-12. Linear relationship
between speed and Mass loss is proved by all three
graphs. Irrespective of speed and grain size, coated
samples mass loss is less compared to uncoated steel
samples which is proved by graphs. From figure 12,
it is observed that mass loss for both coated and
uncoated steel substrate are same for minimum speed
value. At minimum speed, with higher grain size (600
micron) coating does not enhance the abrasive wear
resistance.
At minimum loads and speeds, the difference in
mass loss between the coated specimen and the
uncoated specimen is negligible in comparison to
higher loads and speeds. Coating has the influence
only on higher loads, because of oxide layer
generation in surface which acts as lubricant, which
leads to less mass loss and abrasive wear.
Figure 11: Speed Vs Mass (200 microns).
Figure 12: Speed Vs Mass (600 microns).
ISPES 2023 - International Conference on Intelligent and Sustainable Power and Energy Systems
122

4 CONCLUSION
This paper focused on evaluation of coating
performance of steel substrate which is used in
conveyor rollers which works under highly abrasive
environments. Main objective is to increase the three-
body wear resistance by molybdenum coating using
plasma spray technique. The results obtained from the
experimental analysis proved the improvement in
wear resistance after molybdenum coating. EDAX
and SEM analysis are performed to composition
identification and to find thickness of the coating.
Enhanced resistance to mass loss indicates the
improvement in wear resistance of molybdenum
coated steel. Following observations are made from
the experimental result and analysis
The observed trend indicates that both the
uncoated and coated samples exhibit a linear variation
as the parameters such as speed, load, and grain size
increase.
At lower loads and speeds, the disparity in wear
between the coated specimen and the uncoated
specimen is negligible in comparison to higher loads
and speeds.
The findings indicate that when subjected to
higher loads, an oxide layer is generated on the
surface, acting as a lubricant and decreasing the
friction coefficient. As a result, the presence of
abrasives is reduced, leading to a decrease in mass
loss and material wear.
The experiment was conducted with a consistent
coating thickness ranging from 100 to 150 microns.
This approach can be expanded to create coatings of
different thicknesses.
This research highlights the potential of
molybdenum powder coatings to enhance the
durability and lifespan of steel rollers in conveyor
systems operating in harsh environments. The
findings contribute to the development of effective
strategies for reducing wear and optimizing the
performance of mining and construction equipment.
The experimentation was conducted using the
atmospheric plasma spray process, but it is possible
to expand the study by employing various thermal
spray processes and assessing their performance.
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