Comparative Analysis of Strength Fatigue Properties and Abrasive Wear Resistance for a New Composition of Polymer Concrete Coated with Metal Alloy Powders

The possibility of using powder spraying to improve the strength properties of polymer concrete products has been studied. Different compositions of polymer concrete mixtures have been compared and analyzed in order to find out the adhesive and cohesive properties of coatings. An analysis of the stress-strain state under static loads has been carried out. To improve the tribological properties and wear resistance of critical parts of metal-cutting machine tools, such as beds, it is proposed to spray polymer concrete surfaces using the gas-thermal method. Two types of powder mixtures for spraying have been compared, and the adhesive properties of the analyzed coatings have been considered. The finite element method was used for the calculation of the abrasion resistance of polymer concrete models according to the proposed modification of Ni-7Cr-3Fe + 60% WC coating composition, which showed that the use of gas-thermal coating for polymer concrete is justified. Based on a simulation of adhesive peeling strength, it can be concluded that the wear coefficient of the coated sample is quite large. Under the impact of amplitude loads applied during 5 × 106 loading cycles with a high degree of wear equal to 1.5, the sample showed high safety margins equal to 0.67. The presence of a sprayed layer prevents the concentration of internal stresses in the area of polymer concrete, taking over the resulting stresses under an external force caused by the mechanical properties of the materials, thereby increasing the service life of a manufactured part.