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SURFACE ENGINEERING (2)

THERMAL SPRAY
Prof. Priit Kulu, Andrei Surzhenkov

Surface properties of material/part

Wear

mechanical; corrosive-mechanical. Criteria: wear resistance (by mass/volume, relative)

Methods of surface reinforcement

peening; surface alloying and hardening; coatings (sprayed coatings, vapor deposited coatings, cladded coatings, galvanic coatings, diffusion coatings); metal cladding (bimetal materials).
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Coating-substrate system

Structures types of the coatings

Coatigns processes

CHEMICAL ELECTROCHEMICAL THERMOCHEMICAL THERMOCOATING VAPOR DEPOSITION MECHANICAL

Comparison of the coating processes

Thermal spray methods


Thermal spraying

CHEMICAL ELECTROCHEMICAL THERMOCOATING VAPOR DEPOSITION MECHANICAL

cold gas spraying (CGS)

laser spraying (LS)

molten-metal flame spraying

Sprayed coatings structure


Typical structure of a coating

Sprayed coatings materials

Flame spraying

- flame temperature: acetylene/oxygen 3160 C; propane/oxygen 2850 C; hydrogen/oxygen 2660 C. - sprayed materials: wire: metals and metal alloys; powder: pure metals, alloys, oxides, cermets, composite powders.

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Arc spraying

temperature inside the arc: 6500 C; voltage 18 40 V, current 50 150 A; sprayed materials: electroconductive alloys, ceramics can be deposited, when using core wires.

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Plasma spraying

plasma temperature: up to 30000 C. virtually all existing materials.

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Plasma transfered arc spraying (PTA)

Fe, Ni, Co, Cr based alloys, stainless steels, cermets

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Laser cladding

virtually all metal alloys, cermets and ceramics.

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Detonation gun spraying

flame temperature: 4000 C.

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High-velocity oxy fuel spraying (HVOF)

gas temperature: 3000 C; sprayed materials: virtually all existing materials, in practice mostly carbide/metal and carbide / self-fluxing alloy mixtures.

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Cold spraying

gas temperature: under the phase transition temperature; sprayed materials: pure Al, Zn, Cu, Ni and babbites.

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Thermal energy vs. kinetic energy in thermal spray

WARCS

Wirearc Spray PS FS Plasma Spray Flame Spray 18

rmal Energy

Coatings properties (1).


Influence of velocity and temperature

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Coatings (2).
properties

Adhesion and porosity


Spray technology Flame spraying powder wire Arc spraying Plasma spraying (different modifications) Detonation gun spraying HVOF, HVAF Cold spraying Velocity, m/s 30 180 240 240 1200 910 610 1500 500 1200 Porosity, % 6 15 28 < (0,5 2) <1 < 0,5 13 Adhesion, MPa 17 70 15 20 40 20 70 100 62 83 30 100

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Coatings properties (3).


Obtainable harndess.
Sprayed material Chrome steel NiAl alloy Copper Stellite MCrAlY Self-fluxing alloy (NiCrSiB) WC-Co Al2O3 Spraying technology Flame spraying (wire) PTA Flame spraying Flame spraying (powder) Flame spraying (powder)/HVOF PTA Plasma spraying Flame spraying/HVOF PTA Plasma spraying (powder)/HVOF Plasma spraying Hardness, HV 500 600 800 850 200 250 150 460 770 290 590 400 250 780 360 820 1100 1300 1800 2000

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Coatings properties (4).


HV0.3

Microhardness of WC-17Co coating, sprayed using different technologies.

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Coatings properties (4).


Wear vs. spray method
7PSZ
800 700 600

Weight Loss (mg)

500 400 300 200 100 0


22x 32x 21x

Al2O3

Cr2O3

APS 1

HVOF 2

APS 3

HVOF 4

APS 5

HVOF 6

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Coatings properties (5)


Hardness vs. fracture toughness

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Applications of sprayed materials

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Applications (1)

wear resistant coatings (pumps, compressors, camshafts, etc.) except for cold spraying; corrosion resistant coatings (pipelines, building constructions, etc.);

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Applications (2)

temperature resistant and dielectrical coatings (gas turbines, flue tubes); antifriction coatings (sliding bearings);
size restoration (shafts, bearings, etc.)

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Applications (3).
HVOF sprayed pot rolls for continuous galvanizing line for steel strips.

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Applications (4)
Sprayed coatings in an aircraft engine

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Applications (5)
Process automation. Flame spraying by Kuka robot.

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Thank you for the attention! Questions?

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