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    Surface 8

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    Narkedamilli Tulasi Radha
    This document discusses thermal spray coatings. Thermal spray is a coating method where melted or heated materials are sprayed onto a surface. There are several thermal spray processes that differ in the heat source used, including flame spraying, arc spraying, plasma spraying, detonation gun spraying, high-velocity oxy-fuel spraying, and cold spraying. The structure and properties of thermally sprayed coatings depend on factors like the spray process, material used, coating thickness, and substrate. Common applications of thermal spray coatings include wear and corrosion resistant coatings, high-temperature coatings, and restoration coatings.

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    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd

    Surface 8

    Uploaded by

    Narkedamilli Tulasi Radha
    302 views31 pages
    This document discusses thermal spray coatings. Thermal spray is a coating method where melted or heated materials are sprayed onto a surface. There are several thermal spray processes that differ in the heat source used, including flame spraying, arc spraying, plasma spraying, detonation gun spraying, high-velocity oxy-fuel spraying, and cold spraying. The structure and properties of thermally sprayed coatings depend on factors like the spray process, material used, coating thickness, and substrate. Common applications of thermal spray coatings include wear and corrosion resistant coatings, high-temperature coatings, and restoration coatings.

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    surface-8.ppt

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    This document discusses thermal spray coatings. Thermal spray is a coating method where melted or heated materials are sprayed onto a surface. There are several thermal spray processes that differ in the heat source used, including flame spraying, arc spraying, plasma spraying, detonation gun spraying, high-velocity oxy-fuel spraying, and cold spraying. The structure and properties of thermally sprayed coatings depend on factors like the spray process, material used, coating thickness, and substrate. Common applications of thermal spray coatings include wear and corrosion resistant coatings, high-temperature coatings, and restoration coatings.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    302 views31 pages

    Surface 8

    Uploaded by

    Narkedamilli Tulasi Radha
    This document discusses thermal spray coatings. Thermal spray is a coating method where melted or heated materials are sprayed onto a surface. There are several thermal spray processes that differ in the heat source used, including flame spraying, arc spraying, plasma spraying, detonation gun spraying, high-velocity oxy-fuel spraying, and cold spraying. The structure and properties of thermally sprayed coatings depend on factors like the spray process, material used, coating thickness, and substrate. Common applications of thermal spray coatings include wear and corrosion resistant coatings, high-temperature coatings, and restoration coatings.

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    Download as PPT, PDF, TXT or read online from Scribd
    Download as ppt, pdf, or txt
    of 31

    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).
    2

    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.

    10

    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.

    11

    Plasma spraying

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

    12

    Plasma transfered arc spraying (PTA)

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

    13

    Laser cladding

    virtually all metal alloys, cermets and ceramics.

    14

    Detonation gun spraying

    flame temperature: 4000 C.

    15

    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.

    16

    Cold spraying

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

    17

    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

    19

    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

    20

    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

    21

    Coatings properties (4).


    HV0.3

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

    22

    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

    23

    Coatings properties (5)


    Hardness vs. fracture toughness

    24

    Applications of sprayed materials

    25

    Applications (1)

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

    26

    Applications (2)

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

    27

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

    28

    Applications (4)
    Sprayed coatings in an aircraft engine

    29

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

    30

    Thank you for the attention! Questions?

    31

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