Papers by Keyword: Thermal Spraying

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Authors: Noriyuki Mifune, Yoshio Harada
Abstract: The applicability of 2CaO·SiO2-CaO·ZrO2 ceramic coatings as thermal barrier coatings (TBCs) was investigated. Coatings consisting of various ratios of 2CaO·SiO2-CaO·ZrO2 bond-coated with NiCrAlY were prepared using the plasma spray process. The structure of the coatings was characterized by scanning electron microscopy and X-ray diffraction analysis. The resistance of the coatings to thermal shock was evaluated with acoustic emission techniques under a thermal cycle from 1273 K to room temperature, and the hot corrosion resistance of the coatings was investigated with V2O5 and Na2SO4 at 1273 K for 3 h. The 2CaO·SiO2-10~30mass%CaO·ZrO2 coatings had excellent thermal shock resistance, because the coatings contained a vertical micro-crack in a single flattened ceramic particle. These coatings possessed excellent corrosion protection preventing direct contact between the corrosive ashes and a NiCrAlY bond coating. The CaO in the coating reacted with vanadium compounds and inhibited the penetration of corrosive ashes to the bond coating. The developed 2CaO·SiO2-20mass%CaO·ZrO2 thermal barrier coating on stationary vanes was evaluated in an actual gas turbine. The ceramic coating did not separate from the bond coating and reacted with SOx in combustion gas to produce a stable sulfate (CaSO4), which fixed in the coating. The TBC effectively protected the metal substrate of the vanes in practical operating condition for 25,000 h.
Authors: N. Pistofidis, G. Vourlias, D. Chaliampalias, F. Stergioudis, Efstathios K. Polychroniadis
Abstract: In the present work the phases of the zinc coatings deposited with hot-dip galvanizing, pack cementation and wire flame spraying are examined with Scanning Electron Microscopy and Transmission Electron Microscopy. The different phases which are observed are identified with the combined results of electron and X-Ray diffraction. From the results it is concluded that pack cementation coatings are consisted by two different layers while hot dip galvanized coatings are composed by the same phases and additionally two extra phases of the Fe-Zn phase diagram. Flame sprayed coatings are composed by pure zinc, in the form of thin lamellae, together with nanocrystaline zinc oxide which is formed from the oxidation of liquid metallic droplets during the spray procedure.
Authors: G. Vourlias, N. Pistofidis, D. Chaliampalias, F. Stergioudis
Abstract: One of the most effective methods for the protection of ferrous substrates from corrosion is zinc hot-dip galvanizing. Although this method has many advantages, it is characterized by a very negative effect on the environment. In the present work Zn coatings were formed with thermal spraying, pack cementation and fluidized bed reactor, which are friendlier to the environment. Their microstructure was characterized with X-ray diffraction and scanning electron microscopy, while their corrosion performance was estimated with exposure in a salt spray chamber. From this investigation it was deduced that CVD coatings are composed by two layers referring to Γ-Fe11Zn40 and δ-FeZn10 phase of the Fe-Zn phase diagram. By contrast the thermal coatings are very porous and composed by pure Zn. However, the corrosion performance of all coatings is similar. This conclusion is very important because it verifies that hot-dip galvanizing could be replaced by the other coating methods.
Authors: Zeng Yi, Xue Bin Zheng, Heng Ji, Wei Wu, Soo Wohn Lee
Abstract: The W coatings were prepared by applying the vacuum plasma spraying process (VPS). The phase composition, microstructure and laser irradiation property were characterized by XRD, SEM and laser. Results showed that no tungsten oxide appears in the coatings whose phase composition is similar to the original powder. A better melting state of the coating can be obtained by using the finer powder. The deposition efficiency of the coating is higher in the cases of a higher H2 flow. There is a pitch whose size is about 100μm when the substrate was irradiated by laser. However, there is clearly no change for the W coating surface which was also irradiated under the same condition. It indicates that the laser irradiation resistance is improved significantly for stainless steel after being deposited with W coating.
Authors: Rainer Gadow, Andreas Killinger, Andreas Rempp, Andrei Manzat
Abstract: Protective and functional coatings featuring outstanding tribological performance are of general interest for all kinds of industrial applications i.e for high performance automotive and mechanical applications. Thermal spray coating technologies play a key role in fabricating hard layers based on ceramic, metal - ceramic and further multiphase materials. Additional functionality can be achieved by combining these coatings with polymer based top coats with low friction coefficient or anti adhesive behaviour. Combined coatings feature also designed thermophysical and electrophysical properties. Several case studies will be discussed, ranging from automotive applications to paper and printing industry. Thermally sprayed coatings were applied using APS, HVOF and the newly developed HVSFS processes (High Velocity Suspension Spraying) with a special focus on nanoceramic feedstocks. In some applications polymer top coats with dispersed solid phases are applied to enhance functional properties. Special aspects in manufacturing engineering are addressed with particular importance not only of the influence of spray process parameters on coating properties but also of spray torch kinematic and robot trajectories on hardness, residual stress distributions, dimensional tolerances and porosity distributions will be discussed.
Authors: Andrea Förg, Gerhard Wolf, Klaus Dotzler, Laure Libralesso, Patrick J. Masset
Abstract: Cadmium coatings are used in aerospace and offshore industries for parts in corrosive environments. Since cadmium is a highly toxic heavy metal, it is subject to strong restrictions. Alternatives include Al-based alloys. The present work describes preliminary results for Cd substitution by using Al-Mn with 25 at.-% Mn deposited on 42CrMo4 steel by atmospheric plasma spraying (APS). The prepared alloy powder for the APS process was characterized by laser granulometry, SEM/EDX, and STA. A fraction with particle sizes ranging from 20 µm to 45 µm was used for the thermal spraying process. The APS coating and an Al reference sample were characterized by image analysis, Vickers hardness, and Standard Salt Spray (SSP) testing. The Al-Mn coating exhibits a significantly higher hardness in comparison to pure Al. In both cases, red iron corrosion did not appear during SSP testing. The Al coating was partially covered by a thick oxide film, whereas Al-Mn showed only moderate oxidation but lower adhesion to the substrate
Authors: G.R. Heath, P. Heimgartner, G. Irons, Robert D. Miller, Stefan Gustafsson
Authors: N. Boualem, A. Raid, M.A. Ghaffor, A. Tlemçani, M. Derrar
Abstract: Thermal spraying is a process for surface coating by projecting a material in powder or in wire form on a material with a previously prepared surface. The materials used in our study are 5086 aluminum alloy and 304 L stainless steel with various surface qualities: polished 120, mirror polished and sandblasted. The projection powder is a combination of "ceramic-metal" WC-Co whose average grain size is 30 microns. The layers thicknesses obtained after 3 passes vary between 90 and 120 microns depending on the operating conditions: gas protection, temperature and surface condition. Indentation tests at the substrate-layer interface and micrographic sections revealed the roughness importance to allow a better layers grip.
Authors: Basil R. Marple, R.S. Lima, H. Li, Khiam Aik Khor
Abstract: There is an ongoing effort to improve the quality and performance of orthopedic implants. Part of this work involves the development of coatings suitable for use in the human body and having properties and bio-performance characteristics better than those of existing materials. The present study focused on developing thermal spray titania coatings engineered to have a bimodal structure consisting of a major fraction of micron scale dimensions within which were dispersed zones of nanostructured material. The coatings were found to exhibit much stronger adhesion to Ti-6Al-4V substrates than conventional hydroxyapatite coatings and to possess excellent crack propagation resistance characteristics. Cell culture studies indicated that human osteoblasts attached and proliferated well on the coating surface. The surface nano-features and nanostructured zones in the coating are believed to play an important role in the improved bonding, mechanical properties and bio-performance.
Authors: Rainer Gadow, D. López, A. Candel
Abstract: Actual requirements in the automotive industry are the reduction of fuel consumption and pollution emission, engine efficiency improvement, as well as cost reduction. Most of these requirements are fulfilled by reducing the total weight of the vehicle. This results in an increasing utilization of light metal components for engine applications. Significant weight savings are obtained by changing the engine block material from cast iron to aluminum or even to magnesium aluminum hybrid constructions. Despite of all advantages the industrial implementation of light metals is often inhibited by their poor surface properties especially concerning wear and tribological behavior. Due to the highly loaded operation conditions a cylinder liner surface reinforcement is necessary. A very promising technological alternative is the internal cylinder reinforcement by using HVOF (high velocity oxygen fuel) sprayed coatings. By using these advanced high energetic coating technologies, material combinations containing solid lubricant ceramic dispersions can be deposited. The thermal spray processes represent a cost effective and flexible solution for ultra light weight engine technology. This research is focused on the development of HVOF sprayed coating systems for cylinder liners, the coating optimization and the cost effective implementation of this hypersonic spray technology in a series production process. It will be shown that cast engine block bores can be directly coated by using an automated HVOF process, obtaining improved coating results. The internal coating process by hypersonic flame spraying is a superior technological alternative to the APS process for high quality cylinder liner and engine crankcase applications.
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