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Polymers, Environmentally Friendly Coatings, and Nondestructive Testing
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Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 965-970, June 2–4, 2008,
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Cobalt containing carbide powders such as WC-Co and WC-Co-Cr for thermal spraying exist in numerous modifications varying in chemistry, carbide size, and production method. They are widely used for wear, erosion and corrosion protection in many industrial fields. However, for decades it has been well-known from the hard metal industry that WC and Co containing hard metals in breathable dust form can provoke severe lung diseases if inhaled. Recent examinations have proven that this toxicity can be significantly reduced if the Co is pre-alloyed by Fe. In thermal spraying employees are also dealing with Co containing carbides, for example in powder and coating production. Therefore, in order to reduce the hazards for health and the environment, a new class of agglomerated and sintered carbide powders using Fe based binder materials have been developed and investigated. In the present study the powders were HVOF sprayed in order to examine the influence of their different composition and morphology on the microstructure and the properties of the coatings in comparison to standard materials. The experiments comprise microstructural examinations, wear and corrosion tests.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 971-974, June 2–4, 2008,
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Thermal spray of polymers has had limited investigation due to the narrow processing windows that are inherent to polymer powders, especially their low temperatures of thermal degradation. The polymer poly aryl ether ether ketone (PEEK) has a high thermal degradation temperature and high resistance to alkaline and acidic attack. These properties led to PEEK being selected for investigation. To minimise thermal degradation of the particles, the high velocity air fuel (HVAF) technique was used. To investigate the effect of substrate pre-treatment on single splat properties, single splats were collected on aluminium 5052 substrates with six different pretreatments. The single splats collected were imaged by scanning electron microscopy (SEM) and image analysis was performed with ImageJ, an open source scientific graphics package. On substrates held at 323°C it was found that substrate pretreatment had a significant effect on the circularity and area of single splats, and also on the number of splats deposited on the substrates. Increases in splat circularity, area, and the number of splats deposited on the surface were linked to the decrease in chemisorbed water on the substrate surface and the decrease of surface roughness. This proved that surface chemistry and roughness are crucial to forming single splats with good properties, which will lead to coatings of good properties.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 975-977, June 2–4, 2008,
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Metallization of plastics by thermal spraying is studied. The possibility to obtain high adhesion of metal particles to the surface of a wide range of plastic materials is shown. Powders are sprayed with a new generation detonation gun “Dragon” designed at Lavrentyev Institute of Hydrodynamics SB RAS. The apparatus is characterized by a high-precision gas supply system and a dosed localized powder feeding system. Computer control provides a flexible programmed readjustment of the detonation gases energy impact on powder particles which is a key factor in precision control of spraying parameters for low-melting point powder materials. It is found that under certain spraying conditions molten particles of a low-melting point material not only do not provoke erosion of plastic material at their high velocity impact on the substrate but strong-bond fusion, sufficient to further form a thick coating, occurs. Aluminium, zinc and tin powders are sprayed on substrates from fibreglass, polyester, fluoroplastic and some other plastics. Load capacity of the obtained coatings reaches 100 kg/cm 2 . It is shown that on top of a thin layer from a low-melting point powder material high-melting point metals and even ceramics can be deposited.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 978-983, June 2–4, 2008,
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Residual stresses in plasma-sprayed Al 2 O 3 and Cr 2 O 3 coatings, deposited using commercial powders, and in HVOF-sprayed ceramic coatings, deposited using conventional Al 2 O 3 and Cr 2 O 3 feedstock and nanostructured- Al 2 O 3 feedstock, were studied by combining X-ray diffraction, substrate chemical removal technique and analytical modelling. The in-situ curvature technique was also employed for HVOF-sprayed Al 2 O 3 coatings, for further verification. Both HVOF-sprayed Al 2 O 3 -based coatings display similar, tensile residual stresses (≈120 MPa) near the top surface and possess moderate through-thickness stress gradients (≈10 - 20 MPa). Plasma-sprayed Al 2 O 3 possesses a smaller through-thickness stress gradient and a larger near-surface stress (≈220 MPa): this latter result seems to be due to higher quenching stresses in APS Al 2 O 3 , as determined by analytical computation The analytical model is validated by its fairly good agreement to the experimental results obtained both by substrate chemical removal and by in-situ curvature. Cr 2 O 3 -based coatings possess a lower near-surface residual stress (≈20 MPa); the HVOF one also exhibits a very large stress gradient (≈80 MPa). Machining and sliding processes (like polishing and dry sliding tribological testing) change their surface residual stresses to compressive ones.