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Thermal Spraying of Fe-based Materials
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Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 317-320, June 2–4, 2008,
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The thermal spray application of inert gas atomised iron based powders for combined wear and corrosion protection prospectively offers important economical advantages compared to the well-established cermet coatings due to their lower price. Recent studies revealed basic knowledge about the thermal spray processing of these materials. For protecting the substrate from corrosive media, coatings have to be dense and impermeable to fluids. Especially poor bonding, occurring between partially melted or unmelted spray particles, leads to open porosity. Hence a certain degree of melting of particles is required. The GTV K2 spray gun allows the use of different nozzles to vary process temperature and velocity in a wide range. This paper shows the influence of applicated nozzles and process conditions on coating characteristics. Powder and coating characterisation is carried out by means of optical microscopy, digital image analysis, SEM and XRD. Additionally, some results regarding microhardness and wear behaviour are given.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 321-325, June 2–4, 2008,
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New requirements for modern component part surfaces increasingly demand improvements over friction coefficients in the sense of a reduction of friction losses. A substantial control factor in terms of lower friction and wear is the use of coating solutions such as thermal spray coatings. In practice, the application of coatings by means of thermal spray is more and more often used for influencing tribological matching. However, surface microstructuring might represent an additional, further reaching solution for wear and friction behaviour improvements of tribologically high-stressed surfaces. The aim of the reported research project is the development of atmospheric plasma sprayed (APS) coatings with an inherent porous microstructure and surfaces with stochastically distributed nap volumes (from cut pores) regarding lubricant retention and -distribution in running surfaces of friction-type bearings. Subject of these investigations are in particular thermomechanically highly loaded hydrodynamic tribological matchings, amongst others by the example of a piston ring/cylinder system in engine blocks. The use of special fractioned Fe-base powders enables the production of a new type of coatings with an inherent porous microstructure, which offer advantages due to constantly regenerating their surface topology under wear, and maintain employment in tribological systems with increased loads due to optimized lubricant retention and distribution. Hence, this project has an emphasis on the design of optimal nap sizes in coating surface structure in dependence on the hydrodynamical load, as well as on investigations for the controllability of nap volumes by the design of suitable processes.
Proceedings Papers
ITSC 2008, Thermal Spray 2008: Proceedings from the International Thermal Spray Conference, 326-329, June 2–4, 2008,
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Development of new arc sprayed iron based coatings for protection against gas abrasive wear at room and elevated temperatures are of the great interest because of permanently increasing pressure to reduce production and repair costs of power production facilities. Two cored wires in steel cover with Fe-Cr-B-Al and Fe-Cr-N-Al filling are proposed as an alternative choice for self fluxing and cermet coatings that are considered nowadays for protection of screen tubes of boilers of power stations that are operated under the temperatures 500-600 °C. Oxidation behaviour of arc sprayed coatings is estimated by gravimetric measurements. Abrasive wear resistance at elevated temperatures after 1 hour is investigated by means of laboratory unit that alloys a rotation of coated specimens in heated quartz sand. It is shown that abrasion wear lost of carbon steel increases 1.5 times when test temperature increases from 20 °C to 550 °C. For all investigated coatings the 20-25% decrease of wear lost is observed at higher temperature. Arc sprayed coatings of both investigated systems improve significally the abrasive wear resistance of carbon steel. At room temperature the improvement by factor 1.3-2.2 times and at the temperature 550 °C by factor 2.7-4.6 is observed depending on chemical composition of coatings.