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A. Kirsten
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Proceedings Papers
ITSC 2005, Thermal Spray 2005: Proceedings from the International Thermal Spray Conference, 957-962, May 2–4, 2005,
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Hard chromium, electrochemical deposited, is a widely used and established coating solution for surface protection against wear and corrosion as well as for decorative applications. Due to the possibility to coat bulk goods also, this technique is well suitable to protect small pieces and mass-produced goods. However, the most disadvantage of that technique is the appearance of highly carcinogenic hexa-valence chromium. Because of human health and environmental aspects the replacement of this coating technique is more and more required. At least for bigger parts with larger surfaces H(igh) V(elocity) O(xy) F(uel) -spraying can already produce competitive coatings to galvanic hard chromium with equal or even better properties. Especially thermal sprayed carbide coatings with in terms of corrosion resistance tailored metallic matrices offering the best potential to replace hard chromium in various applications. Beside of the material properties also the spraying conditions have essential influence on the corrosion resistance of those coatings. The present paper will give an overview of different carbide containing materials for HVOF-spraying and their properties with special respect to the replacement of galvanic hard chromium. The closest attention will be on the corrosion resistance of HVOF-coatings of those materials in different aqueous solutions compared with hard chromium. For a liquid fuel high velocity spraying system also the trends will be shown in which way the spraying parameters are influencing the general corrosion behaviour of such coatings. Those tendencies by conviction of the authors are also transferable to other HVOF systems.
Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 361-370, May 5–8, 2003,
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It is well known that thermally sprayed aluminum and aluminum alloys can be used to protect low-alloyed steel against marine corrosion in offshore applications. The efficiency and service life of this protection can be, however, severely limited by the amount and distribution of defects, which are usually present in coating microstructures. In thermal spraying, microstructures and properties are strongly influenced by the type of spray system used for the production of coatings. To investigate the influence of defects like pores, oxides and cracks on the corrosion performance, coatings were processed by conventional thermal spray techniques, such as Flame Spraying (FS) and Arc Spraying (AS). In addition, the more recently introduced High Velocity Combustion Wire (HVCW) spraying technique was used, which, due to higher particle velocities, results in lower porosity and finer coating microstructures as compared to conventional processes. The influence of spray conditions and related microstructures on the performance in corrosion tests was investigated for protective coatings of Al99.5, AlMg5 and Al - 30 wt. % W2C. The resistance against corrosion was analyzed by different electrochemical methods, such as corrosion potential monitoring, polarization resistance and potentiodynamic anodic polarization measurements. Additionally, the microstructures of the coatings were examined before and after the electrochemical tests. The results from these tests are correlated and attributed to the different microstructures obtained by the various spray techniques and different compositions of the feedstock material.
Proceedings Papers
ITSC 2001, Thermal Spray 2001: Proceedings from the International Thermal Spray Conference, 461-466, May 28–30, 2001,
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Thermal spray processes using wires as feedstock are widely used to produce wear and corrosion protective coatings of nickel, cobalt or iron based alloys. In general, these coatings are processed by flame or arc spraying. In view of using massive wires as spraying material, the hardness and wear resistance of layers is limited by the possibility to produce the corresponding wires of such materials. In addition, the performance of wire sprayed coatings can be restrained by the amount of defects in the microstructure, like pores, oxides and cracks, which are particularly evident in the cases of flame and arc spraying. New High Velocity Combustion Wire (HVCW) systems open the opportunity to reduce the amount and size of the defects by an increased particle velocity. Also, improvements on wear resistance may be achieved by using cored wires. The paper gives an overview on recent developments in HVCW spraying using massive and cored wires.
Proceedings Papers
ITSC1999, Thermal Spray 1999: Proceedings from the United Thermal Spray Conference, 90-94, March 17–19, 1999,
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The development and introduction of more advanced spray systems continues to drive the thermal spray market. Most of these developments benefit from an increase in particle velocities. The latest generation of HVOF systems can spray cermet coatings of higher density and higher hardness, wear resistance and corrosion resistance than HVOF systems introduced previously, due to an 30 to 50 % increase in particle velocity. HVAF systems are offered as an cost-effective alternative to HVOF systems. A further increase in particle velocity and the introduction of cold gas spraying can be seen as a transition from thermal to kinetic spraying and may open a wide field of new applications for coatings and structures of oxidation sensitive materials. Advances are also reported for wire spraying. New arc spray systems are capable to increase the density of metal and alloy coatings considerably and to reduce the oxide content of these coatings. Similar improvements but at lower spray rates may be achieved with newly developed HVOF wire systems. Paper text in German.