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C. Herbst
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Proceedings Papers
ITSC 2003, Thermal Spray 2003: Proceedings from the International Thermal Spray Conference, 129-138, May 5–8, 2003,
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Diesel engine development is continuously progressing: light vehicle diesel (LVD) engines are gaining in popularity in Europe and therefore we see a steady improvement in power performance and fuel consumption going along with increased loading of the power-cylinder components. Moreover, heavy-duty (HD) engines for trucks are facing stricter environmental legislation leading amongst other technologies to the introduction of exhaust gas recirculation (EGR). Whatever reduced emission technology will be applied, they all will significantly influence the engine tribology. This paper is dedicated to describing modern piston ring coating technologies to face the future diesel engine demands. The paper mainly focuses onto modern piston ring coating technology such as hard particle reinforced chrome plating, HVOF spraying and PVD. In particular, it will be discussed how thermal spray coatings need to be designed to find their position among established or future coating technologies of the competition.
Proceedings Papers
ITSC2000, Thermal Spray 2000: Proceedings from the International Thermal Spray Conference, 843-849, May 8–11, 2000,
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Quasicrystalline phases improve many alloy properties such as thermomechanical stability, thermal and electrical conductivity, and tribological performance. High hardness, however, is accompanied by brittleness, an undesired property in many applications. Reduced brittleness can be achieved by embedding quasicrystalline phases in a more ductile material, forming a metal-matrix composite that retains some quasicrystalline properties. This study evaluates thermally sprayed coatings made from different compositions of such composites. The coatings assessed were produced by arc-wire, HVOF, and atmospheric plasma spraying using various forms of feed material, including blended, agglomerated, chemical encased, and attrition-milled powders and filled wires. The investigation involved metallurgical analysis, proving the existence of quasicrystal content and assessing the matrix phase, and tests showing how sliding wear is influenced by the composition of quasicrystalline phases.
Proceedings Papers
ITSC2000, Thermal Spray 2000: Proceedings from the International Thermal Spray Conference, 501-508, May 8–11, 2000,
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The paper deals with an analysis of particle behavior in a HVOF-jet as a function of process parameters. The experiments were carried out using a commercial HVOF gun with hydrogen as fuel gas. A commercial 316 L stainless steel powder was used for spray material. The experiments were conducted by using on-line particle diagnostics in order to simultaneously detect particle velocity, temperature and diameter. The results were correlated with caught spray powder and splats. The experiments released that among many parameters the oxygen/fuel gas ratio is the most important parameter. It was found, that fragmentation of partially melted particles in a supersonic jet is not a neglectable phenomenon. It may cause excessive oxidation inflight and therefore is to be avoided in the production of oxygen-poor coatings. Furthermore, it was found that velocity or temperature measurements of particles have to be interpreted very carefully in order to characterize the process. Without taking a possible change of the particle size due to inflight fragmentation into consideration either measurement value will lead to very limited information benefit.
Proceedings Papers
ITSC1998, Thermal Spray 1998: Proceedings from the International Thermal Spray Conference, 19-24, May 25–29, 1998,
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Thermally sprayed coatings of high performance thermoplastics are of interest especially for the chemical industry for anti-corrosion applications at elevated temperatures. In this paper coatings of polyetherether-keton (PEEK) and polyphenylen-sulphide (PPS) have been produced by simple flamespraying. They have been investigated by optical metallography, FT-IR analysis and DSC-analysis. Among the coating properties also the "in-flight" particles have been studied by wipe-tests and FT-IR analysis in order to assess possible decomposition effects during spraying.
Proceedings Papers
ITSC1997, Thermal Spray 1997: Proceedings from the United Thermal Spray Conference, 35-39, September 15–18, 1997,
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The direct conversion of heat into electric current is still less developed form of energy conversion. Thermoelectric material working in a temperature gradient is able to induce a voltage that can drive a serial resistor. New research activities try to broaden the employment of thermoelectric generators from spacecraft technologies to terrestrial applications. The main problem at the moment is rather the lack of economic production methods, than the low efficiency of conversion. After an overview about the basics of thermoelectrics and possible applications the paper presents the thermal spraying as an alternative processing method with first attempts to realize graded structures. Al-doped and Co-doped FeSi 2 has been consolidated by APS, SPS, VPS and HVOF spraying. The microstructure, phase composition and oxygen input have been investigated and set into relation to thermoelectric properties.
Proceedings Papers
ITSC1997, Thermal Spray 1997: Proceedings from the United Thermal Spray Conference, 175-181, September 15–18, 1997,
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For very large structures and parts in critical environments, a materials solution often cannot be found by using one material. The specific desired properties for those structures, like stiffness, ductility, high temperature stability, corrosion resistance, etc. are difficult to fulfill with only one material. In this case a solution may be found by using coatings and design their specific properties to replenish each other by their combination. The Thermal Spraying processes offer the necessary flexibility of producing thin to thick, ductile, soft to hard coatings while due to the wide range of process temperatures it is possible to process a wide range of materials, both as coating and structure. In this paper the some recent and important developments in Thermal Spraying to produce coatings for technical demanding structures will be described. These developments consist of High Power Plasma Spraying, powder- and process control development. To ensure process consistency during long spraying times and to apply reproducible coating quality a suitable process control is of great importance and the development of temperature control by Pyrometry and Thermography will be presented. The example will be drawn according to the application of a coating on a ball valve for off-shore and ship diesel engine parts (piston and valve).
Proceedings Papers
ITSC1996, Thermal Spray 1996: Proceedings from the National Thermal Spray Conference, 933-940, October 7–11, 1996,
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An overview on potential non-destructive testing (NDT) methods for the inspection of thermally sprayed coatings in production lines is given. The suitability of several NDT techniques has been investigated with view on their sensitivity for the detection of defect sizes possibly being critical for Thermal Spray coatings. Eventually, a method is presented that shows qualification for detection of subsurface flaws in coatings such as delaminations and cracks and offers flaw distinction by image analysis procedures. A storage and archiving of test results is possible thus completing full quality control and meeting possible warranty claims. The major advantage of the NDT process is its very high detection speed which guarantees high productivity even for high volume production systems. Thus a full-area detection of large coated components becomes possible. The process is not restricted to plain components, but is usable for the detection of internally coated cylinders as well.