scholarly journals Development of Thermal Spray Processes for Depositing Coatings on Thermoplastics

2021 ◽  
Author(s):  
Kirsten Bobzin ◽  
Wolfgang Wietheger ◽  
Martin Andreas Knoch
Keyword(s):  
Process Parameters ◽  
Signal Transmission ◽  
Thermal Spraying ◽  
Arc Spraying ◽  
Coating Application ◽  
Critical Areas ◽  
Copper Coatings ◽  
Layer Deposition ◽  
Wire Arc Spraying ◽  
Thermal Spray Processes

AbstractThermoplastics combine high freedom of design with economical mass production. Metallic coatings on thermoplastics enable power and signal transmission, shield sensitive parts inside of housings and can reduce the temperature in critical areas by functioning as a heat sink. The most used technical thermoplastics are polyamides (PA), while the described use cases are often realized using Cu. Consequently, several studies tried to apply copper coatings on PA substrates via thermal spraying; so far, this combination is only feasible using an interlayer. In this study, a new approach to metallize thermoplastics via thermal spraying based on validated state-of-the-art predictions of the thermoplastics’ material response at relevant temperatures and strain rates is presented. Using these predictions, high velocity wire-arc spraying was selected as coating process. Furthermore, the process parameters were adapted to realize a continuous coating while also roughening the substrate during coating deposition. The resulting Cu coating on PA6 had a sufficiently high coating adhesion for post-treatment by grinding. The adhesion is achieved by in situ roughening during the coating application. The results indicate that different process parameters for initial layer deposition and further coating buildup are required due to the low thermal stability of PA6.

Influence of Process Parameters and Geometry of the Spraying Nozzle on the Properties of Titanium Deposits Obtained in Wire Arc Spraying

2015 ◽  
Vol 1111 ◽  
pp. 211-216
Author(s):  
Bogdan Florin Toma ◽  
Iulian Ionita ◽  
Diana Antonia Gheorghiu ◽  
Lucian Eva ◽  
Costică Bejinariu ◽  
...  
Keyword(s):  
Fluid Dynamics ◽  
Process Parameters ◽  
High Speed ◽  
Electrical Current ◽  
Electric Arc ◽  
Arc Spraying ◽  
Oxide Content ◽  
Spray Parameters ◽  
Influence Of Process Parameters ◽  
Wire Arc Spraying

Influence of the process parameters and geometry of the spraying nozzle on the properties of titanium deposits obtained in wire arc spraying. Wire arc spraying is a process in which through minor modifications of the spray parameters, they can have a major impact on the coatings properties. In this paper there is presented a study on the influence of process parameters and fluid dynamics of the atomization gas on the properties of titanium deposits (14T - 99.9% Ti). For this there were used three different frontal spraying nozzles, having different geometries, and were varied the spraying gas pressure and the electrical current on three levels. There were evaluated the particles velocity, coating density, chemical composition and characteristic interface between deposition and substrate. Obviously, the high speed of the atomization gas determinate the improving of all properties, but in the same time increased the oxide content in the layer. However, the oxidation can be drastically reduced if the melting and atomization of the wire droplets is produced at the point of formation of the electric arc, and the spraying jet is designed to constrain the electric arc. The assessment of deposits adherence allowed the observation of process parameters that contribute to its improvement.

Processing Effects on Residual Stress in Ni+5%AI Coatings–Comparison of Different Spraying Methods

2000 ◽  
Author(s):  
J. Matejicek ◽  
S. Sampath ◽  
T. Gnaeupel-Herold ◽  
H.J. Prask
Keyword(s):  
Residual Stress ◽  
Thermal Spraying ◽  
Stress Generation ◽  
Arc Spraying ◽  
Twin Wire Arc Spraying ◽  
Wire Arc Spraying ◽  
Generation Mechanisms ◽  
Sprayed Coating ◽  
Plasma Sprayed ◽  
Steel Substrates

Abstract Properties of thermally sprayed coatings, including residual stress, are controlled by various parameters of the spraying process. This study is focused on three thermal spraying techniques with significantly different particle temperatures and velocities. These are plasma spraying, twin wire arc spraying and high velocity oxy-fuel spraying. For each method, in-flight particle diagnostics was performed. Through-thickness residual stress profiles in Ni+5%A1 coatings on steel substrates were determined nondestructively by neutron diffraction. The stresses range from high tensile in the plasma sprayed coating to compressive in the HVOF one. Various stress generation mechanisms, including splat quenching, peening, and thermal mismatch, are discussed with respect to process parameters and material properties.

Steel coating application for engine block bores by Plasma Transferred Wire Arc spraying process

2015 ◽  
Vol 268 ◽  
pp. 115-122 ◽  
Author(s):  
Geoffrey Darut ◽  
Hanlin Liao ◽  
Christian. Coddet ◽  
Jean Michel Bordes ◽  
Moussa Diaby
Keyword(s):  
Engine Block ◽  
Arc Spraying ◽  
Coating Application ◽  
Steel Coating ◽  
Wire Arc Spraying ◽  
Spraying Process

Image-Based Modeling for Assessing Thermal Conductivity of Thermal Spray Coatings at Ambient and High Temperature

2006 ◽  
Author(s):  
Y. Tan ◽  
A. Sharma ◽  
J. P. Longtin ◽  
S. Sampath ◽  
H. Wang
Keyword(s):  
Thermal Conductivity ◽  
High Temperature ◽  
Thermal Spray ◽  
Process Parameters ◽  
Thermal Spraying ◽  
Thermal Spray Coatings ◽  
Analysis Model ◽  
Element Analysis ◽  
Spray Coatings ◽  
Coating Microstructure

Thermal spray coatings are used extensively for protection of engineering components and structures in a variety of applications. Due to the nature of thermal spraying process, the coating thermal, mechanical, and electrical properties depend strongly on the coating microstructure, which consists of many individual splats, interfaces between the splats, defects and voids. The coating microstructure, in turn, is determined by the thermal spray process parameters. In order to relate coating process parameters to the final coating performance, then, it is desirable to relate coating microstructure to coating properties. In this work, thermal conductivity is used as the physical parameter of interest. Thermal conductivity of thermal spray coatings is studied by using an image analysis-based approach of typical coating cross sections. Three coating systems, yttria stabilized zirconia (YSZ), molybdenum, and Ni-5wt.%Al are explored in this work. For each material, thermal conductivity is simulated by using a microstructure image-based finite element analysis model. The model is then applied to high temperature conditions (up to 1200 °C) with a hot stage-equipped scanning electron microscope imaging technique to assess thermal conductivity at high temperatures. The coating thermal conductivity of metallic coatings is also experimentally measured by using a high-temperature laser flash technique.

Fundamentals of Thermal Spraying, Flame and Arc Spraying

2006 ◽  
pp. 119-136 ◽  
Author(s):  
Z. Babiak ◽  
T. Wenz ◽  
L. Engl
Keyword(s):  
Thermal Spraying ◽  
Arc Spraying

Novel Concept for Totally Integrated Automation (TIA) Using Siemens Bus System and WinCC Online Control

2000 ◽  
Author(s):  
T. Frederking ◽  
R. Gadow
Keyword(s):  
Process Parameters ◽  
High Speed ◽  
Data Exchange ◽  
Thermal Spraying ◽  
Software Tool ◽  
Functionally Graded ◽  
Flame Spray ◽  
Total Quality ◽  
Spray Process ◽  
Bus System

Abstract Total quality management requires definite process control as well as online diagnostics, if applied in industrial surface refinement by thermal spraying. A concept for integrated online diagnostics for the high velocity oxygen fuel (HVOF) flame spray process is presented using Siemens S7-300 programmable logic controller and PC-based Siemens WinCC (Windows Control Center) visualization software. The standard functionality of the WinCC programming environment can be extended by C-scripts. The integrated database allows to protocol the relevant process parameters periodically for total quality assurance. Also particle flux imaging software tools can be implemented to adjust online process parameters and for process diagnostic purposes. The Siemens bus system hierarchy thereby provides high speed communication skills for field bus level data exchange and for supervising system components, e.g. CCD-cameras. The interconnection between S7-300 PLC, 6-axis-robot and a novel WinCC software tool enables definite automatic changes of recipes during the coating process to generate functionally graded coatings.

A Study on the Arc Spraying of 7Cr13 Cored Wire and Tribological Properties of the Composite Coating

1998 ◽  
Author(s):  
B. Xu ◽  
S. Ma ◽  
J. Wang ◽  
J. Tan
Keyword(s):  
Bond Strength ◽  
Composite Coating ◽  
Tribological Properties ◽  
High Hardness ◽  
Wear Resistant Coating ◽  
Arc Spraying ◽  
Metallurgical Process ◽  
Cored Wire ◽  
Wear Resistant ◽  
Wire Arc Spraying

Abstract For the purpose of getting high hardness and high wear-resistant coating by arc spraying technology, the arc spraying of 7Cr13 cored wire is adopted in this paper. The metallurgical process of the cored wire arc spraying is discussed. The bond strength, hardness and tribological properties of the composite coating are investigated.

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