Properties of Metal-Sprayed Coating Produced by Electric-Arc-Spraying Process

Electric arc spraying (or metal arc spraying) is a process that deposits metal particles on suitable substrates using two consumable wire electrodes. The high-temperature arc formed between these electrodes in an atomizing jet of air produces small molten particles which are used to coat the substrate. The contribution of the process parameters and their interactions on the coating thickness is analysed using Taguchi's design of experiments. The time and frequency domain sound signals generated during the process are utilized to characterize the spraying phenomenon. Stochastic modelling of acoustic signals forms the basis for a closed-loop control mechanism of the arc-spraying process proposed for the first time. Experimental proof of the Gaussian nature of the deposition profile is provided and a mathematical approach has been suggested to obtain a uniform deposit thickness in a single pass.

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THE RESEARCH OF PSEUDO COATINGS SPRAYED WITH ELECTRIC ARC SPRAY / PSEUDODANGŲ, UŽPURKŠTŲ ELEKTROLANKINIU BŪDU, TYRIMAS

Mokslas - Lietuvos ateitis ◽

10.3846/mla.2016.982 ◽

2017 ◽

Vol 8 (6) ◽

pp. 602-608

Author(s):

Tomas Rodžianskas ◽

Ovidijus Jarašiūnas ◽

Irmantas Gedzevičius ◽

Gediminas Mikalauskas ◽

Justinas Gargasas ◽

...

Keyword(s):

Power Source ◽

Electric Arc ◽

Arc Spraying ◽

Main Task ◽

Arc Spray ◽

Tribological Coatings ◽

Steel Aisi ◽

Aisi 316 ◽

Spraying Process ◽

Stainless Steel Aisi

The paper presents coatings obtained using two different stainless steel (AISI 316) and marine bronze (CuAl8) wires sprayed with electric arc spraying. Substrate: mild steel S235J2 (LST EN 10025: 2004). Arc spray equipment – “EuTronic Arc Spray 4” with an additional power source. The main task was to select optimal technological spraying process and obtain coatings which possess the best mechanical, physical, tribological properties that meet the requirements of the specific requirements in service coatings. The microhardness, elastic modulus, and morphology was examined. Dry friction wear was assessed in the mass loss of the coatings. The results of tribological coatings properties were assessed in determining the mass lost. Straipsnyje nagrinėjamos elektrolankinio purškimo būdu suformuotos dangos, gautos užpurškus dvi skirtingas pilnavidurės nerūdijančiojo plieno (AISI 316) ir jūrinės bronzos (CuAl8) vielas. Substratas – mažaanglis plienas S235J2 (LST EN 10025:2004). Elektrolankinio purškimo įranga – „EuTronic Arc Spray 4“ su papildomu srovės šaltiniu. Eksperimentų metu siekiama parinkti optimalų technologinį purškimo procesą ir gauti dangas, pasižyminčias geriausiomis mechaninėmis, fizikinėmis, tribologinėmis savybėmis, kurios atitinka konkrečius keliamus reikalavimus eksploatuojamoms dangoms. Nustatytas dangų mikrokietumas, tamprumo modulis ir nagrinėta dangų morfologija. Dangų tribologiniai rezultatai vertinti nustatant prarastąją bandinių masę.

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High Speed Dry Sliding Tribological Behaviors of Amorphous Fe-Based Alloy Coatings

Applied Mechanics and Materials ◽

10.4028/www.scientific.net/amm.184-185.1006 ◽

2012 ◽

Vol 184-185 ◽

pp. 1006-1009

Author(s):

San Ming Du ◽

Yue Chen ◽

Yong Zhen Zhang

Keyword(s):

High Speed ◽

Steel Substrate ◽

Electric Arc ◽

Arc Spraying ◽

Dry Sliding ◽

Friction Process ◽

Wear Rates ◽

Pin On Disc ◽

Sprayed Coating ◽

Amorphous Coatings

In the present study, amorphous coatings on plain steel substrate were prepared by electric arc spraying technique. The high-speed dry sliding tribological properties of the coating were investigated on a pin-on-disc tribo-meter. The results show that amorphous phase generates in the sprayed coating. When the sliding speeds are less than 40m/s, the friction coefficient increases. The friction coefficients decrease with the sliding speed exceeding 60m/s. The wear rates increase with increasing the sliding. Phase transition occurs in the friction process.

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Characterization of spherical stainless steel powders prepared by electric arc spraying process

IOP Conference Series Materials Science and Engineering ◽

10.1088/1757-899x/848/1/012033 ◽

2020 ◽

Vol 848 ◽

pp. 012033

Author(s):

A A Kirsankin ◽

T A Kalaida ◽

M A Kaplan ◽

M A Smirnov ◽

A Yu Ivannikov ◽

...

Keyword(s):

Stainless Steel ◽

Electric Arc ◽

Arc Spraying ◽

Spraying Process

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Phase Structure Evolution of the Fe-Al Arc-Sprayed Coating Stimulated by Annealing

Materials ◽

10.3390/ma14123210 ◽

2021 ◽

Vol 14 (12) ◽

pp. 3210

Author(s):

Tomasz Chmielewski ◽

Marcin Chmielewski ◽

Anna Piątkowska ◽

Agnieszka Grabias ◽

Beata Skowrońska ◽

...

Keyword(s):

Phase Structure ◽

Protective Coatings ◽

Structural Evolution ◽

Intermetallic Phases ◽

Structure Evolution ◽

Arc Spraying ◽

Sem Images ◽

Sprayed Coating ◽

Spraying Process

The article presents the results of research on the structural evolution of the composite Fe-Al-based coating deposited by arc spray with initial low participation of in situ intermetallic phases. The arc spraying process was carried out by simultaneously melting two different electrode wires, aluminum and low alloy steel (98.6 wt.% of Fe). The aim of the research was to reach protective coatings with a composite structure consisting of a significant participation of FexAly as intermetallic phases reinforcement. Initially, synthesis of intermetallic phases took place in situ during the spraying process. In the next step, participation of FexAly fraction was increased through the annealing process, with three temperature values, 700 °C, 800 °C, and 900 °C. Phase structure evolution of the Fe-Al arc-sprayed coating, stimulated by annealing, has been described by means of SEM images taken with a QBSD backscattered electron detector and by XRD and conversion electron Mössbauer spectroscopy (CEMS) investigations. Microhardness distribution of the investigated annealed coatings has been presented.

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Modeling Arc Spraying Process for Eccentric Sleeve of Cone Crusher GP 500 Using Computer-Aided Design

Materials Science Forum ◽

10.4028/www.scientific.net/msf.970.343 ◽

2019 ◽

Vol 970 ◽

pp. 343-355

Author(s):

Saulekul Aizhambaeva ◽

Gulnara Zhetessova ◽

Tatyana Nikonova ◽

Galina Vavilova ◽

Michael Belik

Keyword(s):

Computer Aided Design ◽

Electric Arc ◽

Point Of View ◽

Arc Spraying ◽

Main Criterion ◽

Cone Crusher ◽

Aided Design ◽

Spraying Process ◽

Selection Of ◽

Strength Of Adhesion

This article deals with studying the technology of electric arc spraying of the eccentric body by selection of the copper-steel pseudo-alloy for spraying a covering. The part durability with the placed covering depends on the technology of spraying and the properties of the sprayed material. By increasing the strength of adhesion of the covering to the base it is possible to establish the optimal indicators of the coating mode. It became the main criterion of studying the arc spraying technology from the mathematical point of view.

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Study influence factors of the spraying process on the properties of electric arc spraying coatings

PROBLEMS OF TRIBOLOGY ◽

10.31891/2079-1372-2021-99-1-74-83 ◽

2021 ◽

Vol 99 (1) ◽

pp. 74-83

Author(s):

M. Ageev ◽

◽

E. Solovuch ◽

V. Lopata ◽

O. Burlachenko ◽

...

Keyword(s):

Corrosion Resistance ◽

Service Life ◽

Flow Rate ◽

Electric Arc ◽

Alternative Methods ◽

Basic Material ◽

Arc Spraying ◽

Wire Material ◽

Spraying Process ◽

Combustion Mixture

The paper considers possibilities to increase the wear resistance, corrosion resistance, and service life for parts machines and mechanisms via their hardening and renovating using electric arc coatings characterized by high density, adhesion strength, and micro hardness thanks to activation of the spraying process. Also, the possibility of controlling the properties of restored surfaces owing to choice of the related equipment with required structure and characteristics in order to prolong the service life of machinery parts is shown. The right choice of equipment for spraying makes it possible to increase the speed and temperature of the spraying gas and particles, reduce the droplet diameter, increase the density and reduce the oxidation of coatings. The influence of spray factors such as the flow rate and pressure of working gases, composition of combustion mixture, spraying distance, dispersion of the spray, properties of wire material, etc. on the properties of the coatings obtained has been investigated. The possibility of controlling the properties of surfaces owing to choice with required characteristics electric arc coatings is shown. The influence of spray factors such as the flow rate and pressure of working gases, composition of combustion mixture, spraying distance, dispersion of the spray, properties of wire material, etc. on the properties of the coatings obtained has been investigated. The use of coatings makes it possible to increase the wear and corrosion resistance of working surfaces of machine parts and mechanisms, in particular ship parts, and so to reduce the costs of alloyed steels and alloys. The coatings application is associated with implementation of a fundamentally new approach, according to which the strength and carrying capacity of a part is provided by its basic material, whereas the resistance to corrosion, wear, and other factors may be increased via using hardening protective coatings. There are many alternative methods for producing coatings, from which it is advisable to choose an optimal, easy to implement, and inexpensive one. Of the variety of methods for hardening coating deposition, the most common technologies used to restore and improve the performance properties of parts are gas-thermal spraying techniques, among which the cheapest and simplest method is electric arc spraying (EAS), whose current improvement is aimed at modifying and activating the spraying process. Such combined technologies do not require additional expensive equipment and operations, which predetermines a reduction in the cost of hardening processes.

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Use of pulsed spray airflow for electric arc spraying of different types of wires

Technology audit and production reserves ◽

10.15587/2706-5448.2021.235405 ◽

2021 ◽

Vol 3 (1(59)) ◽

pp. 23-27

Author(s):

Vyacheslav Royanov ◽

Irina Zakharova

Keyword(s):

Chemical Composition ◽

Adhesion Strength ◽

Chemical Elements ◽

Air Flow ◽

Arc Spraying ◽

Capital Costs ◽

Burn Out ◽

Sprayed Coating ◽

Spraying Process

The object of research is the control of the process of formation of a spraying air flow and the transfer of particles of liquid metal from electrodes during arc spraying. One of the problem areas of the arc spraying process is the oxidation of the sprayed metal particles by the oxygen of the air flow during their transportation to the sprayed surface. This leads to the formation of a sufficiently large amount of oxides of chemical elements, which significantly deteriorate the adhesion strength and burn out alloying elements that are necessary to obtain a wear-resistant and corrosion-resistant coating. The suitability and durability of coatings during use depends on the strength of adhesion to the substrate. In the course of the study, methods were used to determine the adhesion strength of the coating to the base – the Steffens method and methods for studying the microstructure of coatings were taken as the basis. The data was processed and dependencies were plotted. The proposed method makes it possible to improve the quality of the resulting coating in terms of such an indicator as improvements in chemical composition. And also to influence the chemical composition by controlling the process of transfer of molten metal using a pulsating air flow. The obtained results of approbation of the method allow us to consider it effective, as evidenced by the quality of the obtained coatings. This is due to the fact that the correctness of the formulation and solution of the problem provided adequate results. In contrast to the existing methods, the proposed one makes it possible to significantly influence the amount of harmful oxygen involved in the formation of a sprayed coating, which makes it possible to obtain a sprayed layer with the required performance characteristics. And also allows to improve its quality without significant capital costs. In addition, the issues of resource and energy saving are being addressed, since the burnout of chemical elements decreases and the air consumption during arc metallization decreases. To solve this problem, a simple design of the pulsator is proposed, which provides the ability to control the spray flow by adjusting the level of overlapping of the holes.

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

Advanced Materials Research ◽

10.4028/www.scientific.net/amr.1111.211 ◽

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.

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