Solid Lubricant Containing Coatings for Cylinder Liners in Pressure Casted Aluminum Crankcases

2000 ◽  
Author(s):  
M. Buchmann ◽  
R. Gadow ◽  
A. Killinger
Keyword(s):  
Residual Stress ◽  
Solid Lubricant ◽  
Atmospheric Plasma Spraying ◽  
Thermal Spray Coatings ◽  
Atmospheric Plasma ◽  
Coating Materials ◽  
Spray Coatings ◽  
Wide Range ◽  
Cylinder Liners ◽  
Potential Use

Abstract This paper evaluates a wide range of thermal spray coatings for potential use lining cylinder bores in aluminum engines. Coatings were applied by atmospheric plasma spraying (APS) and high-velocity oxyfuel (HVOF) techniques. More than a dozen coating materials were screened, including ceramics, cermets, and metals. The paper describes the equipment and procedures used in the investigation and assesses the resulting coatings based on their microstructure, hardness, friction coefficient, wear resistance, bonding strength, and residual stress.

Atmospheric Plasma Spraying of Run-in Coatings for Twin-Screw Compressors

2000 ◽  
Author(s):  
Fr.-W. Bach ◽  
T. Duda ◽  
W. Unterberg ◽  
L.A. Josefiak
Keyword(s):  
Corrosion Resistance ◽  
Plasma Spraying ◽  
Atmospheric Plasma Spraying ◽  
Yttria Stabilized Zirconia ◽  
Thermal Spray Coatings ◽  
Atmospheric Plasma ◽  
Stabilized Zirconia ◽  
Spray Coatings ◽  
Twin Screw ◽  
Screw Rotors

Abstract This paper examines the potential of thermal spray coatings for manufacturing and repairing twin-screw rotors. The coatings evaluated were produced by atmospheric plasma spraying (APS). Tests show that 7% yttria stabilized zirconia (ZrO27Y2O3) coatings provide sufficient run-in characteristics and corrosion resistance. The coatings, along with a NiCrAl bond coat, were applied to various substrate materials.

Abrasion-Corrosion of Thermal Spray Coatings

2015 ◽  
pp. 88-120 ◽  
Author(s):  
Robert J. K. Wood ◽  
Mandar R. Thakare
Keyword(s):  
Thermal Spray ◽  
Applied Load ◽  
Thermal Spray Coatings ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Wear Rates ◽  
Spray Coatings ◽  
Drilling Tools ◽  
Wide Range ◽  
Aqueous Environments

WC-based thermal-spray and High Velocity Oxy-Fuel (HVOF) coatings are extensively used in a wide range of applications ranging from downhole drilling tools to gas turbine engines. WC-based thermal spray coatings offer improved wear resistance as a result of hard phases dispersed in binder-rich regions. However, the presence of hard and soft phases within the coating can also lead to the formation of micro-galvanic couplings in aqueous environments leading to some reduction in combined wear-corrosion resistance. Furthermore, the coating also responds differently to change in mechanical loading conditions. This chapter examines the wear-corrosion performance of thermal spray coatings in a range of wear, electrochemical, and wear-corrosion tests under varying contact conditions to develop models and establish relationships between wear mechanisms, wear rates, and environmental factors such as pH and applied load.

Residual Stress Evolution in Zirconia (Y8%) Coatings During Atmospheric Plasma Spraying for Substrates Under Rotating Kinematic

2020 ◽  
Vol 29 (6) ◽  
pp. 1313-1321
Author(s):  
V. Lasseur ◽  
S. Goutier ◽  
V. Martinez Garcia ◽  
A. Denoirjean ◽  
E. Meillot ◽  
...  
Keyword(s):  
Residual Stress ◽  
Plasma Spraying ◽  
Atmospheric Plasma Spraying ◽  
Atmospheric Plasma ◽  
Stress Evolution

Modeling Residual Stress Development in Thermal Spray Coatings: Current Status and Way Forward

2017 ◽  
Vol 26 (6) ◽  
pp. 1115-1145 ◽  
Author(s):  
Abba A. Abubakar ◽  
Abul Fazal M. Arif ◽  
Khaled S. Al-Athel ◽  
S. Sohail Akhtar ◽  
Javad Mostaghimi
Keyword(s):  
Residual Stress ◽  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Current Status ◽  
Stress Development ◽  
Spray Coatings

scholarly journals Residual Stress Distributions in Cold-Sprayed Copper 3D-Printed Parts

2020 ◽  
Vol 29 (6) ◽  
pp. 1525-1537 ◽  
Author(s):  
Rebecca Sinclair-Adamson ◽  
Vladimir Luzin ◽  
Andrew Duguid ◽  
Krishnan Kannoorpatti ◽  
Rebecca Murray
Keyword(s):  
Residual Stress ◽  
Residual Stresses ◽  
Cold Spray ◽  
Pure Copper ◽  
Liquid Phase Sintering ◽  
Manufacturing Method ◽  
Spray Coatings ◽  
Neutron Diffractometer ◽  
Heat Treated ◽  
Wide Range

AbstractCold-spray additive manufacturing (CSAM) builds strong, dense metal parts from powder feedstock without melting and offers potential advantages over alternatives such as casting, liquid phase sintering, laser or e-beam melting or welding. Considerable effort is required to relieve residual stresses that arise from melt/freeze cycling in these methods. While CSAM does not involve melting, it imposes high strain rates on the feedstock and stress anisotropies due to complex build paths. This project explores residual stress in two CSAM objects. The CSAM components were produced from 99% pure copper powder (D50 = 17 µm): (1) a cylinder (∅ = 15 mm, height = 100 mm, weight = 145 g) and (2) a funnel (upper outer ∅ = 60 mm, lower outer ∅ = 40 mm, wall thickness = 8 mm, weight = 547 g). The non-heat-treated components were strain-scanned using a residual stress neutron diffractometer. Maximum residual stresses in any direction were: tensile: 103 ± 16 MPa (cylinder) and 100 ± 23 MPa (funnel); compression: 58 ± 16 MPa (cylinder) and 123 ± 23 MPa (funnel). Compared to the literature, the tensile residual stresses measured in the CSAM components were lower than those measured in cast materials, laser or welding AM methods, and numerical modelling of cold-spray coatings, while within the wide range reported for measurements in cold-spray coatings. These comparatively low residual stresses suggest CSAM is a promising manufacturing method where high residual stresses are undesirable.

Fatigue Life in Bending and Coatings Residual Stress in Tungsten Carbide Thermal Spray Coatings

1997 ◽  
Author(s):  
R.T.R. McGrann ◽  
J.R. Shadley ◽  
E.F. Rybicki ◽  
D.J. Graving ◽  
B.E. Badger ◽  
...  
Keyword(s):  
Residual Stress ◽  
Fatigue Life ◽  
Tungsten Carbide ◽  
Thermal Spray ◽  
Thermal Spray Coatings ◽  
Chrome Plating ◽  
Spray Coatings ◽  
Wear Protection ◽  
Carbide Coatings ◽  
Flat Beam

Abstract Tungsten caibide (WC) thermal spray coatings are being used for wear protection on selected components of aircraft. Tungsten carbide coatings are being used on aircraft flap tracks and fan and compressor blade mid-span dampers. However, a larger use of tungsten carbide coatings is being considered for other commercial aircraft applications where it would be used as a replacement for chrome plating. For instance, WC coatings are currently being tested on aircraft landing gear parts. One factor that affects the suitability of WC coatings for these applications is the fatigue life of the coated part. Coatings, whether chrome plating or thermal spray coating, can reduce the fatigue life of the part compared to an uncoated part. This study compares the fatigue life of uncoated 6061 aluminum specimens to the fatigue life of WC thermal sprayed coated 6061 aluminum specimens. The relation between the residual stress level in the coating and the fatigue life of the specimens is also investigated. Fatigue tests were run on cantilever flat beam specimens that were coated on one side. Specimens were cycled in bending so that the coatings experienced tensile fatigue stresses. Residual stress levels for each type of coating were determined using the Modified Layer Removal Method on specimens processed along with the cantilever flat beam specimens. Test results show that the fatigue life of the WC coated specimens is directly related to the level of compressive residual stress in the coating.

Abrasion-Corrosion of Thermal Spray Coatings

2017 ◽  
pp. 1265-1292
Author(s):  
Robert J. K. Wood ◽  
Mandar R. Thakare
Keyword(s):  
Thermal Spray ◽  
Applied Load ◽  
Thermal Spray Coatings ◽  
Turbine Engines ◽  
Gas Turbine Engines ◽  
Wear Rates ◽  
Spray Coatings ◽  
Drilling Tools ◽  
Wide Range ◽  
Aqueous Environments

WC-based thermal-spray and High Velocity Oxy-Fuel (HVOF) coatings are extensively used in a wide range of applications ranging from downhole drilling tools to gas turbine engines. WC-based thermal spray coatings offer improved wear resistance as a result of hard phases dispersed in binder-rich regions. However, the presence of hard and soft phases within the coating can also lead to the formation of micro-galvanic couplings in aqueous environments leading to some reduction in combined wear-corrosion resistance. Furthermore, the coating also responds differently to change in mechanical loading conditions. This chapter examines the wear-corrosion performance of thermal spray coatings in a range of wear, electrochemical, and wear-corrosion tests under varying contact conditions to develop models and establish relationships between wear mechanisms, wear rates, and environmental factors such as pH and applied load.

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