Interfacial Adhesion between Thermal Spray Coating and Substrate Achieved by Ultrasonic Finishing

2014 ◽  
Vol 682 ◽  
pp. 459-463 ◽  
Author(s):  
Zhanna G. Kovalevskaya ◽  
Vasilii A. Klimenov ◽  
Konstantin V. Zaitsev
Keyword(s):  
Interfacial Adhesion ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Substrate Material ◽  
Metallographic Analysis ◽  
Alternating Projections ◽  
Optical Profilometry ◽  
Surface Optical ◽  
Spraying Process

The paper presents a pretreatment of the substrate material prior to the thermal spraying process. The ultrasonic finishing method allowed creation of a rolling topography comprising alternating projections and cavities, compressive stress, and increase of the number of defects on the surface. Optical profilometry and metallographic analysis allowed detecting of adhesion zones which form a strong physicochemical bond at the interface between the coating and the substrate material. This interfacial adhesion should provide a firm adhesion strength in end products.

Crack Resistance of Weld Seals, Hardening Methods and Composite Tools Quality

2014 ◽  
Vol 682 ◽  
pp. 431-437 ◽  
Author(s):  
V.A. Petrova ◽  
A.A. Bakanov ◽  
A.V. Walter
Keyword(s):  
Crack Resistance ◽  
Interfacial Adhesion ◽  
Thermal Spraying ◽  
Substrate Material ◽  
Metallographic Analysis ◽  
Alternating Projections ◽  
Optical Profilometry ◽  
Surface Optical ◽  
End Products ◽  
Spraying Process

The paper presents a pretreatment of the substrate material prior to the thermal spraying process. The ultrasonic finishing method allowed creation of a rolling topography comprising alternating projections and cavities, compressive stress, and increase of the number of defects on the surface. Optical profilometry and metallographic analysis allowed detecting of adhesion zones which form a strong physicochemical bond at the interface between the coating and the substrate material. This interfacial adhesion should provide a firm adhesion strength in end products.

Influence of Surface Condition on the Bonding Strength of Thermal Sprayed Coatings

1997 ◽  
Author(s):  
V.Yu. Ulianitsky ◽  
J.A. Nikolaev ◽  
T.P. Gavrilenko ◽  
M.C. Kim ◽  
J.W. Hong
Keyword(s):  
Bonding Strength ◽  
Substrate Surface ◽  
Surface Condition ◽  
Surface Preparation ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Substrate Material ◽  
Detonation Spraying ◽  
Wide Scale ◽  
Detonation Gun

Abstract The role of surface roughness in coating adhesion mechanism is studying for detonation spraying. Roughness was produced by conventional grit blasting, D-gun blasting and was formed as a result of spraying of high-adhesive thin layer of detonation coating. Cermet and alloy powders were sprayed by detonation gun Ob. The coating bonding strength measurements show the WC+25Co adhesion to be above 200 MPa independently of a substrate surface preparation. Contrary, NiCrSiB coatings are very sensitive to surface conditions their adhesion varies from 180 MPa to zero. As-sprayed alloy particles fail in adherence because of insufficient energy to fuse substrate material at a flat surface. Only developed (wide scale) roughness may be fused partially by these particles for their bonding to the substrate. Otherwise, high heated cermet particles do not need special surface preparation (except cleaning) for fusion of substrate material to provide high bonding with it. The wide scale and ball shape roughness, which is similar to the self-reproduced coating roughness, provides the best conditions for the coating bonding and it is recommended as the purpose of surface treatment before thermal spray coating.

Thermal Spray for Corrosion Control: A Competitive Edge for Commercial Shipbuilding

1995 ◽  
Vol 11 (01) ◽  
pp. 53-55
Author(s):  
Frank S. Rogers
Keyword(s):  
Thermal Spray ◽  
Marine Environment ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Cost Effective ◽  
Thermal Spray Coating ◽  
Coating System ◽  
Protection Mechanism ◽  
Arc Spray ◽  
Spray System

Thermal spraying of steel with aluminum to protect it from corrosion is a technology that has been proven to work in the marine environment. The thermal spray coating system includes a paint sealer that is applied over the thermally sprayed aluminum; this extends the service life of the coating, and provides color to the end product. The thermal spray system protects steel both through the principle of isolation (as in painting) and galvanization (as in galvanizing). With this dual protection mechanism, steel is protected from corrosion even when the coating is damaged. The thermal sprayed aluminum coating system has proven to be the most cost-effective corrosion protection system for the marine environment. Until recently, however, the initial cost of application has limited its use for general application. Today a new arc spray technology has reduced the application cost of thermal spraying aluminum to below that of painting. Commercial shipbuilders could use this technology to enhance their market position in the marine industry.

International and National Thermal Spray Standards Program with Comment on Those for the Corrosion Protection of Steel and Reinforced Concrete

1996 ◽  
Author(s):  
R.A. Sulit
Keyword(s):  
Reinforced Concrete ◽  
Corrosion Protection ◽  
Thermal Spray ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Test Methods ◽  
Current Status ◽  
Work Program ◽  
Society Committee

Abstract A review of selected national and international thermal spraying guides and specifications for the preservation of steel and reinforced concrete using thermal spray coating of aluminum, zinc and their alloys is presented. The work program and current status of the US national organizations contributing to and developing test methods and process standards are summarized along with those of ISOATC 107/SC 5. The Secretariat of the ISO/TC 107/SC 5, Thermal Spraying was transferred from AFNOR, France, to ANSI, US, in June 1995. ANSI, in turn, designated AWS to be its delegate in thermal spray matters. The work program of the newly formed SSPC/NACE/AWS Tri-Society Committee on thermal spray coatings for the corrosion protection of steel is summarized.

The Comparison Study on Abrasive and Erosive Resistance Properties of Thermal Spray Coatings

2020 ◽  
Vol 901 ◽  
pp. 49-54
Author(s):  
Jirasak Tharajak ◽  
Noppakun Sanpo
Keyword(s):  
Thermal Spray ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Solid Material ◽  
Thermal Spray Coating ◽  
Comparison Study ◽  
Spray Coatings ◽  
Wide Range ◽  
Resistance To Wear ◽  
Sprayed Coating

Thermal spraying is a technology which improves and restores the surface of a solid material. The process can be used to apply coatings to a wide range of materials and components, in order to provide resistance to wear, erosion, cavitation, corrosion, abrasion or heat. In this paper, the study of abrasive and erosive properties of Cr3C2/20%NiCr and FeCrB + Al thermal sprayed coating samples were focused. It was revealed that both received thermal spray coating samples show outstanding abrasive and erosive resistance properties.

Computer predictions of thermo-mechanical behavior and residual stresses in spray coating process

2004 ◽  
Vol 120 ◽  
pp. 381-388
Author(s):  
D.-Y. Ju ◽  
V. Ji ◽  
H. Gassot
Keyword(s):  
Heat Conduction ◽  
Residual Stresses ◽  
Mechanical Behavior ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Coating Process ◽  
X Ray Diffraction ◽  
Stress Strain ◽  
Coupled Equations

This paper presents a numerical method in order to forecast the thermo-mechanical behavior and the residual stresses in the thermal spray coating process by using high velocity oxygen fuel (HVOF). A set of coupled equations of the heat conduction and stress/strain and solidification based on the metallo-thermo-mechanical theory is introduced into the simulation of thermal spraying. Here, an inelastic constitutive equation with capacity to represent relation of stress/strain during rapid solidification is employed. The numerical modelling based on the finite element method is proposed to solve the heat conduction associated with solidification in the sprayed layer and residual stresses on the interface between multi-layer materials, especially. In this paper, the simulated results of the temperature field, solidified domain and residual stresses in the sprayed layer including interfacial combinations between substrate and spray layer are presented, and the validity of the calculated results is discussed in comparison with the measured results obtained by X-ray diffraction.

Study on the Machining of Iron-Based Thermal Spray Coating for Sleeveless Engine Cylinder

2012 ◽  
Vol 472-475 ◽  
pp. 991-996 ◽  
Author(s):  
Kan Ding ◽  
Hiroyuki Sasahara
Keyword(s):  
Tool Wear ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Cylinder Liner ◽  
Thermal Spray Coating ◽  
Machining Performance ◽  
Dominant Effect ◽  
Root Cause ◽  
Engine Cylinder ◽  
Iron Based

In the cylinder of a sleeveless engine, molten iron-based alloy is directly sprayed onto the aluminum engine block instead of the previously used cast iron cylinder liner. However, a thermal spraying cylinder liner exhibits poor machining performance during the finish boring process because of severe tool wear. This research investigates the finish boring performance of a thermal spraying cylinder liner to clarify the root cause of tool wear. The results show that mechanical wear is a dominant effect.

Thermal Spray Alternatives for Electroplated Chromium

1996 ◽  
Author(s):  
G. Irons ◽  
W. Kratochvil ◽  
M. Schroeder ◽  
C. Brock
Keyword(s):  
Thermal Spray ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Ceramic Materials ◽  
Thermal Spray Coating ◽  
Waste Products ◽  
Spray Process ◽  
Arc Spray ◽  
Chromium Plating ◽  
Thermal Spray Processes

Abstract Many thermal spray coatings provide excellent wear and corrosion resistance, while providing die same surface finish offered by chromium plating. In the past, the choice between thermal spraying or plating was usually based on part size, area to be coated, cost and familiarity with one or the other method. Today, the thermal spray processes are showing greater popularity due to: ♦ New thermal spray processes and coatings with better properties ♦ Increased chromium plating costs due to stricter regulations on the process and the disposal of its waste products ♦ The closing of chromium plating facilities Thermal spraying offers an opportunity to select a coating from a wide variety of processes and materials that will meet the specific requirements of each application. While this may cause some difficulty in selecting the optimum coating, the selected thermal spray coating often has superior propolies and/or lower cost compared to chromium plating. The highest quality coatings are sprayed by the HVOF process, many with carbide containing materials. Dense plasma grayed ceramic materials offer good wear resistance plus elevated temperature capability. The most economical replacements for chromium plate are applied by the two-wire arc spray process. This paper examines the properties and costs of eight different dismal sprayed coatings and compares them with electroplated chromium.

Modelling Sequential Impact of Molten Droplets on a Solid Surface in Plasma Spray Process

2011 ◽  
Vol 227 ◽  
pp. 111-115
Author(s):  
Ilhem R. Kriba ◽  
A. Djebaili
Keyword(s):  
Plasma Spray ◽  
High Performance ◽  
Spray Deposition ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Atmospheric Plasma ◽  
Formation Mechanisms ◽  
Temperature Plasma ◽  
Spray Process ◽  
Spraying Process

Plasma spray deposition is one of the most important technologies available for producing the high-performance surfaces required by modern industry. In this process, powder of the coating material is fed into high-temperature plasma, which melts and accelerates the powder; the molten particles subsequently hit and solidify on the surface to be coated. To obtain good quality coating, the powder particle must be at least partially molten and hit the substrate with a high velocity. The flattening characteristics of the droplets impinging on a substrate are important determinants in governing the eventual quality of the plasma spray coating. Different codes have been developed in recent years to simulate the overall thermal spraying process, as well as the growth of the 3D coatings, in which entrained particles are modeled by stochastic particle models, fully coupled to the plasma flow. The present investigation was carried out to have an approach to systematize the atmospheric plasma spraying process in order to create a basis for numerically modeling the plasma dynamics, the coating formation mechanisms and to predict the particle thermo- kinetic state at impact.

Thermal Spraying of Aluminium Cylinder Bores by the Ford PTWA Spray Process

2006 ◽  
Author(s):  
C. Verpoort ◽  
W. Blume ◽  
R. Ehrenpreis ◽  
M. Silk ◽  
W. Polich ◽  
...  
Keyword(s):  
Thermal Spray ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Thermal Spray Process ◽  
Spray Process ◽  
Nano Material ◽  
Future Demands ◽  
Engine Blocks ◽  
Cylinder Bore

One of the main drivers in the automotive industry is the reduction in fuel consumptions and emissions. In order to achieve these goals, the weight of the engine block as well as the friction in the cylinder bore has to be optimized. This paper describes the FORD PTWA (Plasma Transferred Wire Arc) thermal spray process that protects the aluminum cylinder bore surface against wear by a thermal spray coating. The PTWA technology was originally developed for the application in gasoline V8 engines and it will be shown in this paper how this process can be modified to apply nano-material to produce high-wear resistant, low-friction coatings for highly loaded engine blocks for future demands. A large German BMBF “Nanomobile” Research Program was started in 2005 with 13 partners (DaimlerChrysler, Opel, Porsche, Ford, Gehring, Federal Mogul, GTV Thermal Spray Systems, DURUM, RWTH University and other institutes) in order to develop next generation nano-material coatings for cylinder bores.

Sign in / Sign up

Export Citation Format

Share Document