低压等离子和超音速火焰喷涂NiCoCrAlYTa层的结构和性能

NiCoCrAlYTa高温氧化防护涂层是发动机高温叶片的重要防护层,已得到广泛应用。分别采用空气助燃的超音速火焰喷涂(HVAF)、氧气助燃的超音速火焰喷涂(HVOF)、低压等离子喷涂(LPPS)和低温超音速火焰喷涂(LT-HVOF)制备了NiCoCrAlYTa涂层,并研究了4种工艺制备的涂层的结构与性能。结果表明:4种工艺制备的NiCoCrAlYTa涂层主要由γ’-Ni3Al,β-NiAl和固溶体γ-Ni相组成,含少量单质Cr,而β-NiAl相的含量比喷涂粉末中低;除LT-HVOF涂层外,其他3种涂层中均有未熔或部分熔融颗粒存在;HVOF涂层中存在大量氧化物区;HVAF涂层沉积率较低;LT-HVOF涂层致密度高,没有明显的氧化物区;LPPS涂层中也没有氧化物区,但致密度比其他涂层低;LPPS涂层含氧量低,但致密度和结合强度均低于HVAF和HVOF涂层;LT-HVOF涂层含氧量与LPPS涂层相当,但致密度和结合强度优于LPPS涂层。     

Effect of Gas Conditions on HVOF Flame and Properties of WC-Co Coatings

The flow conditions of both fuel and oxygen gases to produce a supersonic flame with a high velocity oxy-fuel (HVOF) gun are experimentally investigated. The range of both fuel and oxygen flows to produce supersonic flame is limited by the choking condition and influenced by the gas pressures. The velocity of a typical flame was estimated to be over 1500 ms^-1. The flame conditions also influence the structure and property of HVOF sprayed WC-Co coatings. The increase in the pressures of both fuel and oxygen tends to suppress the decarburization of WC during spraying. The flows of the both gases greatly influenced the properties of WC-Co coatings.     

Microstructural characterization of high velocity oxy-fuel sprayed coatings of Inconel 625

High velocity oxy-fuel (HVOF) thermal spraying is being increasingly used to deposit high quality surface coatings. In the present study HVOF spraying was used to deposit coatings of the Ni-based alloy Inconel 625 onto mild steel substrates and the structure of the sprayed coatings were related to the processing conditions employed. The microstructural characteristics of the deposits were investigated using X-ray diffraction together with optical, scanning electron and transmission electron microscopy. The as-sprayed microstructure was found to consist of Ni-based metallic regions together with oxides exhibiting the Cr2O3 and NiCr2O4 crystal structures. Transmission electron microscopy revealed that although the metallic regions were predominantly highly alloyed, Ni-rich grains (depleted in solute) were also present in all coatings. Three processing variables were examined: oxygen to fuel gas ratio, total gas flow rate in the gun and combustion chamber length. All were found to significantly influence the oxide contents of coatings as measured by X-ray diffraction methods. This revised version was published online in November 2006 with corrections to the Cover Date.     

Characterization of Thermal Spray Coatings

The ability to characterize fully the microstructure of a coating is paramount for understanding the in-service properties and eventual optimization of the coating. This article discusses sample preparation and subsequent analytical techniques (LOM, SEM, XRD, WDS, and QIA) for several cermet thermal spray coatings and provides a detailed analysis of as-sprayed microstructures in addition to processing trends for several FeCrAIY-carbide coatings. It was found that the splats produced in these high velocity oxy-fuel (HVOF) coatings tended to exhibit a predominantly dendritic structure most likely retained from the gas atomization process that produced the original powder. Chemical analysis showed that the carbides tend to breakdown during spraying producing a complex mixture of oxides and various carbides. Finally, image analysis revealed that as the carbides in the pre-sprayed powder were increased, more carbides and oxides with less FeCrAIY and thinner coatings were found. These techniques allow the thorough characterization of thermal spray cermet coatings, which in turn should further the understanding of the thermal spray processes and help provide superior coatings in the future.     

超音速火焰(HVOF)喷涂过程中颗粒行为数值模拟的研究进展

介绍了近年来描述HVOF喷涂过程中颗粒行为的数学模型,并结合不同粉末的特点给出了相应的模型修正.简要总结了数值模拟的研究成果,从颗粒的尺寸、形貌、密度及喷涂距离等方面分析了不同工艺参数对喂料颗粒在喷涂过程中状态变化的影响以及与涂层组织和性能之间的关系,从而为深入了解HVOF喷涂工艺的特点提供了一条有效途径,也为热喷涂的模拟研究提供了一些参考和借鉴.     

Influence of the Thermal Barrier Coatings Design on the Oxidation Behavior

The properties of two different types of thermal barrier coatings(TBCs) were compared to improve the surface characteristics on high temperature components.These TBCs consisted of a duplex TBC and a five-layered functionally graded TBC.NiCrAlY bond coats were deposited on a number of Inconel-738LC specimens using high velocity oxy-fuel spraying(HVOF) technique.For duplex coating,a group of these specimens were coated with yttria stabilized zirconia(YSZ) using plasma spray technique.Functionally graded NiCrA...     

Thermal spraying of a nitrogen alloyed austenitic steel

Stainless steel coatings provide an alternative to protect steel surfaces against corrosive attack. The 316 L stainless steel coatings have been conventionally produced by different spraying processes for such applications. Because the nitrogen alloyed stainless steels exhibit not only superior mechanical properties, but also better corrosion behaviour than conventional stainless steels, in this study the coatings of a nitrogen alloyed austenitic steel were produced using a high velocity oxy-fuel (HVOF) spraying process and an atmospheric plasma spraying (APS) process. Due to much stronger deformation strengthening, the coatings deposited by the HVOF spraying process presented a much higher microhardness than the coatings deposited by the APS process. Moreover, the coatings deposited by the HVOF spraying process were also more corrosion resistant than the coatings deposited by the APS process, because the oxidation of the powder material during HVOF spraying was much lower than that during APS. Compared with the coatings of the conventional stainless steel 316 L, the nitrogen alloyed steel coating deposited by the HVOF spraying process showed a much better corrosion performance.     

Computational simulation of thermally sprayed WC–Co powder

WC–Co cemented carbides are a class of hard composite materials of great technological importance. They are widely used as tool materials in a large variety of applications that have high demands on hardness and toughness, including mining, turning, cutting and milling. The HVOF (high velocity oxygen fuel) technology has been very successful in spraying wear resistant WC–Co coatings with higher density, superior bond strengths and less decarburization than many other thermal spray processes, attributed mainly to its high particle impact velocities and relatively low peak particle temperatures. The degree of decomposition and bond strength is directly related to relevant particle parameters such as velocity, temperature and state of melting or solidification. These are consecutively related to process parameters such as powder particle size distribution, carrier gas flow rate, and fuel type employed. To obtain detailed particle data important for thermal spraying, mathematical models are developed in the present paper to predict the particle dynamic behavior in a liquid fuelled HVOF thermal spray gun. The particle transport equations are coupled with the three-dimensional, chemically reacting, turbulent gas flow, and solved in a Lagrangian manner. The melting and solidification within the particles as a result of heat exchange with the surrounding gas flow is solved numerically. The in-flight characteristics of WC–Co particles are studied and the effects of carrier gas parameters on particle behavior are examined. The results demonstrate that WC–Co particles smaller than 5 μm in diameter undergo melting and solidification prior to impact while most particles never reach liquid state during the HVOF thermal spraying. The flow rate of carrier gas has considerable influence on particle dynamics as well as deposition on substrate. At higher flow rate the powder particles are redirected further away from the substrate center, while smaller flow rate results in better heating, higher impact velocity and deposition closer to the substrate center.     

Development of dense corrosion resistant coatings by an improved HVOF spraying process

For 6 years, we have developed corrosion resistant coatings to protect steel structures in the marine environment by using a thermal spray technique. This paper summarizes the major developments and results obtained. Such a coating requires primarily impermeability and secondarily homogenous and clean microstructure. In order to make denser and highly corrosion resistant coatings, we selected spray materials and improved fabrication processes. HastelloyC was a suitable material for High Velocity Oxy-Fuel (HVOF) spraying to form corrosion resistant coatings because of its high resistance against thermal oxidation as well as seawater corrosion, especially crevice and pitting corrosion. An inert gas shroud system was attached with a commercial HVOF apparatus and this attachment increased the in-flight velocity of spray particles over 750 m s^?1 and simultaneously suppressed oxidation significantly. In addition, some new methods were designed to evaluate the sprayed particle’s state and the coating properties with high accuracy and sensitivity. Thermal energy of in-flight spray particles was revealed by molten fraction of spray particles, determined by quantitative analysis of melted and unmelted particles captured in an agar gel. Through-porosity of the coatings with open porosity below 0.1% was determined by using Inductively Coupled Plasma analysis of dissolved substance from substrate through the penetrating path of the coatings. The coating of HastelloyC nickel base alloy by the HVOF spraying with the gas shroud attachment had zero through-porosity and 0.2 mass% of oxygen content. The laboratory corrosion tests showed that the on-shroud HastelloyC coating was comparable to the bulk material of HastelloyC in terms of corrosion resistance. This coating, formed on steel, demonstrated an excellent protective performance over 10 months in the marine exposure test.     

nanoHVOF – Prozesstechnik und Schichteigenschaften einer neuen,hochdichten Spritzschicht

Thermal spray layers are used as protective coatings against wear and corrosion. A vast range of metallic and non metallic materials can be utilized in tailor made surfaces for engines, turbines or agricultural equipment. Conventional thermal spray coatings often show imperfections. Melting or infiltrations of porous layers are methods to improve coating quality even though they are expensive. Special thermal spray processes like HVOF are more advantageous in these cases. The nanoHVOF produces high density coatings with a high hardness. It includes powder, torch and nozzle techniques. The new developed nanoHVOF‐process is described, wear properties are evaluated and nanoHVOF‐coatings metallographically examined. The comparison between nanoHVOF and conventional HVOF coatings is presented.     

Microstructural characterisation of high velocity oxyfuel thermally sprayed Stellite 6

Abstract

High velocity oxyfuel (HVOF) thermal spraying with an oxygen-propylene combustion flame was used to deposit coatings of a Co–Cr–W–C alloy (similar in composition to Stellite 6) from gas atomised feedstock powder. The microstructural characteristics of the deposits were investigated using the combined techniques of X-ray diffraction (XRD), scanning electron microscopy (SEM), and transmission electron microscopy (TEM). In particular, the tripod polishing technique was used to prepare large areas of electron transparent membrane for TEM analysis; these areas were typically of the order of several hundred square micrometres. Accordingly, SEM and TEM analysis could be directly correlated, providing a clear understanding of the overall nature of the coatings. The coatings exhibited characteristic splatlike, layered morphologies due to the deposition and resolidification ofmolten or semimolten powder particles. The as sprayed microstructure consisted of a face centred cubic Co rich metallic matrix with a small fraction of CoCr₂O₄ spinel oxide. The latter formed either as intersplat lamellae or intrasplat globules. Under the HVOF spray conditions employed, a high proportion of the feedstock powder appeared to have been fully melted prior to impact on the substrate, with partially or unmelted powder accounting for < 20% of the microstructure. Formation of the M₇C₃ phase, normally present in Stellite 6, appeared to have been suppressed by the high cooling rate during spray deposition.     

热喷涂亚稳态复合涂层研究进展

热喷涂亚稳态复合涂层能克服许多亚稳材料不易直接成形的不足,有效发挥非晶、纳米晶和准晶材料的特殊功效.等离子喷涂和高速火焰喷涂亚稳态铁基、镍基、陶瓷粉末制备的涂层质量优异,在热障、耐磨、防腐等领域应用前景广阔,但尚需拓展涂层功能,降低成本.电弧喷涂粉芯丝材制备亚稳态涂层具有成本低、效率高、成分易调节等优势,在大规模高效制备耐磨、防腐、防高温腐蚀与冲蚀涂层方面优势明显,但尚需提高涂层稳定性,开发更多涂层材料体系.目前,我国需要从自动化热喷涂设备开发和新型亚稳态材料体系研究两方面展开深入研究,提高亚稳态喷涂层的组织结构稳定性和性能质量可靠性,使该技术走出实验室面向工业应用,更好地为国家循环经济建设服务.     

燃气流量对超音速氧焰喷涂羟基磷灰石颗粒的影响

为了掌握燃气流量对羟基磷灰石(HA)粉末颗粒产生的影响,采用超音速氧焰喷涂(HVOF)技术制备了HA涂层,运用X射线、XRD和SEM分析了HA喷涂粉末颗粒的相组成,观察了涂层的形貌.结果表明:增加燃气流量,HA粉末颗粒表面的熔化程度提高,但整体熔化比例仅有微量增加(从13%增加到18%),原因是增大燃气流量在提高火焰温度的同时加快了颗粒的飞行速度,缩短了粉末颗粒在火焰中滞留的时间;火焰加热后3种颗粒结晶相只有HA;提高燃气流量降低了颗粒的结晶度(从91.4%降至73.8%);3种HA颗粒在涂层表面形成了3种典型的结构.     

Herstellung HVOF gespritzter,feinststrukturierter Cermetschichten unter Verwendung von feinen WC‐12Co Pulvern

Manufacturing of HVOF sprayed, finest structured cermet coatings using fine WC‐12Co powders The continuous increase in productivity and performance of modern sheet metal forming processes combined with the employment of novel, high strength materials cause high wear on tool systems. Coating technologies like thermal spraying provide a high potential to functionalize and to protect the surface of forming tools. However, it has to be ensured that the high shape and dimensional accuracy of the tool contour is preserved after the application of a wear protective coating. This aim cannot be achieved using currently applied, thermally sprayed coating systems with conventional, coarse grained microstructure. To solve this problem, novel finest structured coatings have been developed in this study by thermal spraying of fine WC‐12Co powders using the HVOF technique. For this purpose the influence of varying HVOF combustion gas compositions on the spray process as well as on the corresponding coating properties has been investigated. Next to a high surface quality the focus was placed on achieving coatings with high hardness and corresponding high wear resistance, low porosity as well as a good adhesive strength on the substrate material.     

粘结层喷涂方法对铜基体与热障涂层结合强度的影响

为提高铜基体上热障涂层的工作温度和寿命,分别采用超音速火焰喷涂(HVOF)和等离子喷涂(APS)制备NiCrAlY粘结层,采用等离子喷涂制备ZrO2-8%Y2O3陶瓷面层.用拉伸试验测试了热障涂层的结合强度,利用SEM分析了拉伸断口的成分分布和微观形貌.研究表明,用HVOF制备粘结层的热障涂层的结合强度为47.9 MPa,用APS制备粘结层的热障涂层的结合强度为31.2 MPa.与等离子喷涂制备粘结层相比,采用超音速火焰喷涂制备粘结层可明显提高ZrO2陶瓷涂层的结合强度.     

Numerical modeling the bonding mechanism of HVOF sprayed particles

During high velocity oxy-fuel (HVOF) thermal spraying, most powder particles remain in solid state prior to the formation of coating. A finite element (FE) model is developed to study the impact of thermally sprayed solid particles on substrates and to establish the critical particle impact parameters needed for adequate bonding. The particles are given the properties of widely used WC-Co powder for HVOF thermally sprayed coatings. The numerical results indicate that in HVOF process the kinetic energy of the particle prior to impact plays the most dominant role on particle stress localization and melting of the particle/substrate interfacial region. Both the shear-instability theory and an energy-based method are used to establish the critical impact parameters for HVOF sprayed particles, and it is found that only WC-Co particles smaller than 40 μm have sufficient kinetic and thermal energy for successful bonding.     

Effect of WC Particle Size on the Abrasive Wear of Thermally Sprayed WC-Co Coatings

Four types of WC-Co powders with different WC particle sizes are sprayed to produce WC-Co coatings with a Jet-Kote gun using a gas mixture of C₂H₂-30% C₃H₆ and pure propylene as fuel gases. The carbide size in sprayed high velocity oxy-fuel (HVOF) WC-Co coatings is measured from the microstructure. The abrasive wear of the coatings is characterized using a Suga abrasive wear tester. The abrasive wear mechanism of thermally sprayed WC-Co is discussed. The relationship between the relative wear of WC-Co coatings and carbide sizes is established according to the strength theory on hard alloy. The correlation with experimental data proves that the relative abrasive wear of WC-Co coating is proportional to square root of relative carbide size.     

Characterization and hot corrosion performance of LVPS and HVOF-CoNiCrAlYSi coatings

The CoNiCrAlYSi coatings were produced by using low vacuum plasma spray (LVPS) and high velocity oxy-fuel (HVOF) techniques on the Inconel-738. Hot corrosion behavior and microstructure characterization was investigated by exposing the sample to a molten film of Na₂SO₄-20? wt NaVO₃ at 880 °C for up to 560 h. The hot corrosion rate was determined by measuring the weight gain of the specimens at regular intervals for a duration of 20 h. The result of weight change measurements showed better hot corrosion resistance for HVOF-CoNiCrAlYSi coatings. This was attributed to the α-Al₂O₃ nucleation during the HVOF coating process and replacement of non-protective oxide due to a fluxing mechanism. It was also observed that the non-protective and porous oxides such as (Co,Ni)Al₂O₄ and (Co,Ni)Cr₂O₄ were formed on the both types of coatings due to large β-depleted zone after long exposure time of hot corrosion testing.     

不同喷涂工艺下NiCoCrAlYTa涂层的显微结构和性能

为探索不同喷涂工艺对NiCoCrAlYTa涂层的显微结构和性能的影响规律,确定最优工艺,采用大气等离子、低压等离子、常规超音速火焰和低温超音速火焰4种工艺在镍基单晶高温合金表面制备了NiCoCrAlYTa涂层。采用X射线衍射(XRD)、扫描电镜(SEM)和显微硬度计等分析手段对喷涂态涂层的相组成、显微结构和显微硬度等进行了表征。结果表明,不同喷涂工艺下涂层的相组成均为γ′-Ni_3Al、β-NiAl和γ-Ni固溶体。低压等离子和超音速火焰喷涂的涂层致密且孔隙率低,其中超音速火焰喷涂的涂层孔隙率低于1%。低压等离子和低温超音速火焰喷涂的涂层氧含量很低,控制在0.3%~0.6%的范围。综合来说,低温超音速火焰喷涂工艺制备的涂层结构致密,孔隙率和氧含量很低。该工艺是沉积NiCoCrAlYTa涂层的首选。     

Surface Refinement of Metal Foams

Aluminium foams produced via the PM‐process are characterized by a moderate specific strength, a high surface roughness, and a poor wear behavior; to increase their mechanical properties and to improve the surface finish, wear and corrosion resistance; thermally sprayed coatings can be applied. The quality of the coating depends on the coating material, the chosen process, the preparation of the surface and spraying parameters. Aluminium alloys and iron based alloys for abrasive applications were deposited via electric arc spraying, ceramic coatings against wear were deposited by means of plasma spraying. Hard metallic coatings for severe abrasive applications were applied by high‐velocity‐oxyfuel spraying (HVOF). The results proved the suitability of this technique to significantly enhance the mechanical properties and the surface finish of metal foams. The specific strength and stiffness of the new composite materials outperform pure metal foams. The corrosion behavior was tested performing a salt spray test.