CA1083856A - High hardness copper aluminum alloy flame spray powder - Google Patents
High hardness copper aluminum alloy flame spray powderInfo
- Publication number
- CA1083856A CA1083856A CA276,541A CA276541A CA1083856A CA 1083856 A CA1083856 A CA 1083856A CA 276541 A CA276541 A CA 276541A CA 1083856 A CA1083856 A CA 1083856A
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- CA
- Canada
- Prior art keywords
- powder
- aluminum bronze
- alloy
- flame spray
- coating
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
- C22C9/01—Alloys based on copper with aluminium as the next major constituent
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/06—Metallic material
- C23C4/08—Metallic material containing only metal elements
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
Abstract of the Disclosure A copper-aluminum alloy flame spray powder is pro-vided consisting essentially by weight of 0 to about 5%
Fe, about 2% to 8% Ni, about 5% to 15% Al, and the balance essentially copper, a coating produced from said powder being characterized by improved as-sprayed hardness in combina-tion with resistance to oxidation and galling.
Fe, about 2% to 8% Ni, about 5% to 15% Al, and the balance essentially copper, a coating produced from said powder being characterized by improved as-sprayed hardness in combina-tion with resistance to oxidation and galling.
Description
1~83856 This invention relates to an aluminum bronze flame spray alloy powder and, in particular, to an aluminum bronze flame spray powder having improved as-sprayed hardness in com-bination with good.resistance to wear and to galling.
', 5 State of the Art Aluminum bronze flame spray powders are known for producing metal coatin~s ,on metal substratcs which e~hibit lubricity and resistance to oxidation and galling. A typica], alloy which is generally used as an atomized powder consists essentially by weight of about 2% ~2, 10% Al, and the balance '~ . essentially copper, for example 88%.
A preferred method of producing an adherent coating of the foregoing alloy is first to spray a layer of a bonding ~ metal onto a metal substrate and then follow this with a spray 'I 15 coating of the aluminum bronze alloy. A particular bond coat-¦ ing metal is a me~al powder formed by agglomerating nickel powder with aluminum powder'using a resin as a binding agent.
,' The agglomerated powder may range in composition by weight from , about 3% to 15% Al (preferably 3% to 10%) and the balance essen-,) . 20 tially nickel. A bond coating produced from the ~i-Al system ' exhibits good adherence with the metal substrate and serves as , a foundation layer to which the aluminum bronze alloy strongly ' adheres. Thus, a fairly thick coating of the aluminum bronze alloy can be applied which can be easily machined with a car-bide tip tool bit.
One of the disaavantages of the foregoing aluminum bronze composition is that it has a relatively low hardness which ranr,es from about 65 to 70 Rb which limits tl~e use of ,~ , such coatings in cer,tain applications.
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. .
~ . .
~083856 There is a need for aluminum bronze coatings of higher hardness while still retaining lubricity of the coating in com-bination with resistance to galling and oxidation.
We have now discovered an improved aluminum bronze flame spray powder which provides higher as-sprayed hardness than obtained heretofore by adding a controlled amount of nickel to the aluminum bronze composition.
One aspect of the invention provides an atomized aluminum bronze flame spray alloy powder capable of free flowing under gravity-fed flame spray conditions characterized by im-proved hardness in combination with improved resistance to oxidation and resistance to galling when sprayed as a metal coating onto a metal substrate, said alloy powder consisting essentially by weight of 0 to about 5% Fe, about 2% to 8% Ni, about 5% to 15% Al and the balance essentially copper, said atomized free flowing flame spray powder having an average size ranging substantially from minus 100 mesh to plus 325 mesh.
Another aspect of the invention provides a flame spray method of producing an aluminum bronze alloy as-sprayed coating on a metal substrate, said coating characterized by im-proved hardness and resistance to oxidation and resistance to .. ~ .
galling which comprises, spraying a preliminary coating of a bonding metal on said metal substrate, and then spraying said aluminum bronze alloy as an atomized free flowing powder on ; said bonding metal, said aluminum bronze alloy consisting ' essentially by weight of 0 to about 5% Fe, about 5% to 15% Al, : !
about 2% to 8% nickel and the balance essentially copper, where-by a hard adherent coating of said aluminum bronze alloy is provided on said metal substrate.
Preferably, the alloy contains 0 to 3% iron, about ; 4 to 6% nickel and about 8 to 12% aluminum, with the balance essentially copper.
In the accompanying drawing:
Figure 1 is a set of curves showing the effect of nickel on increasing the hardness of the aluminum bronze alloy;
Figure 2 depicts one type of a gravity fed metal spray gun which may be employed in producing a sprayed-on coating; and Figure 3 is a schematic of a device for use in measur-ing resistance to wear of deposited coatings.
Broadly speaking, the amount of nickel added should be at least sufficient to raise the as-sprayed hardness to at least 10% higher than the hardness of the as-sprayed alloy with-out nickel.
We have found that, by working over the foregoing ranges of nickel, markedly improved as-sprayed hardness is ob-tainable as compared to the alloy without nickel. This will be clearly apparent by referring to Figure 1 which shows an in-crease in as-sprayed hardness when nickel is added to the alloy over the range of about 2% to 8% Ni, and particularly over the range of about 4% to 6% Ni.
The presence of nickel does not adversely affect the resistance of the alloy to oxidation and wear so that improved ~. ~
hardness is obtained in combination with the foregoing properties.
Also, the addition of nickel does not change the attractive yellow aluminum bronze color. Thicknesses of up to about 0.125 inch and higher can be obtained which adhere strongly to the metal substrate by employing a bond coat of another metal as the foundation layer, the bond coat generally having a thickness of about 0.005 to 0.015 inch. The aluminum bronze coating may range in thickness from about 0.005 to 0.125 inch and generally from about 0.01 to 0.1 inch.
The aluminum bronze powder is preferably employed in the atomized form, this type of powder having exceptionally . ~
good free flowing properties. Such powder is particularly -adapted for use in gravity fed torches as shown in Figure 2.
As indicated above, the atomized powder ranges in average size substantially from about minus 100 mesh to plus 325 mesh and, preferably substantially from about minus 140 mesh to plus 325 mesh.
In producing a layer of the bronze alloy on a metal substrate, the substrate is first cleaned in the usual manner followed by shot blasting with steel grit or other mechanical operation and a foundation layer of a bonding metal applied by flame spraying.
A preferred bonding metal is a powder made up of agglomerates of metallic nickel and aluminum referred to here-inbefore. This powder is produced by mixing nickel with i aluminum powder in a solution of an evaporatable organic sol-vent containing a binding resin, e.g. a phenolic resin (such as phenolformaldehyde) dissolved in ethyl alcohol, methyl meth-acrylate, polyvinyl chloride, polyvinyl alcohol, and the like, such that, when the organic solvent is evaporated and agglomer-ated, a powder containing by weight anywhere from about 1% to , ;
, 5% of the resin is obtained, prefera~ly 3% by weight, in the form of agglomerates. The agglomerates are broken up by passing them through screens to provide a powder ranging substantially -l from about minus 100 mesh to plus 325 mesh and, more preferably, substantially from about minus 140 mesh to plus 325 mesh.
,..1 `l As stated earlier, the agglomerate excluding the .~i resin may contain 3% to 15% aluminum and the balance essentially nickel (preferably 3% to 10% Al, such as 6% Al). The ''' , ~ , aluminum powder is adhesively bonded to the nickel powder by the resin, the aluminum powder size not exceeding about one-half the average size of the nickel`powder, and preferably not exceeding one-quar-ter the average size of said nickel powder.
The nickel powder may range from about 60 to 80 microns in size and the aluminum powder less than about 15 microns in size, e.g. 2 to 10 microns average size.
The r1i-Al foundation layer or bond coat may be sprayed using various types of flame spray torches well known in the art. As regards such torches, the powder formula~ion is injec-, ; ted into the stream of burning gas and emitted from the torch and applied to the metal substrate.
The atomized aluminum bronze powder may similarly be sprayed with the type of torches referred to hereinabove.
; 15 A pre$erred torch is the gravity fed torch shown in Fig. 2 which is described in U.S. Patent No. 3,620,454.
Re~erring to Fig 2, the torch 25 has a housing in the shape of a five-sided polygon with one leg of the polygon arranged as a handle portion 27, another leg as a base portion 20 28, a further leg as a feed portion 29, and another leg of : the polygon as the top portion of the torch. The housing 26 has coupled to it a powder feed assembly 31 and a flame as-sembly 32 to which is coupled nozzle 33.
The top portion 30 is provided with a fitting 34 adapted to receive a receptacle 35 (shown fragmentarily) for holding the alloy powder, a metering device being employed to control powder feed comprising a feed actuator plate 36 .
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slidably mounted in a slot 37 located in the housing top portion 30 below fitting 34. Feed plate 36 i9 provided with a knob 38 which protrudes upwardly above the housin~ and per-mits the sliding o~ feed plate 36 reciprocally toward and away from housing feed portion 29.
The powder flows by gravity unhindered through cir-cular orifices which may range in size from 0.075 ~o 0.120 inch for different alloy powders, the flow being maintained : substantially constant over a mesh size range of minus 100 to plus 300 mesh. Atomized powder being spherical in shape ; is particularly adapted to.. this type of gravity fed gun.
' In achieving the desired flow rate, feed plate 36 i ~s selectively aligned with powder flow orifice 39 to control ., variably the flow rate of the powder from receptacle 35 through flow orifice 39 through conduit 40 and through variable spray control assembly 41. Assembly 41 has a housing 42 which holds a powder feed tube 43 and having a central core hollow cylinder 44 slidably and telescopically fitted within feed tube 43 and communicating directly with powder flow conduit 40 . to deliver powder directly by gravity to feed tube 43, the ' : powder then flowing through discharge end 45. A portion of the outer surace of feed tube 43 is provided with indexing ~ means or grooves 46 which t.hrough latching assembly 47 enables the setting of powder feed tube 43 in order to locate discharge end 45 at the correct distance from the flame end of nozzle 33.
... . .
.` The latching assembly comprises a holding pin 48 that is nor-mally urged toward one of the indexing grooves 46 by spring ; . 49, the holding pin 48 being acutated by rod 50 in making the ~ ' .
setting. Thus, by depressing rod 50, the pin is moved out of contact with one of the indexing grooves and tube 43 set according to the desired position.
The fla~e assembly 32 is supported by sliding ele-ment 51 which can be lockingly moved along a track 52 located at the bottom leg of housing 26, a locking pin l5A being provided as sllown. Gas flow tube 53 is fi~cdly hcld by slid-ing element 51 and may be factory set, one end of the tube having a connector 54 for attaching to a source of oxygen and ; 10 acetylene.
The powder flows down tube 43 and is discharged at 45 into the flame issuing from nozzle 33.
The bond coat produced with the foregoing type of torch generally has a thickness of about 0.005 to 0.015 inch.
The aluminum bronze coating is sprayed onto the bond coat to a thickness of about 0.08 inch.
As illustrative of the invention, the following example is given:
, EXAMPLE
20 Three atomized aluminum bronze compositions were produced having the following composition:
(1) 88% Cu-10% Al-2% Fe
', 5 State of the Art Aluminum bronze flame spray powders are known for producing metal coatin~s ,on metal substratcs which e~hibit lubricity and resistance to oxidation and galling. A typica], alloy which is generally used as an atomized powder consists essentially by weight of about 2% ~2, 10% Al, and the balance '~ . essentially copper, for example 88%.
A preferred method of producing an adherent coating of the foregoing alloy is first to spray a layer of a bonding ~ metal onto a metal substrate and then follow this with a spray 'I 15 coating of the aluminum bronze alloy. A particular bond coat-¦ ing metal is a me~al powder formed by agglomerating nickel powder with aluminum powder'using a resin as a binding agent.
,' The agglomerated powder may range in composition by weight from , about 3% to 15% Al (preferably 3% to 10%) and the balance essen-,) . 20 tially nickel. A bond coating produced from the ~i-Al system ' exhibits good adherence with the metal substrate and serves as , a foundation layer to which the aluminum bronze alloy strongly ' adheres. Thus, a fairly thick coating of the aluminum bronze alloy can be applied which can be easily machined with a car-bide tip tool bit.
One of the disaavantages of the foregoing aluminum bronze composition is that it has a relatively low hardness which ranr,es from about 65 to 70 Rb which limits tl~e use of ,~ , such coatings in cer,tain applications.
.
. .
~ . .
~083856 There is a need for aluminum bronze coatings of higher hardness while still retaining lubricity of the coating in com-bination with resistance to galling and oxidation.
We have now discovered an improved aluminum bronze flame spray powder which provides higher as-sprayed hardness than obtained heretofore by adding a controlled amount of nickel to the aluminum bronze composition.
One aspect of the invention provides an atomized aluminum bronze flame spray alloy powder capable of free flowing under gravity-fed flame spray conditions characterized by im-proved hardness in combination with improved resistance to oxidation and resistance to galling when sprayed as a metal coating onto a metal substrate, said alloy powder consisting essentially by weight of 0 to about 5% Fe, about 2% to 8% Ni, about 5% to 15% Al and the balance essentially copper, said atomized free flowing flame spray powder having an average size ranging substantially from minus 100 mesh to plus 325 mesh.
Another aspect of the invention provides a flame spray method of producing an aluminum bronze alloy as-sprayed coating on a metal substrate, said coating characterized by im-proved hardness and resistance to oxidation and resistance to .. ~ .
galling which comprises, spraying a preliminary coating of a bonding metal on said metal substrate, and then spraying said aluminum bronze alloy as an atomized free flowing powder on ; said bonding metal, said aluminum bronze alloy consisting ' essentially by weight of 0 to about 5% Fe, about 5% to 15% Al, : !
about 2% to 8% nickel and the balance essentially copper, where-by a hard adherent coating of said aluminum bronze alloy is provided on said metal substrate.
Preferably, the alloy contains 0 to 3% iron, about ; 4 to 6% nickel and about 8 to 12% aluminum, with the balance essentially copper.
In the accompanying drawing:
Figure 1 is a set of curves showing the effect of nickel on increasing the hardness of the aluminum bronze alloy;
Figure 2 depicts one type of a gravity fed metal spray gun which may be employed in producing a sprayed-on coating; and Figure 3 is a schematic of a device for use in measur-ing resistance to wear of deposited coatings.
Broadly speaking, the amount of nickel added should be at least sufficient to raise the as-sprayed hardness to at least 10% higher than the hardness of the as-sprayed alloy with-out nickel.
We have found that, by working over the foregoing ranges of nickel, markedly improved as-sprayed hardness is ob-tainable as compared to the alloy without nickel. This will be clearly apparent by referring to Figure 1 which shows an in-crease in as-sprayed hardness when nickel is added to the alloy over the range of about 2% to 8% Ni, and particularly over the range of about 4% to 6% Ni.
The presence of nickel does not adversely affect the resistance of the alloy to oxidation and wear so that improved ~. ~
hardness is obtained in combination with the foregoing properties.
Also, the addition of nickel does not change the attractive yellow aluminum bronze color. Thicknesses of up to about 0.125 inch and higher can be obtained which adhere strongly to the metal substrate by employing a bond coat of another metal as the foundation layer, the bond coat generally having a thickness of about 0.005 to 0.015 inch. The aluminum bronze coating may range in thickness from about 0.005 to 0.125 inch and generally from about 0.01 to 0.1 inch.
The aluminum bronze powder is preferably employed in the atomized form, this type of powder having exceptionally . ~
good free flowing properties. Such powder is particularly -adapted for use in gravity fed torches as shown in Figure 2.
As indicated above, the atomized powder ranges in average size substantially from about minus 100 mesh to plus 325 mesh and, preferably substantially from about minus 140 mesh to plus 325 mesh.
In producing a layer of the bronze alloy on a metal substrate, the substrate is first cleaned in the usual manner followed by shot blasting with steel grit or other mechanical operation and a foundation layer of a bonding metal applied by flame spraying.
A preferred bonding metal is a powder made up of agglomerates of metallic nickel and aluminum referred to here-inbefore. This powder is produced by mixing nickel with i aluminum powder in a solution of an evaporatable organic sol-vent containing a binding resin, e.g. a phenolic resin (such as phenolformaldehyde) dissolved in ethyl alcohol, methyl meth-acrylate, polyvinyl chloride, polyvinyl alcohol, and the like, such that, when the organic solvent is evaporated and agglomer-ated, a powder containing by weight anywhere from about 1% to , ;
, 5% of the resin is obtained, prefera~ly 3% by weight, in the form of agglomerates. The agglomerates are broken up by passing them through screens to provide a powder ranging substantially -l from about minus 100 mesh to plus 325 mesh and, more preferably, substantially from about minus 140 mesh to plus 325 mesh.
,..1 `l As stated earlier, the agglomerate excluding the .~i resin may contain 3% to 15% aluminum and the balance essentially nickel (preferably 3% to 10% Al, such as 6% Al). The ''' , ~ , aluminum powder is adhesively bonded to the nickel powder by the resin, the aluminum powder size not exceeding about one-half the average size of the nickel`powder, and preferably not exceeding one-quar-ter the average size of said nickel powder.
The nickel powder may range from about 60 to 80 microns in size and the aluminum powder less than about 15 microns in size, e.g. 2 to 10 microns average size.
The r1i-Al foundation layer or bond coat may be sprayed using various types of flame spray torches well known in the art. As regards such torches, the powder formula~ion is injec-, ; ted into the stream of burning gas and emitted from the torch and applied to the metal substrate.
The atomized aluminum bronze powder may similarly be sprayed with the type of torches referred to hereinabove.
; 15 A pre$erred torch is the gravity fed torch shown in Fig. 2 which is described in U.S. Patent No. 3,620,454.
Re~erring to Fig 2, the torch 25 has a housing in the shape of a five-sided polygon with one leg of the polygon arranged as a handle portion 27, another leg as a base portion 20 28, a further leg as a feed portion 29, and another leg of : the polygon as the top portion of the torch. The housing 26 has coupled to it a powder feed assembly 31 and a flame as-sembly 32 to which is coupled nozzle 33.
The top portion 30 is provided with a fitting 34 adapted to receive a receptacle 35 (shown fragmentarily) for holding the alloy powder, a metering device being employed to control powder feed comprising a feed actuator plate 36 .
.
.
slidably mounted in a slot 37 located in the housing top portion 30 below fitting 34. Feed plate 36 i9 provided with a knob 38 which protrudes upwardly above the housin~ and per-mits the sliding o~ feed plate 36 reciprocally toward and away from housing feed portion 29.
The powder flows by gravity unhindered through cir-cular orifices which may range in size from 0.075 ~o 0.120 inch for different alloy powders, the flow being maintained : substantially constant over a mesh size range of minus 100 to plus 300 mesh. Atomized powder being spherical in shape ; is particularly adapted to.. this type of gravity fed gun.
' In achieving the desired flow rate, feed plate 36 i ~s selectively aligned with powder flow orifice 39 to control ., variably the flow rate of the powder from receptacle 35 through flow orifice 39 through conduit 40 and through variable spray control assembly 41. Assembly 41 has a housing 42 which holds a powder feed tube 43 and having a central core hollow cylinder 44 slidably and telescopically fitted within feed tube 43 and communicating directly with powder flow conduit 40 . to deliver powder directly by gravity to feed tube 43, the ' : powder then flowing through discharge end 45. A portion of the outer surace of feed tube 43 is provided with indexing ~ means or grooves 46 which t.hrough latching assembly 47 enables the setting of powder feed tube 43 in order to locate discharge end 45 at the correct distance from the flame end of nozzle 33.
... . .
.` The latching assembly comprises a holding pin 48 that is nor-mally urged toward one of the indexing grooves 46 by spring ; . 49, the holding pin 48 being acutated by rod 50 in making the ~ ' .
setting. Thus, by depressing rod 50, the pin is moved out of contact with one of the indexing grooves and tube 43 set according to the desired position.
The fla~e assembly 32 is supported by sliding ele-ment 51 which can be lockingly moved along a track 52 located at the bottom leg of housing 26, a locking pin l5A being provided as sllown. Gas flow tube 53 is fi~cdly hcld by slid-ing element 51 and may be factory set, one end of the tube having a connector 54 for attaching to a source of oxygen and ; 10 acetylene.
The powder flows down tube 43 and is discharged at 45 into the flame issuing from nozzle 33.
The bond coat produced with the foregoing type of torch generally has a thickness of about 0.005 to 0.015 inch.
The aluminum bronze coating is sprayed onto the bond coat to a thickness of about 0.08 inch.
As illustrative of the invention, the following example is given:
, EXAMPLE
20 Three atomized aluminum bronze compositions were produced having the following composition:
(1) 88% Cu-10% Al-2% Fe
(2) 83% Cu-lO~/o Al-2% Fe-5% Ni
(3) 78% Cu-10% Al-2% Fe-10% Ni These powders were employed to produce an over-layer on a bond coat deposited on a 1020 steel substrate.
The particle size was minus 140 mesh to plus 325 mesh.
The bond layer was produced by spraying an agglo-merated,powder of the Ni-Al system containing 6% Al and 94% Ni, the alum1num powder being adhesive]y bond~d to the nickel pow-der with a resin. _The bond layer had a thickness of about 0.008 inch.
Following the laying down of the bond coat, alloy powders (l), (2) and (3) above were sprayed using thc ~ravity fed torch shown in Fig. 2, the coating thickness being about' 0.08 inch.
The coatings were then tested for hardness using a standard Rockwell testing machine and a standard Tukon micro-hardness testing machine using the Knoop indenter (KHN). The Knoop hardness readings were obtained directly on the sprayed particle in the coa~ing by locating the area of the particle or particles under the microscope. Ten hardness readings were obtained for each alloy. The results obtained are as follows:
Alloy ' Average Average No. _ Composition Rb** KHN
(l) 88% Cu-10% Al-2% Fe 67.5 280 *(2) 83% Cu-10% Al-2% Fe-5% Ni 93. 428 , 20 ' '(3) 78% Cu-10% Al-2% Fe-10% Fe 53.5 230 ' .
The invention * *
Rockwell B hardness ' As will be noted from Fig. l, a marked improvement in hardness is obtained in the coating of the invention con-taining 5% Ni as compared to Alloy No. (l) with no nickel' and Alloy No.,(3) containing 10% Ni. The improvement over Alloy (l) is over 37% for ,the Rockwell B hardness and over 50% for the Knoop hardness.
108;~856 A metallographic examination of ~he microstructure of Alloy No. (2) (the INVF,NTION) showed e:~cellent particle-to-particle bonding oE the sprayed aluminum bronze alloy and the coating integrity was very good.
The hardness trends relative to the nickel content is shown in Fig. 2, peak hardness results being obtained with 5% nickel. Broadly speaking, the nickel content may rangc ~rom about 2% to 8% and, more preferably, from about 4% to 6%.
It is not clearly understood why the hardness falls off as the nickel content approaches 10~/o~ It is believed that the markedly improved hardness obtained between 2 and 8%
nickel may be related to the precipitation of hard phases which are not visible under a microscope under ordinary light.
However, this is not certain. Whatever the reasons, the results , 15 are surprising and unexpected.
Subsequent tests relating to wear resistance showed that the addition of nickel does not adversely affect the re-sistance of the coating to wear.
Wear Testing 20 . Wear tests were conducted in duplicate on Alloys No.
(1) and No. (2), wherein No.(2)(the INVENTION) was compared to the wear characteristics of the No. (1) alloy. The wear test-ing device is illustrated schematically in Fig. 3 and comprises a lever 14 having two legs at right angles to each other, one of the legs 14A carrying a sample 13 which bears against a rotating wheel 12 as shown, the lever being pivotally mounted at fulcrum 15. The area of the sample is 3 square inches, the contact area with the wheel being l square inch.
.; . . .
, The free end of lever arm 14 supports a weight 16 which is located sixteen inches from the pivot end thereof for applying pressure to sample 13 in contact with the peri-phery of rubber whéel 12A.
The hopper contains hard particles o~ material, e.g.
silica (SiO2) or silicon carbide (SiC) and the lilce which are fed via the opening of gate lOA down chuLe 11 which is inclined relative to the horizontal axis of the lever arm and extends , to the surface of the sample and is adapted to feed a steady flow of hard particles to said sample 13 mounted on leg 14A
; in tangential contact with rubber wheel 12A by virtue of wei~ht 16, the hard particles being fed into the bite ormed between the contacting surfaces of the sample and the wheel, the hard particles 17 being shown emi~tin8 downwardly there~
from after passing through the bite area in rictional contact 7 with the surface of the sample. The following conditions were employed in the tests.
Coarse abrasive test: (-20 ~40 mesh sand) Test time: 15 minutes Flow rate of sand: 1 lb/min.
The average of duplicate sam~les are given as follows:
88% Cu-10% Al-2% Fe 83~/q Cu-10% Al-2% Fe-5% ~li Wt. ~oss (grs) 1.25 1.08 Wear Factor 6.8 7.85 The wear factor is determined as the reciprocal of the volume loss of the coating during testing, the loss in weight (in grams) bei~6 converted to cubic centimeters. Tbe .
10838~i6 higher the wear ~actor value, the grea~cr is the resistance to wear. As will be noted, the wear resi~ance is not adversely affected by the addition of nickel bùt, on the contrary, is improved. The wea~ factor of the alloy with 5% Ni improved by over 15% relative to the alloy without nickel.
A shaft of 1020 steel coated with the No. 2 alloy (the invention) machined very smoothly with a carbidc ~ip cuttin~
tool as evidenced by a smoothness determined in microinches of 20 to 25 RMS (root mean square).
Broadly, the aluminum bronze alloy may be applied ! to ferrous metal substrates, e.g. steel,l~ast iron, etc., as well as to non-ferrous metals, e.g . mnr~ (67% Ni-33% Cu) and . other metal substrates.
It ig cle~rly apparent that adding nickel over the controlled range of 2% to 8~/o and preferably 4% to 6% to alumi-num bronze alloy provides markedly improved results with regard , to increase in hardness while maintaining resistance to wear¦ and resistance to galling for coating produced from said alumi-num bronze alloy.
20 . Although the present invention has been described in : conjunction with preferred embodiments" it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention as.those skilled in the art will readily understand. Such modi~ications : 25 and variations are considered to be within the Purview and scope of the invention and the appended claims.
7~~3~
The particle size was minus 140 mesh to plus 325 mesh.
The bond layer was produced by spraying an agglo-merated,powder of the Ni-Al system containing 6% Al and 94% Ni, the alum1num powder being adhesive]y bond~d to the nickel pow-der with a resin. _The bond layer had a thickness of about 0.008 inch.
Following the laying down of the bond coat, alloy powders (l), (2) and (3) above were sprayed using thc ~ravity fed torch shown in Fig. 2, the coating thickness being about' 0.08 inch.
The coatings were then tested for hardness using a standard Rockwell testing machine and a standard Tukon micro-hardness testing machine using the Knoop indenter (KHN). The Knoop hardness readings were obtained directly on the sprayed particle in the coa~ing by locating the area of the particle or particles under the microscope. Ten hardness readings were obtained for each alloy. The results obtained are as follows:
Alloy ' Average Average No. _ Composition Rb** KHN
(l) 88% Cu-10% Al-2% Fe 67.5 280 *(2) 83% Cu-10% Al-2% Fe-5% Ni 93. 428 , 20 ' '(3) 78% Cu-10% Al-2% Fe-10% Fe 53.5 230 ' .
The invention * *
Rockwell B hardness ' As will be noted from Fig. l, a marked improvement in hardness is obtained in the coating of the invention con-taining 5% Ni as compared to Alloy No. (l) with no nickel' and Alloy No.,(3) containing 10% Ni. The improvement over Alloy (l) is over 37% for ,the Rockwell B hardness and over 50% for the Knoop hardness.
108;~856 A metallographic examination of ~he microstructure of Alloy No. (2) (the INVF,NTION) showed e:~cellent particle-to-particle bonding oE the sprayed aluminum bronze alloy and the coating integrity was very good.
The hardness trends relative to the nickel content is shown in Fig. 2, peak hardness results being obtained with 5% nickel. Broadly speaking, the nickel content may rangc ~rom about 2% to 8% and, more preferably, from about 4% to 6%.
It is not clearly understood why the hardness falls off as the nickel content approaches 10~/o~ It is believed that the markedly improved hardness obtained between 2 and 8%
nickel may be related to the precipitation of hard phases which are not visible under a microscope under ordinary light.
However, this is not certain. Whatever the reasons, the results , 15 are surprising and unexpected.
Subsequent tests relating to wear resistance showed that the addition of nickel does not adversely affect the re-sistance of the coating to wear.
Wear Testing 20 . Wear tests were conducted in duplicate on Alloys No.
(1) and No. (2), wherein No.(2)(the INVENTION) was compared to the wear characteristics of the No. (1) alloy. The wear test-ing device is illustrated schematically in Fig. 3 and comprises a lever 14 having two legs at right angles to each other, one of the legs 14A carrying a sample 13 which bears against a rotating wheel 12 as shown, the lever being pivotally mounted at fulcrum 15. The area of the sample is 3 square inches, the contact area with the wheel being l square inch.
.; . . .
, The free end of lever arm 14 supports a weight 16 which is located sixteen inches from the pivot end thereof for applying pressure to sample 13 in contact with the peri-phery of rubber whéel 12A.
The hopper contains hard particles o~ material, e.g.
silica (SiO2) or silicon carbide (SiC) and the lilce which are fed via the opening of gate lOA down chuLe 11 which is inclined relative to the horizontal axis of the lever arm and extends , to the surface of the sample and is adapted to feed a steady flow of hard particles to said sample 13 mounted on leg 14A
; in tangential contact with rubber wheel 12A by virtue of wei~ht 16, the hard particles being fed into the bite ormed between the contacting surfaces of the sample and the wheel, the hard particles 17 being shown emi~tin8 downwardly there~
from after passing through the bite area in rictional contact 7 with the surface of the sample. The following conditions were employed in the tests.
Coarse abrasive test: (-20 ~40 mesh sand) Test time: 15 minutes Flow rate of sand: 1 lb/min.
The average of duplicate sam~les are given as follows:
88% Cu-10% Al-2% Fe 83~/q Cu-10% Al-2% Fe-5% ~li Wt. ~oss (grs) 1.25 1.08 Wear Factor 6.8 7.85 The wear factor is determined as the reciprocal of the volume loss of the coating during testing, the loss in weight (in grams) bei~6 converted to cubic centimeters. Tbe .
10838~i6 higher the wear ~actor value, the grea~cr is the resistance to wear. As will be noted, the wear resi~ance is not adversely affected by the addition of nickel bùt, on the contrary, is improved. The wea~ factor of the alloy with 5% Ni improved by over 15% relative to the alloy without nickel.
A shaft of 1020 steel coated with the No. 2 alloy (the invention) machined very smoothly with a carbidc ~ip cuttin~
tool as evidenced by a smoothness determined in microinches of 20 to 25 RMS (root mean square).
Broadly, the aluminum bronze alloy may be applied ! to ferrous metal substrates, e.g. steel,l~ast iron, etc., as well as to non-ferrous metals, e.g . mnr~ (67% Ni-33% Cu) and . other metal substrates.
It ig cle~rly apparent that adding nickel over the controlled range of 2% to 8~/o and preferably 4% to 6% to alumi-num bronze alloy provides markedly improved results with regard , to increase in hardness while maintaining resistance to wear¦ and resistance to galling for coating produced from said alumi-num bronze alloy.
20 . Although the present invention has been described in : conjunction with preferred embodiments" it is to be understood that modifications and variations may be resorted to without departing from the spirit and scope of the invention as.those skilled in the art will readily understand. Such modi~ications : 25 and variations are considered to be within the Purview and scope of the invention and the appended claims.
7~~3~
Claims (4)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. An atomized aluminum bronze flame spray alloy powder capable of free flowing under gravity-fed flame spray conditions characterized by improved hardness in combination with improved resistance to oxidation and resistance to galling when sprayed as a metal coating onto a metal substrate, said alloy powder con-sisting essentially by weight of 0 to about 5% Fe, about 2% to 8% Ni, about 5% to 15% Al and the balance essentially copper, said atomized free flowing flame spray powder having an average size ranging substantially from minus 100 mesh to plus 325 mesh.
2. The aluminum bronze flame spray powder of claim 1, wherein the nickel content ranges from about 4% to 6% and the aluminum content ranges from about 6% to 12%.
3. A flame spray method of producing an aluminum bronze alloy as-sprayed coating on a metal substrate, said coating characterized by improved hardness and resistance to oxidation and resistance to galling which comprises, spraying a preliminary coating of a bonding metal on said metal substrate, and then spraying said aluminum bronze alloy as an atomized free flowing powder on said bonding metal, said aluminum bronze alloy consisting essentially by weight of 0 to about 5% Fe, about 5% to 15% Al, about 2% to 8% nickel and the balance essentially copper, whereby a hard adherent coating of said aluminum bronze alloy is provided on said metal substrate.
4. The method of claim 3, wherein the aluminum bronze alloy consists essentially of 0 to about 3% Fe, about 4% to 6% Ni, about 6% to 12% Al and the balance essentially copper.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US70625376A | 1976-07-19 | 1976-07-19 | |
| US706,253 | 1976-07-19 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1083856A true CA1083856A (en) | 1980-08-19 |
Family
ID=24836833
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA276,541A Expired CA1083856A (en) | 1976-07-19 | 1977-04-20 | High hardness copper aluminum alloy flame spray powder |
Country Status (9)
| Country | Link |
|---|---|
| JP (1) | JPS608302B2 (en) |
| AT (1) | AT358356B (en) |
| BE (1) | BE854289A (en) |
| BR (1) | BR7703371A (en) |
| CA (1) | CA1083856A (en) |
| CH (1) | CH620711A5 (en) |
| DE (1) | DE2729753A1 (en) |
| FR (1) | FR2359212A1 (en) |
| GB (1) | GB1577075A (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE19908107C2 (en) * | 1999-02-25 | 2003-04-10 | Man B & W Diesel As Kopenhagen | Method for producing a wear-resistant surface in the case of components made of steel and machine with at least one such component |
| EA019463B1 (en) * | 2011-06-27 | 2014-03-31 | Государственное научное учреждение "Институт механики металлополимерных систем имени В.А. Белого Национальной академии наук Беларуси" | Method for producing wear-resistant surfaces of steel and cast-iron parts |
Family Cites Families (7)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2430419A (en) * | 1945-02-02 | 1947-11-04 | Walter W Edens | Welding rod |
| GB818271A (en) * | 1955-04-30 | 1959-08-12 | Power Gas Ltd | Improvements in or relating to implements for use in inflammable or explosive atmospheres |
| US3176410A (en) * | 1958-02-12 | 1965-04-06 | Ampco Metal Inc | Aluminum bronze cylindrical shell |
| GB1184295A (en) * | 1968-08-07 | 1970-03-11 | Int Nickel Ltd | Cladding Stainless Steel |
| DE2023899A1 (en) * | 1969-05-22 | 1971-02-18 | Asea Ab | Machine element with applied outer layer |
| DE2514810C2 (en) * | 1975-04-04 | 1983-01-05 | Castolin Gmbh, 6239 Kriftel | Process for improving the properties of powdery Cu alloys for the powder flame spraying process |
| FR2334431A1 (en) * | 1975-12-12 | 1977-07-08 | Gen Electric | THERMAL SPRAYING DEPOSIT PROCESS |
-
1977
- 1977-04-20 GB GB1647877A patent/GB1577075A/en not_active Expired
- 1977-04-20 CA CA276,541A patent/CA1083856A/en not_active Expired
- 1977-04-27 CH CH521477A patent/CH620711A5/en not_active IP Right Cessation
- 1977-04-27 FR FR7712840A patent/FR2359212A1/en active Granted
- 1977-05-05 BE BE177293A patent/BE854289A/en not_active IP Right Cessation
- 1977-05-25 BR BR7703371A patent/BR7703371A/en unknown
- 1977-07-01 DE DE19772729753 patent/DE2729753A1/en active Granted
- 1977-07-13 AT AT501877A patent/AT358356B/en not_active IP Right Cessation
- 1977-07-19 JP JP8573077A patent/JPS608302B2/en not_active Expired
Also Published As
| Publication number | Publication date |
|---|---|
| FR2359212B1 (en) | 1983-11-04 |
| AT358356B (en) | 1980-09-10 |
| GB1577075A (en) | 1980-10-15 |
| CH620711A5 (en) | 1980-12-15 |
| BE854289A (en) | 1977-09-01 |
| JPS5311837A (en) | 1978-02-02 |
| DE2729753C2 (en) | 1988-06-16 |
| ATA501877A (en) | 1980-01-15 |
| FR2359212A1 (en) | 1978-02-17 |
| DE2729753A1 (en) | 1978-02-02 |
| JPS608302B2 (en) | 1985-03-01 |
| BR7703371A (en) | 1978-11-21 |
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