EP0285313B1 - Membre composite et son procédé de fabrication - Google Patents

Membre composite et son procédé de fabrication Download PDF

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Publication number
EP0285313B1
EP0285313B1 EP19880302533 EP88302533A EP0285313B1 EP 0285313 B1 EP0285313 B1 EP 0285313B1 EP 19880302533 EP19880302533 EP 19880302533 EP 88302533 A EP88302533 A EP 88302533A EP 0285313 B1 EP0285313 B1 EP 0285313B1
Authority
EP
European Patent Office
Prior art keywords
core
surface layer
intermediate layer
plasma spray
spray deposition
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.)
Expired - Lifetime
Application number
EP19880302533
Other languages
German (de)
English (en)
Other versions
EP0285313A3 (en
EP0285313A2 (fr
Inventor
Tetsuro Uchida
Hideyo Kodama
Koichi Anzai
Osamu Shitamura
Masaki Shimizu
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Hitachi Ltd
Original Assignee
Hitachi Ltd
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Filing date
Publication date
Application filed by Hitachi Ltd filed Critical Hitachi Ltd
Publication of EP0285313A2 publication Critical patent/EP0285313A2/fr
Publication of EP0285313A3 publication Critical patent/EP0285313A3/en
Application granted granted Critical
Publication of EP0285313B1 publication Critical patent/EP0285313B1/fr
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • 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
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas

Definitions

  • the present invention relates to a compound member comprising a core and a surface layer used for compound rolls, turbine rotors, various tools or the like and a method for producing the same.
  • the hot isostatic pressing method is a method in which powders produced through a gas-atomizing method are arranged around the core, and are pressurized under a hot environment to form a compound member after the powders have been cold-molded.
  • a stress concentration occurs during the heat treatment, disadvantageously, so that a crack or peel is likely to be occurred in the surface layer.
  • the insert metal method is a method in which a sleeve which has been made of powder material by sintering is shrink-fitted over a core to form a compound member. This method suffers from such a disadvantage that, when the operational loads imposed on the compound rolls or turbine rotors produced by this method is increased, the contact portion between the core and the sleeve would be peeled.
  • the liquid phase sintering method is a method in which a sleeve that has been made of powder material by sintering is diffused into a surface layer of a core to form a compound member.
  • a thickness of the diffused layer in the interface portion between the sleeve and the core is small at about 2 mm. Therefore, this method suffers from a disadvantage that residual stresses would be concentrated on the interface portion resulting in occurrence of cracks or peels.
  • the plasma spray deposition method is a method in which powder material is deposited on a core surface by plasma spray to thereby form a compound member.
  • the compound roll or turbine rotor produced by this method suffers from a disadvantage that a crack or a peel is likely to be occurred due to differences in coefficient of linear thermal expansion and elastic modulus between the core and the surface layer.
  • the compound roll or turbine rotor suffers from the disadvantages that the stress concentration would occur in the vicinity of the interface between the core and the surface layer and that the surface layer would be peeled or cracked.
  • a method for producing a compound member having a core and a surface layer of which mechanical properties are different from those of the core including a step of forming said surface layer by plasma spray deposition of powder material onto said core wherein said method includes: forming at least one intermediate layer between said core and surface layer by the plasma spray deposition so that the differences in the coefficients of linear thermal expansion between adjacent layers including said core and surface layer is not greater than 3 x 10 ⁇ 6/°C and the thickness of each of said at least one intermediate layer is at least 1.5mm.
  • a compound member having a core and a surface layer formed by plasma spray deposition characterised in that: there is at least one intermediate layer between said core and surface layer, formed by plasma spray deposition, said at least one intermediate layer being such that the differences in the coefficients of linear thermal expansion of adjacent layers including said core and surface layer is not greater than 3 x 10 ⁇ 6/°C and each of said at least one intermediate layer has a thickness of at least 1.5mm.
  • a compound roll for rolling comprising a shaft portion formed by a core having high mechanical strength and high toughness and a surface layer having wear-proof and spalling-proof characterised in that: there is at least one intermediate layer between said shaft portion and surface layer formed by plasma spray deposition, said at least one intermediate layer being such that the differences in the coefficients of linear thermal expansion of adjacent layers including said shaft portion and surface layer is not greater than 3 x 10 ⁇ 6/°C, and each of said at least one intermediate layer has a thickness of at least 1.5mm.
  • the present invention may thus provide a compound member comprising a core and a surface layer for which the mechanical properties are different from those of the core and a method for producing the same, which can eliminate any occurrence of stress concentration in an interface between the core and the surface layer and occurrence of peeling and crack of the surface layer, and which makes the mechanical properties of the surface layer be greatly different from those of the core and which is suitable for producing a compound roll for rolling and a turbine rotor.
  • the present invention may further provide a compound roll of which surface layer is superior in spalling-proof and friction resistance, of which core has a high mechanical strengthh and a high stiffness, which is free from the crack and peeling of the surface layer and of which diameter can be reduced.
  • the shaft portion is made of steel and the surface layer and the at least one intermediate layer are formed of powder material of hard metal by a plasma spray deposition over the shaft portion.
  • the shaft portion is made of steel and the surface layer and the at least one intermediate layer are formed of powder material of ceramics by a plasma spray deposition over the shaft portion.
  • the compound roll 4 has a shaft portion formed by a core 1 made of a steel with desired high mechanical strength and toughness.
  • a core 1 made of a steel with desired high mechanical strength and toughness.
  • an intermediate layer 3a is formed of which difference in the coefficient of linear thermal expansion to that of the core 1 is 3 x 10 ⁇ 6/°C and below and a thickness is 1.5 mm and over.
  • another intermediate layer 3b is formed of which difference in the coefficient of linear thermal expansion to that of the intermediate layer 3a is 3 x 10 ⁇ 6/°C and below and a thickness is 1.5 mm and over.
  • another intermediate layer 3c is formed of which difference in the coefficient of linear thermal expansion to that of the intermediate layer 3b is also 3 x 10 ⁇ 6/°C and below and a thickness is 1.5 mm and over.
  • a surface layer 2 having desired spalling-proof and wear-proof properties is formed on an outer surface of the outermost intermediate layer 3c.
  • a difference in the coefficient of linear thermal expansion between the outermost intermediate layer 3c and the surface layer 2 is also 3 x 10 ⁇ 6/°C and below.
  • the intermediate layers 3a, 3b, 3c, and the surface layer 2 are formed of powder material of hard metal by plasma spray deposition, thereafter sintered, subsequently hot forged and finally heat treated in a predetermined manner.
  • the plasma spray deposition of the powder material of hard metal is performed by an apparatus shown in Fig. 2.
  • the apparatus includes a spray torch 5 with a spray nozzle 13, and powder material supply means 6 and 6' for supplying plural powder materials 8 and 8' to the spray torch 5.
  • a controller 7 is connected to the spray torch 5 for controlling an operation of the torch 5 and for supplying working gas 10 and cooling water 11 to the spray torch 5.
  • Reference numeral 12 denotes an electric supply source.
  • Powder material supply gas 9 is supplied to the powder material supply means 6, 6' for supplying the powder materials 8, 8' to the torch 5.
  • the powder materials 8, 8' are applied to the core 1 by the plasma spray deposition while rotating the core 1 in a direction indicated by an arrow a in Fig. 2, to thereby form the intermediate layer 3a.
  • a mixture ratio or composition of the powder materials 8, 8' is changed so that the powder materials are applied to the intermediate layer 3a by the plasma spray deposition so as to form the intermediate layer 3b having a difference in coefficient of linear thermal expansion of 3 x 10 ⁇ 6°C and below to that of the intermediate layer 3a.
  • the intermediate layer 3c is formed on the intermediate layer 3b.
  • the surface layer 2 having the desired mechanical properties is formed on the intermediate layer 3c by the plasma spray deposition.
  • the powder material forming the intermediate layers and the surface layer is the powder material of hard metal but it is apparent that other powder materials such as ceramics and steel may be used.
  • the present inventors made various compound members having different coefficients of linear thermal expansion in the core and the plasma spray deposition layer in order to determine a suitable value of the coefficient of linear thermal expansion of the plasma spray deposition layers and inspect the state of occurrence of the cracks in the plasma spray deposition layers.
  • the results are shown in Fig. 3.
  • Fig. 3 shows the experimental results showing the relationship between the state of the crack occurrence in the plasma spray deposition layer and the coefficient of linear thermal expansion, the abscissa indicating the coefficient of linear thermal expansion of the plasma spray deposition layer and the ordinate indicating the coefficient of linear thermal expansion of the core.
  • the present inventors have inspected the stress distribution within the compound member in the case where the core is made of steel and the plasma spray deposition layers are made of hard metal and ceramics.
  • the experimental results are shown in Figs. 4 and 5 in which ⁇ r is the thickness of the plasma spray deposition layers.
  • ⁇ r is the thickness of the plasma spray deposition layers.
  • the thickness of the plasma spray deposition layers is selected at 1.5 mm and over, the tensile stress generated in the plasma spray deposition layers does not exceed the allowable stress level of the material forming the plasma spray deposition layers. Therefore, if the thickness of the plasma spray deposition layers is selected at 1.5 mm and over, it is possible to prevent the occurrence of cracks or peels in the plasma spray deposition layers.
  • the number of the intermediate layers is three but it is possible to change the number of the intermediate layers in accordance with the magnitude of the difference in coefficient of linear thermal expansion between the core 1 and the surface layer 2.
  • the difference in coefficient of linear thermal expansion between the core 1 and the surface layer 2 is at 6 x 10 ⁇ 6/°C
  • at least one intermediate layer is formed between the core and the surface layer by the plasma spray deposition so that the difference in coefficient of linear thermal expansion between the adjacent layers including the core and the outer surface is 3 x 10 ⁇ 6/°C and below.
  • the above-described embodiment is related to the compound roll, the above-described numerical limitation in the thickness and the difference in coefficient of linear thermal expansion of the plasma spray deposition layer (intermediate layer) may be applied to a turbine roller or various tools.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Reduction Rolling/Reduction Stand/Operation Of Reduction Machine (AREA)
  • Coating By Spraying Or Casting (AREA)

Claims (7)

  1. Procédé pour fabriquer un élément composite possédant un noyau (1) et une couche superficielle (2), dont les propriétés mécaniques sont différentes de celles du noyau, comprenant une étape de formation de ladite couche superficielle par dépôt d'un matériau en forme de poudre au moyen d'une projection de plasma, sur ledit noyau, caractérisé en ce que :
       ledit procédé comprend :
       la formation d'au moins une couche intermédiaire (3) entre ledit noyau (1) et ladite couche superficielle (2) par dépôt par projection de plasma de sorte que les différences entre les coefficients de dilatation thermique linéaire entre des couches adjacentes y compris ledit noyau et ladite couche superficielle ne sont pas supérieures à 3 x 10⁻⁶/°C et que l'épaisseur de la ou de chacune desdites couches intermédiaires (3) est égale au moins à 1,5 mm.
  2. Élément composite comportant un noyau (1) et une couche superficielle (2) formée par dépôt par projection de plasma, caractérisé en ce que :
       il existe au moins une couche intermédiaire (3) entre ledit noyau et ladite couche superficielle, formée par un dépôt par projection de plasma, ladite au moins une couche intermédiaire (3) étant telle que les différences des coefficients de dilatation thermique linéaire de couches adjacentes y compris ledit noyau et ladite couche superficielle, ne sont pas supérieures à 3 x 10⁻⁶/°C et que la ou chacune desdites couches intermédiaires (3) possède une épaisseur égale au moins à 1,5 mm.
  3. Élément composite selon la revendication 2, dans lequel ledit noyau (1) est en acier et ladite au moins une couche intermédiaire (3) et ladite couche superficielle (2) sont formées d'une poudre d'un métal dur.
  4. Élément composite selon la revendication 2, dans lequel ledit noyau (1) est réalisé en acier et ladite au moins une couche intermédiaire (3) et ladite couche superficielle (2) sont formées d'une poudre d'un matériau céramique.
  5. Cylindre composite de laminage (4) comprenant une partie formant arbre (1) constituée par un noyau possédant une résistance mécanique élevée et une ténacité élevée et une couche superficielle (2) résistante à l'usure et à l'écaillage, caractérisé en ce que :
       au moins une couche intermédiaire (3) est prévue entre ladite partie formant arbre (1) et ladite couche superficielle (2) formée par dépôt par projection de plasma, ladite au moins une couche intermédiaire (3) étant telle que les différences des coefficients de dilatation thermique linéaire de couches adjacentes y compris ladite partie formant arbre et ladite couche superficielle ne sont pas supérieures à 3 x 10⁻⁶/°C, et que la ou chacune desdites couches intermédiaires possède une épaisseur égale au moins à 1,5 mm.
  6. Cylindre composite de laminage selon la revendication 5, dans lequel ladite partie formant arbre (1) est réalisée en acier et ladite couche superficielle (2) et ladite au moins une couche intermédiaire (3) sont des couches formées d'une poudre d'un métal dur, qui est projetée sur ladite partie formant arbre selon un dépôt par projection de plasma.
  7. Cylindre composite de laminage selon la revendication 5, dans lequel ladite partie formant arbre (1) est en acier et ladite couche superficielle (2) et ladite au moins une couche intermédiaire (3) sont des couches formées d'une poudre d'un matériau céramique, qui est projetée sur ladite partie formant arbre au moyen d'un dépôt par projection de plasma.
EP19880302533 1987-03-30 1988-03-23 Membre composite et son procédé de fabrication Expired - Lifetime EP0285313B1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP7675387A JPS63242408A (ja) 1987-03-30 1987-03-30 圧延用複合ロ−ル
JP76753/87 1987-03-30

Publications (3)

Publication Number Publication Date
EP0285313A2 EP0285313A2 (fr) 1988-10-05
EP0285313A3 EP0285313A3 (en) 1989-08-16
EP0285313B1 true EP0285313B1 (fr) 1993-01-13

Family

ID=13614348

Family Applications (1)

Application Number Title Priority Date Filing Date
EP19880302533 Expired - Lifetime EP0285313B1 (fr) 1987-03-30 1988-03-23 Membre composite et son procédé de fabrication

Country Status (3)

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EP (1) EP0285313B1 (fr)
JP (1) JPS63242408A (fr)
DE (1) DE3877399T2 (fr)

Families Citing this family (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB9419328D0 (en) * 1994-09-24 1994-11-09 Sprayform Tools & Dies Ltd Method for controlling the internal stresses in spray deposited articles
US6048586A (en) * 1996-06-05 2000-04-11 Caterpillar Inc. Process for applying a functional gradient material coating to a component for improved performance
US5912087A (en) * 1997-08-04 1999-06-15 General Electric Company Graded bond coat for a thermal barrier coating system
US8974865B2 (en) * 2011-02-23 2015-03-10 General Electric Company Component and a method of processing a component

Family Cites Families (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3976809A (en) * 1973-08-13 1976-08-24 Dowell Robert D Coating for metal surfaces and method for application
US4109031A (en) * 1976-12-27 1978-08-22 United Technologies Corporation Stress relief of metal-ceramic gas turbine seals
US4159353A (en) * 1978-01-19 1979-06-26 Corning Glass Works Platinum coating dense refractories
JPS5852451A (ja) * 1981-09-24 1983-03-28 Toyota Motor Corp 耐熱・断熱性軽合金部材およびその製造方法
US4485151A (en) * 1982-05-06 1984-11-27 The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration Thermal barrier coating system
JPS60158906A (ja) * 1984-01-30 1985-08-20 Hitachi Ltd 圧延用複合ロ−ルおよびその製造方法
US4576874A (en) * 1984-10-03 1986-03-18 Westinghouse Electric Corp. Spalling and corrosion resistant ceramic coating for land and marine combustion turbines
JPS6187859A (ja) * 1984-10-04 1986-05-06 Showa Denko Kk 溶射皮膜形成方法
DE3513882A1 (de) * 1985-04-17 1986-10-23 Plasmainvent AG, Zug Schutzschicht

Also Published As

Publication number Publication date
DE3877399D1 (de) 1993-02-25
DE3877399T2 (de) 1993-05-06
JPS63242408A (ja) 1988-10-07
EP0285313A3 (en) 1989-08-16
EP0285313A2 (fr) 1988-10-05

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