EP1478790A1 - Pulverisation thermique d'une partie d'une machine - Google Patents

Pulverisation thermique d'une partie d'une machine

Info

Publication number
EP1478790A1
EP1478790A1 EP02712931A EP02712931A EP1478790A1 EP 1478790 A1 EP1478790 A1 EP 1478790A1 EP 02712931 A EP02712931 A EP 02712931A EP 02712931 A EP02712931 A EP 02712931A EP 1478790 A1 EP1478790 A1 EP 1478790A1
Authority
EP
European Patent Office
Prior art keywords
machine part
coating material
coating
heat treatment
layers
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.)
Withdrawn
Application number
EP02712931A
Other languages
German (de)
English (en)
Inventor
Lech Moczulski
Michael Eis Benzon
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.)
MAN B&W Diesel AS
Original Assignee
MAN B&W Diesel AS
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by MAN B&W Diesel AS filed Critical MAN B&W Diesel AS
Publication of EP1478790A1 publication Critical patent/EP1478790A1/fr
Withdrawn legal-status Critical Current

Links

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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • 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
    • C23C4/18—After-treatment
    • 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
    • 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
    • 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

Definitions

  • the present invention relates to a machine part, preferably an engine machine part, coated with a coating material by a thermal spray process and exposed to heat treatment of said coating material at an elevated temperature.
  • the invention also discloses a method of applying a coating to machine parts.
  • machine parts are generally manufactured from a cast-iron blank, which substantially meets the requirements imposed on the material as regards strength and resilience but when heated above certain limits a wear problem arise.
  • the friction forces can be of a large magnitude.
  • the hot environment can lower the strength of the material and rapidly result in great wear on a machine part made of cast iron, which does not possess the required scuffing resistance at high temperatures.
  • a cast-iron engine part therefore often is provided with a wear-resistant layer or a running-in layer on the surfaces most exposed to wear.
  • Thermal spraying is conveniently used to apply coatings on e.g. iron blanks.
  • the resulting coating comprises a fraction of loose particles. These loose particles increase the risk for "three-body- abrasion" between the sliding surfaces of two machine parts. Three-body-abrasion is often causing the process of gradual wearing indicated in the above.
  • 5,268,045 provides an example of such a prior art coating method, wherein the work piece to be coated is electro- chemically cleaned, thermal spray coated with a metal or metals in order to provide an overlay coating and post heat treated at an elevated temperature, to diffuse said metal or metals into the surface of the work piece.
  • the coating will reach its melting temperature and there is a risk that also the underlying substrate is affected in such a way that stress is induced in the substrate.
  • a hard coating with reduced ductility is obtained. This is an issue for coatings on substrates and often for coatings on curve shaped blanks. When a coating applied to a blank is heated the blank will also be heated and it will consequently lead to an expansion of the machine part blank.
  • the object of the present invention is to provide a method of applying a coating, particularly intended for machine parts, that meets the requirements necessary re- garding wear resistance, resilience, anti-corrosiveness, hardness, thermal stability and ductility.
  • Another object is to provide a coated machine part, which does not suffer from the above drawbacks found in the prior art.
  • Other features and advantages of the present invention will become apparent from the following description of the invention.
  • the present invention provides a method of applying a coating material to at least part of a surface of a ma- chine part, said method comprising the following steps, application of said coating material by a thermal spray process, heat treatment of said coating material at an elevated temperature and for a time effective to at least partially diffuse said coating material into the underly- ing surface, and to apply an additional coating material layer subject to successive heat treatments of each said coating material layer in order to lay down on said machine part surface a plurality of layers of same said coating material, wherein said heat treatment result in formation of necks in contact points between particles of at least said coating.
  • a strong bond between the coating material and the machine part surface as well as internally strong bonds within the coating is formed.
  • the coating material By controlling the heating temperature, to which the coating material is exposed when applied on the machine part the coating material will develop necks in contact points (microwelds) between particles in said coating and machine part surface resulting in a strong bond between said particles.
  • the contact point necks are developed by exposing said material to heating temperature below or close to the melting point of the coating material .
  • a coating material intended for machine parts typically comprises a matrix material and a reinforcement material. Conveniently, but not exclusively, the coating material applied to the machine part is in the range of 60 to 80% of the melting temperature of the reinforcement material of the coating.
  • the matrix material will accordingly be exposed to heat near its melting temperature during short periods in time causing the formation of said necks in the material .
  • a coating comprising open pores between the particles of the coating.
  • the thermal spray device and a heat treatment device are connected and moved relatively to a machine part, while applying said coating material and heat treatment to said machine part .
  • induction heating is preferably used.
  • Heat treatment by induction heating is considered effective and cost efficient but also other alternatives known by a person skilled in the art can be used.
  • One such other alternative is laser.
  • the resulting machine part coating has an evenly distributed porosity.
  • said resulting machine part coating has a porosity of between 1 to 15 vol%.
  • the coating material comprising the yielded pores hence has the possibility to absorb deformations and imperfections caused by induced stress during use.
  • each of said coating material layers typically have a thickness of between 0.005 to 0.40 mm.
  • the thickness of one layer according to the inven- tive method is around 0.01 mm.
  • the thickness of one coating layer according to the inventive method is conveniently between 0.005 to 0.10 mm in order to develop the desired necks in the contact points between particles of the coating layer during heat exposure.
  • the coating material is of pulverulent type when fed to said thermal spray process.
  • said coating material has a wire like form when fed to said thermal spray process in order to achieve an efficient and controlled manufacturing process.
  • the method is applied on a machine part comprising a curve shaped surface on which curve shaped surface said coating material is applied at least on some zones.
  • the method is particularly well suited since problems with induced stress using conventional coating techniques on curve shaped machine parts are particularly difficult as mentioned in the background art.
  • said machine part is preheated before the step of applying said coating material.
  • a machine part coated with a coating material by a thermal spray process, exposed to heat treatment of said coating material at an elevated temperature and for a time effective to at least partially diffuse said coating material into the underlying surface, and an additionally applied coating material layer subject to suc- cessive heat treatments of each said coating material layer in order to provide on said machine part surface a plurality of layers of same said coating material, said coating material comprising necks in contact points between particles in at least said coating.
  • a strong bond between the coating material and the machine part surface as well as internally strong bonds within the coating are achieved.
  • the coating material By controlling the heat, to which the coating material is exposed when applied on the machine part the coating material will develop necks in contact points (microwelds) between particles in said coating and machine part surface resulting in a strong bond between said particles.
  • the contact point necks are developed by exposing said material to heat below the melting point of the material.
  • the elevated heat treatment of the coating material on the machine part is applied within the range of 60 to 80% of the melting temperature of a reinforcement material used for the coat- ing.
  • a material creating open pores between the particles of the coating is provided.
  • the coating material is chosen from the group of at least one of the groups of the following materials: metals, metal alloys, carbides, silicates, ceramics, ox- ides, cermets and mixtures thereof.
  • the coating material comprises a metallic compound chosen from a group consisting of Cr 3 C 2/ Cr 2 0 3/ CuAl and Al 2 0 3 . These compounds and metal alloys have proven well adapted for the making of machine part coatings of high quality with excellent wear and sliding performances.
  • the coating according to a preferred embodiment comprises a mixture partly in the form of metal, partly in the form of reinforcement .
  • the coating material is a cermet. Cermet is a group of coatings that combine a ceramic and a metal or alloy. A frequently used example is Chrome Carbide (the ceramic constituent) in a Nickel/Chrome matrix.
  • each of o'ne said coating material layers typically have a thickness of between 0.005 to 0.10 mm.
  • the thickness of one layer according to the inventive machine part is around 0.01 mm.
  • the thickness of a coating layer according to the inventive machine part is conveniently between 0.005 to 0.10 mm in order to develop the desired necks in the contact points between particles of the coating layer during manufactur- ing.
  • the total thickness of the coating depends on the size and type of machine part. For machine parts used in marine diesel engines a total thickness of the coating can be up to around 5 mm.
  • Fig. 1 is a schematic representation of an arrange- ment for using the method of applying a coating material to a machine part according to the present invention.
  • Fig. 2 is a schematic representation of a part of a machine part comprising a coating in accordance with the invention.
  • Fig. 3 is a schematic representation of an enlarged partial view of fig. 2 in accordance with the present invention.
  • Fig. 4 is a schematic representation of an example of a resulting coating using another prior art method.
  • a machine part 1 is arranged for being provided with a coating.
  • the coating manufacturing arrangement further comprises a thermal spraying device 3 and a heat treatment device 5.
  • a protective cover (not shown) is provided for covering surrounding elements from e.g. spraying.
  • an inductor constitutes the heat treatment device 5.
  • the inductor 5 can be applied in a number of ways depending on the size of the machine part 1. In the present embodiment more than one inductor 5 is shown.
  • a cleaned machine part 1 is arranged to be treated by the coating arrangement.
  • the machine part is preferably a cast-iron blank.
  • a coating material 4 is applied to the desired parts of the machine part 1 by means of thermal spraying.
  • the thermal spraying device 3 conven- iently uses e.g. plasma, arc, HVOF, or flame spraying technology, which is considered well known for a person skilled in the art .
  • the machine part 1 is continuously moved in relation to the thermal spraying device 3 and heat treatment de- vice 5 or vice versa during the spraying and instantly the coating material can be subject to heat treatment at elevated temperature.
  • the periphery speed of the machine part surface to be coated is around 20 m/min in relation to the thermal spraying device when applying the coating material and heat treatment .
  • the coating according to a preferred embodiment comprises a mixture partly in the form of metal, partly in the form of a reinforcement material.
  • the coating mate- rial is preferably heated to between 60 to 80 % of the melting temperature of the reinforcement material in said coating during a short period of time.
  • each cycle of applying the coating material 4 and heating the coating material 4 will result in a new coat- ing layer 24 on the machine part surface, which is illustrated in Fig. 2.
  • Fig. 2 only three layers 24 are shown to illustrate the principle, but normally more than 10 layers will be applied and preferably more than 50.
  • the number of layers 24 of course depends on e.g. the thickness of the layers 24 etc.
  • each coating layer 24 has a thickness of typically 0.01 mm.
  • the total thickness of the applied coating 24a of a machine part 1 is preferably around 0.8 mm, but possibly up to around 5 mm.
  • the coating material 4 comprises a metallic compound chosen from a group consisting of e.g. Cr 2 0 3 and Al 2 0 3 . These compounds and metal alloys have proven to result in machine part coat- ings of high quality.
  • the coating material is a cermet. Cermet is a group of coatings that combine at least a ceramic and at least a metal or an alloy. A frequently used example is Chrome Carbide (the ceramic constituent) in a Nickel/Chrome matrix. It is anticipated that a person skilled in the art may use other ceramic compounds, alloys and cermets (not mentioned here in detail) in order to provide a coating on a machine part according to the invention.
  • a strong bond between the coating material 4 and the machine part surface 22 as well as internally strong bonds within the coating is achieved.
  • the coating material 4 will be forced to develop necks (microwelds) in contact points between particles in said coating and machine part surface resulting in a strong bond between said particles.
  • the elevated heat treatment of the coating material on the machine part is in the range of 60 to 80% of the melting temperature of at least the reinforcement material of said coating material .
  • a coating of a machine part which coating comprises open pores between the particles 21 of the coating.
  • the contact point necks 23 are developed by exposing said material to heat below the melting point of the material.
  • the contact point necks 23 provides additional strength to the coating.
  • the step of exposing the coating to an elevated temperature will hence cause a significantly stronger bond compared to the mechanical bonding normally achieved by just thermal spraying.
  • Fig. 4 the effect of applying excessive heat, which for other applications might be beneficial but not for these types of machine part coatings, to a coating layer or an entire coating of a substrate is shown.
  • the coating material When applying excessive heat during coating of a substrate the coating material will melt. In order to be able to compare the size of the illustrated coated part in Fig. 3 it has a size that is about equal to that of Fig. 4. It can be seen that the coating in Fig. 4 show a significant decrease in porosity, the porosity is not evenly distrib- uted, and that the pores are closed.
  • the inventive coating is suitably applied on sliding surfaces of machine parts, which are exposed to wear.
  • the coating can be used on sliding surfaces in pumps, hydraulic pumps, and fire extinguishing pumps.
  • the inventive coating is particularly suitable for coating machine parts used in internal combustion engines, and most preferably in marine diesel engines .
  • the coating is applied to at least parts of the sliding surface of a cylinder liner.
  • the cylinder liner could either be fully coated or coated in a predetermined pattern on desired parts.
  • One example of such a coating pattern is a helical geometry on the inside surface of the cylinder liner.
  • the machine part is a piston, a piston rod or a piston skirt. It is considered particularly suitable to provide a coating of the annular grooves of a piston with the inventive coating. According to yet another alternative embodiment of the invention the coating is applied partly or fully on certain parts of the inner sliding surface of stuffing box rings. Other alternative embodiments, on which the coating according to the invention may be applied are on at least suitable parts of a cam shaft and/or a crank shaft and sliding surfaces of camshaft cams.
  • a sliding surface of a fuel pump is provided with the inventive coating material.
  • a coating may be provided on heat and wear loaded parts of inlet valves and/or outlet valves, which valves are preferably used in large two-stroke diesel engines.

Landscapes

  • 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)
  • Coating By Spraying Or Casting (AREA)
  • Cylinder Crankcases Of Internal Combustion Engines (AREA)

Abstract

L'invention concerne une surface d'une partie d'une machine (22) revêtue au moins partiellement au moyen d'un matériau de revêtement par un procédé de pulvérisation thermique. Le matériau de revêtement a été exposé à un traitement thermique à une température élevée et pendant une durée permettant au moins de diffuser partiellement le matériau de revêtement dans une surface sous-jacente, créant ainsi des saillies entre le matériau de revêtement et la surface sous-jacente. De plus, des couches de matériau de revêtement (24) sont appliquées et soumises individuellement à des traitements thermiques successifs, de manière à déposer sur la surface de la partie de la machine (22) une pluralité de couches (24) du même matériau de revêtement (24), de manière que celui-ci forme des saillies (23) dans des points de contact entre des particules (21) et des couches dans au moins le revêtement. L'invention concerne également un procédé de préparation de tel revêtement sur une surface d'une partie d'une machine.
EP02712931A 2002-02-28 2002-02-28 Pulverisation thermique d'une partie d'une machine Withdrawn EP1478790A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2002/002151 WO2003072844A1 (fr) 2002-02-28 2002-02-28 Pulverisation thermique d'une partie d'une machine

Publications (1)

Publication Number Publication Date
EP1478790A1 true EP1478790A1 (fr) 2004-11-24

Family

ID=27763319

Family Applications (1)

Application Number Title Priority Date Filing Date
EP02712931A Withdrawn EP1478790A1 (fr) 2002-02-28 2002-02-28 Pulverisation thermique d'une partie d'une machine

Country Status (7)

Country Link
EP (1) EP1478790A1 (fr)
JP (1) JP2005519190A (fr)
KR (1) KR100820987B1 (fr)
CN (1) CN100385033C (fr)
AU (1) AU2002244734A1 (fr)
NO (1) NO20044022L (fr)
WO (1) WO2003072844A1 (fr)

Families Citing this family (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102010017859B4 (de) * 2010-04-22 2012-05-31 Mtu Aero Engines Gmbh Verfahren zum Bearbeiten einer Oberfläche eines Bauteils
KR102633626B1 (ko) * 2019-11-21 2024-02-02 코오롱인더스트리 주식회사 표면코팅체

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3066042A (en) * 1959-11-27 1962-11-27 Engelhard Ind Inc Method of coating metal
US3615099A (en) * 1969-02-26 1971-10-26 Ramsey Corp Multiple layer faced piston rings
DE3137731A1 (de) * 1981-09-23 1983-04-14 Battelle-Institut E.V., 6000 Frankfurt Hochtemperatur- und thermoschockbestaendige kompaktwerkstoffe und beschichtungen
US5143139A (en) * 1988-06-06 1992-09-01 Osprey Metals Limited Spray deposition method and apparatus thereof
JP2858013B2 (ja) * 1989-08-03 1999-02-17 ティーディーケイ株式会社 光記録方法
US5897921A (en) * 1997-01-24 1999-04-27 General Electric Company Directionally solidified thermal barrier coating
WO1999043861A1 (fr) * 1998-02-28 1999-09-02 General Electric Company Revetement de liaison multicouche pour systeme de revetement a barriere thermique et procede y relatif
SE519494C2 (sv) * 2000-07-14 2003-03-04 Koncentra Verkst S Ab Komposit för beläggning av kolvringar, kolvring och sätt att framställa kompositen

Non-Patent Citations (1)

* Cited by examiner, † Cited by third party
Title
See references of WO03072844A1 *

Also Published As

Publication number Publication date
NO20044022L (no) 2004-09-24
CN1630734A (zh) 2005-06-22
KR100820987B1 (ko) 2008-04-10
WO2003072844A1 (fr) 2003-09-04
AU2002244734A1 (en) 2003-09-09
JP2005519190A (ja) 2005-06-30
CN100385033C (zh) 2008-04-30
KR20040088544A (ko) 2004-10-16

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