EP1825016A1 - Method for coating a workpiece - Google Patents

Method for coating a workpiece

Info

Publication number
EP1825016A1
EP1825016A1 EP05820936A EP05820936A EP1825016A1 EP 1825016 A1 EP1825016 A1 EP 1825016A1 EP 05820936 A EP05820936 A EP 05820936A EP 05820936 A EP05820936 A EP 05820936A EP 1825016 A1 EP1825016 A1 EP 1825016A1
Authority
EP
European Patent Office
Prior art keywords
coating
workpiece
aggregate
fluorescent marker
injection process
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.)
Granted
Application number
EP05820936A
Other languages
German (de)
French (fr)
Other versions
EP1825016B1 (en
Inventor
Manuel Hertter
Andreas Jakimov
Wolfgang Wachter
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.)
MTU Aero Engines AG
Original Assignee
MTU Aero Engines GmbH
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 MTU Aero Engines GmbH filed Critical MTU Aero Engines GmbH
Publication of EP1825016A1 publication Critical patent/EP1825016A1/en
Application granted granted Critical
Publication of EP1825016B1 publication Critical patent/EP1825016B1/en
Not-in-force legal-status Critical Current
Anticipated expiration legal-status Critical

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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
    • C23C4/18—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
    • 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
    • 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

Definitions

  • the invention relates to a method for coating a workpiece according to the preamble of patent claim 1.
  • thermal spraying is a coating process in which a thermally active coating material is sprayed or sprayed onto a surface of a workpiece to be coated. Since almost all fusible coating materials can be used, thermal spraying can be used to produce coatings with different properties or functions, such as thermal insulation, corrosion protection or wear protection. In thermal spraying, there are virtually unlimited possible combinations between the material of the article or workpiece to be coated and the thermally active coating material to be used for the coating.
  • thermal spraying methods namely, for example, plasma spraying, arc spraying, flame spraying or else high-speed flame spraying.
  • Cold kinetic compaction is also a thermal spraying process.
  • the selection of the corresponding thermal spraying method depends, for example, on the coating material, the desired properties of the coating and on the respective costs.
  • a porous coating on the workpiece to be coated it is already known, in addition to the actual coating material to apply a aggregate by thermal spraying on the workpiece to be coated, wherein the aggregate is decomposed or dissolved after the thermal spraying so to provide the porous coating.
  • the decomposing aggregate leaves pores in the coating.
  • the decomposition of the aggregate material is carried out in particular by a heat treatment of the coated workpiece. If no porosity is desired, the aggregate material can also remain in the layer and affect the properties of the layer, provided that it does not have a detrimental effect.
  • the present invention based on the problem to provide a novel method for coating a workpiece.
  • a method for coating a workpiece according to claim 1 in addition to the coating material, a aggregate material is applied to the workpiece, in which or on which a fluorescent marker material is firmly bound, wherein the injection process is monitored online that at least the particles of the fluorescent marker material located in a spray jet are detected and evaluated.
  • a coating material is used for coating a workpiece, in which or on which a fluorescent marker material is bound.
  • the fluorescent marker material is recorded online during the injection process.
  • the quality of the porous coating which sets up after the decomposition of the aggregate material can already be concluded during the injection process. This makes it possible for the first time to subject coatings produced by thermal spraying to comprehensive online quality control and thus to dispense with destructive test methods.
  • the aggregate material is decomposed after the injection process together with the fluorescent marker material, in particular by heat treatment of the coated workpiece.
  • the invention relates to a method for coating a workpiece by means of thermal spraying.
  • a coating material is applied to the workpiece together with a aggregate material by thermal spraying, namely sprayed or sprayed.
  • the aggregate is decomposed, in particular, by a heat treatment of the coated workpiece so as to provide a porous coating on the workpiece.
  • the invention will be described below for plasma spraying as a preferred thermal spraying process. However, the invention should not be limited to plasma spraying. Rather, the invention can also be used in other thermal spraying processes, for example in flame spraying, high-speed flame spraying, arc wire spraying or cold kinetic compaction.
  • EP 0 851 720 B1 discloses a plasmatron suitable for plasma spraying.
  • an arc is ignited during plasma spraying between a cathode and an anode of a non-illustrated plasmatron. This arc heats a plasma gas flowing through the plasmatron.
  • the plasma gases used are, for example, argon, hydrogen, nitrogen, helium or mixtures of these gases.
  • a plasma jet sets in, which can reach temperatures of up to 20,000 0 C in the core.
  • the coating material used for coating is injected into the plasma jet using a carrier gas.
  • this coating material to be used for the coating is accelerated to a high speed by the plasma jet.
  • the accelerated in this way material is applied to the workpiece to be coated, that is sprayed.
  • an aggregate material is also sprayed onto the workpiece to be coated.
  • a spray jet is formed, wherein the spray jet is formed on the one hand by the plasma jet and on the other by the particle beam of the coating material and aggregate material. The particles impinge with high thermal and kinetic energy on a surface of the workpiece to be coated and form a coating there.
  • the desired properties of the coating are formed.
  • a supplemental material is used in the thermal spraying, in which or on which a fluorescent marker material is tied.
  • both the particles of the coating material and the particles of the marker material, which is firmly bound in or on the aggregate, are made to shine, so that the particles of the coating material and the particles of the marker material contained in the spray jet or particle beam can be recorded and evaluated in terms of on-line monitoring.
  • the excitation of the fluorescent marker material and of the coating material can take place, for example, via the plasma jet. Alternatively, the excitation can be accomplished via a laser source, which excites the particles to glow.
  • marker materials are used which shine in a different wavelength range than the coating material. This makes it possible to distinguish in the particle beam, the particles of the coating material from the particles of the marker material and thus the aggregate material.
  • marker materials are used in particular laser dyes whose fluorescence is in the visible wavelength range. Particularly suitable as a laser dye rhodamine 6G, the fluorescence emission maximum is at about 560 nm.
  • Rhodamine 6G can be firmly bound in organic aggregates, such as polyester, by, for example, diffusing Rhodamine 6G into polyester.
  • FIG. 1 shows in highly schematic form a spray jet 10 which adjusts during plasma spraying.
  • the spray jet 10 is optically monitored by a camera 11 through an optical filter 12.
  • the camera 11 is in the illustrated embodiment as a CCD camera educated.
  • the optical filter can be embodied as a gray filter or color filter or bandpass filter. It is also possible to use a plurality of cameras and / or other process control systems, in particular a spectrometer for monitoring the injection process.
  • the image acquired by the camera 11 is supplied to an image processing system not shown in detail.
  • properties of the optically monitored spray jet are determined from the data acquired by the camera 11.
  • the properties of the spray jet 10 determined from the optical monitoring of the spray jet are compared with predetermined desired values for these properties. If a deviation of the determined properties (actual values) of the spray jet from the predetermined values (nominal values) for the properties is detected, the process parameters for the plasma spraying are automatically adapted by a controller.
  • the method described here can also be used in combination with other methods for monitoring the spray jet, in particular the laser-induced fluorescence.
  • the invention is preferably used in the production of porous coatings, it is not limited to this application. Rather, the invention can also be used in the production of solid coatings, in which case the aggregate material with the fluorescent marker material remains in the coating.
  • boron nitride (BN) or benzonite can be incorporated as an aggregate in a massive coating so as to form a predetermined breaking point in the coating. The boron nitride can be detected online during the coating by a fluorescent marker material bound to or in the boron nitride.

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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)
  • Coating By Spraying Or Casting (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

The invention relates to a method for coating a workpiece, whereby a coating material and an aggregate material are applied to the workpiece by thermal spraying. The inventive method is characterized by applying to the workpiece, in addition to the coating material, an aggregate material in which or to which a fluorescent marker material is firmly fixed. The spraying process is monitored online by detecting and evaluating at least the particles of the fluorescent marker material present in the spray jet.

Description

Verfahren zur BeSchichtung eines Werkstücks Process for coating a workpiece
Die Erfindung betrifft ein Verfahren zur Beschichtung eines Werkstücks nach dem Oberbegriff des Patentanspruchs 1.The invention relates to a method for coating a workpiece according to the preamble of patent claim 1.
Aus dem Stand der Technik sind zahlreiche Verfahren zur Beschichtung von Werkstücken bekannt. Beim sogenannten thermischen Spritzen handelt es sich um ein Beschichtungsverfahren, bei welchem ein thermisch aktiver Be- schichtungswerkstoff auf eine zu beschichtende Oberfläche eines Werkstücks gespritzt bzw. gesprüht wird. Da nahezu alle schmelzbaren Be- schichtungswerkstoffe verwendet werden können, lassen sich durch thermisches Spritzen Beschichtungen mit unterschiedlichen Eigenschaften bzw. Funktionen wie zum Beispiel Wärmedämmung, Korrosionsschutz oder Verschleißschutz realisieren. Beim thermischen Spritzen gibt es nahezu unbegrenzte Kombinationsmöglichkeiten zwischen dem Werkstoff des zu beschichtenden Gegenstands bzw. Werkstücks und dem für die Beschichtung zu verwendenden, thermisch aktiven Beschichtungswerkstoff.Numerous methods for coating workpieces are known from the prior art. The so-called thermal spraying is a coating process in which a thermally active coating material is sprayed or sprayed onto a surface of a workpiece to be coated. Since almost all fusible coating materials can be used, thermal spraying can be used to produce coatings with different properties or functions, such as thermal insulation, corrosion protection or wear protection. In thermal spraying, there are virtually unlimited possible combinations between the material of the article or workpiece to be coated and the thermally active coating material to be used for the coating.
Abhängig von der verwendeten Wärmequelle unterscheidet man verschiedene thermischen Spritzverfahren, nämlich zum Beispiel das Plasmaspritzen, Lichtbogenspritzen, Flammspritzen oder auch Hochgeschwindigkeitsflammspritzen. Auch das Kalt Kinetische Kompaktieren ist ein thermisches Spritzverfahren. Die Auswahl des entsprechenden thermischen Spritzverfahrens hängt zum Beispiel vom Beschichtungswerkstoff, den gewünschten Eigenschaften der Beschichtung und von den jeweiligen Kosten ab.Depending on the heat source used, a distinction is made between various thermal spraying methods, namely, for example, plasma spraying, arc spraying, flame spraying or else high-speed flame spraying. Cold kinetic compaction is also a thermal spraying process. The selection of the corresponding thermal spraying method depends, for example, on the coating material, the desired properties of the coating and on the respective costs.
Zur Bereitstellung von zum Beispiel einer porösen Beschichtung auf dem zu beschichtenden Werkstück ist es bereits bekannt, zusätzlich zu dem eigentlichen Beschichtungswerkstoff einen Zuschlagwerkstoff durch thermisches Spritzen auf das zu beschichtende Werkstück aufzutragen, wobei der Zuschlagwerkstoff nach dem thermischen Spritzvorgang zersetzt bzw. aufgelöst wird, um so die poröse Beschichtung bereitzustellen. So hinterlässt der sich zersetzende Zuschlagwerkstoff in der Beschichtung Poren. Das Zersetzen des Zuschlagwerkstoffs erfolgt dabei insbesondere durch eine Wärmebehandlung des beschichteten Werkstücks. Sollte keine Porosität gewünscht sein, kann der Zuschlagswerkstoff - soweit er sich nicht schädlich auswirkt - auch in der Schicht verbleiben und die Eigenschaften der Schicht beeinflussen.To provide, for example, a porous coating on the workpiece to be coated, it is already known, in addition to the actual coating material to apply a aggregate by thermal spraying on the workpiece to be coated, wherein the aggregate is decomposed or dissolved after the thermal spraying so to provide the porous coating. Thus, the decomposing aggregate leaves pores in the coating. The decomposition of the aggregate material is carried out in particular by a heat treatment of the coated workpiece. If no porosity is desired, the aggregate material can also remain in the layer and affect the properties of the layer, provided that it does not have a detrimental effect.
Bei der Beschichtung von Werkstücken mit einem thermischen Spritzverfahren kommt der Qualitätskontrolle der sich einstellenden Beschichtung eine wichtige Rolle zu. Nur dann, wenn die Beschichtung vorgegebene Qualitätskriterien erfüllt, kann das beschichtete Werkstück die Qualitätskontrolle passieren und gegebenenfalls weiterverarbeitet werden. Da die Zuschlagstoffe, die zur Bereitstellung von zum Beispiel einer porösen Beschichtung zusammen mit dem Beschichtungswerkstoff auf das Werkstück aufgetragen werden, im Wege einer Online-Qualitätskontrolle nicht erfasst bzw. detektiert werden können, werden nach dem Stand der Technik zur Qualitätskontrolle zerstörende Prüfmethoden stichprobenartig eingesetzt. Eine das Werkstück zerstörende Qualitätskontrolle ist zum einen kosten- und zeitintensiv, zum anderen können nur stichprobenartige Kontrollen durchgeführt werden.When coating workpieces with a thermal spraying process, quality control of the resulting coating takes place important role too. Only if the coating meets specified quality criteria, the coated workpiece can pass the quality control and optionally further processed. Since the aggregates, which are applied to the workpiece for providing, for example, a porous coating together with the coating material, can not be detected or detected by means of online quality control, destructive testing methods are randomly used according to the state of the art for quality control. On the one hand, a quality control destroying the workpiece is costly and time-consuming, on the other hand only random checks can be carried out.
Hiervon ausgehend liegt der vorliegenden Erfindung das Problem zu Grunde ein neuartiges Verfahren zur Beschichtung eines Werkstücks zu schaffen.On this basis, the present invention based on the problem to provide a novel method for coating a workpiece.
Dieses Problem wird durch ein Verfahren zur Beschichtung eines Werkstücks gemäß Patentanspruch 1 gelöst. Erfindungsgemäß wird zusätzlich zu dem Beschichtungswerkstoff ein Zuschlagwerkstoff auf das Werkstück aufgetragen, in dem bzw. auf dem ein fluoreszierender Markerwerkstoff fest gebunden ist, wobei der Spritzvorgang dadurch online überwacht wird, dass zumindest die in einem Spritzstrahl befindlichen Partikel des fluoreszierenden Markerwerkstoffs erfasst und ausgewertet werden.This problem is solved by a method for coating a workpiece according to claim 1. According to the invention, in addition to the coating material, a aggregate material is applied to the workpiece, in which or on which a fluorescent marker material is firmly bound, wherein the injection process is monitored online that at least the particles of the fluorescent marker material located in a spray jet are detected and evaluated.
Im Sinne des erfindungsgemäßen Verfahrens wird zur Beschichtung eines Werkstücks ein Zuschlagwerkstoff verwendet, in dem bzw. auf dem ein fluoreszierender Markerwerkstoff gebunden ist. Der fluoreszierende Markerwerkstoff wird während des Spritzvorgangs online erfasst. Bei der Herstellung von zum Beispiel porösen Beschichtungen kann so bereits während des Spritzvorgangs auf die Qualität der sich nach dem Zersetzen des Zuschlagwerkstoffs einstellenden, porösen Beschichtung, geschlossen werden. Hierdurch ist es erstmals möglich, durch thermisches Spritzen hergestellte Beschichtungen einer umfassenden Online-Qualitätskontrolle zu unterziehen und damit auf zerstörende Prüfmethoden zu verzichten.For the purposes of the method according to the invention a coating material is used for coating a workpiece, in which or on which a fluorescent marker material is bound. The fluorescent marker material is recorded online during the injection process. In the production of, for example, porous coatings, the quality of the porous coating which sets up after the decomposition of the aggregate material can already be concluded during the injection process. This makes it possible for the first time to subject coatings produced by thermal spraying to comprehensive online quality control and thus to dispense with destructive test methods.
Bei der Herstellung poröser Beschichtungen wird nach dem Spritzvorgang der Zuschlagwerkstoff zusammen mit dem fluoreszierenden Markerwerkstoff insbesondere durch Wärmebehandlung des beschichteten Werkstücks zersetzt.In the production of porous coatings, the aggregate material is decomposed after the injection process together with the fluorescent marker material, in particular by heat treatment of the coated workpiece.
Bevorzugte Weiterbildungen der Erfindung ergeben sich aus den Unteran- sprüchen und der nachfolgenden Beschreibung. Ein Ausführungsbeispiel der Erfindung wird, ohne hierauf beschränkt zu sein, an Hand der Zeichnung näher erläutert. Dabei zeigt: Fig. 1 eine stark schematisierte Darstellung einer Vorrichtung zur Be- schichtung eines Werkstücks zur Verdeutlichung des erfindungsgemäßen Verfahrens.Preferred developments of the invention will become apparent from the subclaims and the following description. An embodiment of the invention will be described, without being limited thereto, with reference to the drawing. Showing: 1 is a highly schematic representation of a device for coating a workpiece to illustrate the method according to the invention.
Nachfolgend wird die hier vorliegende Erfindung unter Bezugnahme auf Fig. 1 am Beispiel der Herstellung einer porösen Beschichtung in größerem Detail beschrieben.Hereinafter, the present invention will be described in more detail with reference to FIG. 1 by the example of producing a porous coating.
Die Erfindung betrifft ein Verfahren zur Beschichtung eines Werkstücks mittels thermischem Spritzen. Hierzu wird ein Beschichtungswerkstoff zusammen mit einem Zuschlagwerkstoff durch thermisches Spritzen auf das Werkstück aufgetragen, nämlich gespritzt bzw. gesprüht. Nach dem thermischen Spritzvorgang wird der Zuschlagwerkstoff insbesondere durch eine Wärmebehandlung des beschichteten Werkstücks zersetzt, um so eine poröse Beschichtung auf dem Werkstück bereitzustellen.The invention relates to a method for coating a workpiece by means of thermal spraying. For this purpose, a coating material is applied to the workpiece together with a aggregate material by thermal spraying, namely sprayed or sprayed. After the thermal spraying operation, the aggregate is decomposed, in particular, by a heat treatment of the coated workpiece so as to provide a porous coating on the workpiece.
Nachfolgend wird die Erfindung für das Plasmaspritzen als bevorzugtes thermisches Spritzverfahren beschrieben. Die Erfindung soll jedoch nicht auf das Plasmaspritzen beschränkt sein. Vielmehr kann die Erfindung auch bei anderen thermischen Spritzverfahren, so zum Beispiel beim Flammspritzen, Hochgeschwindigkeitsflammspritzen, Lichtbogendrahtspritzen oder beim Kalt Kinetischen Kompaktieren, zum Einsatz kommen.The invention will be described below for plasma spraying as a preferred thermal spraying process. However, the invention should not be limited to plasma spraying. Rather, the invention can also be used in other thermal spraying processes, for example in flame spraying, high-speed flame spraying, arc wire spraying or cold kinetic compaction.
Das Plasmaspritzen als solches ist aus dem Stand der Technik hinlänglich bekannt. So offenbart zum Beispiel die EP 0 851 720 Bl ein für das Plasmaspritzen geeignetes Plasmatron. Der Vollständigkeit halber soll lediglich angemerkt werden, dass beim Plasmaspritzen zwischen einer Kathode und einer Anode eines nicht-dargestellten Plasmatrons ein Lichtbogen gezündet wird. Dieser Lichtbogen erhitzt ein durch das Plasmatron strömendes Plasmagas. Als Plasmagase werden zum Beispiel Argon, Wasserstoff, Stickstoff, Helium oder Gemische dieser Gase verwendet. Durch das Erhitzen des Plasmagases stellt sich ein Plasmastrahl ein, der im Kern Temperaturen von bis 20.0000C erreichen kann. Der zur Beschichtung verwendete Beschichtungswerkstoff wird mithilfe eines Trägergases in den Plasmastrahl injiziert. Des weiteren wird dieser für die Beschichtung zu verwendende Beschichtungswerkstoff durch den Plasmastrahl auf eine hohe Geschwindigkeit beschleunigt. Der auf diese Art und Weise beschleunigte Werkstoff wird auf das zu beschichtende Werkstück aufgetragen, nämlich aufgespritzt. Zur Bereitstellung der porösen Beschichtung wird neben dem Beschichtungs- werkstoff auch ein Zuschlagwerkstoff auf das zu beschichtende Werkstück aufgespritzt. Hierbei bildet sich ein Spritzstrahl aus, wobei der Spritzstrahl zum einen von dem Plasmastrahl und zum anderen von dem Partikelstrahl des Beschichtungswerkstoffs und Zuschlagwerkstoffs gebildet wird. Die Partikel prallen mit einer hohen thermischen sowie kinetischen Energie auf eine Oberfläche des zu beschichtenden Werkstücks auf und bilden dort eine Beschichtung. Abhängig von den Parametern des Spritzprozesses bilden sich die gewünschten Eigenschaften der Beschichtung aus.As such, plasma spraying is well known in the art. For example, EP 0 851 720 B1 discloses a plasmatron suitable for plasma spraying. For the sake of completeness, it should merely be noted that an arc is ignited during plasma spraying between a cathode and an anode of a non-illustrated plasmatron. This arc heats a plasma gas flowing through the plasmatron. The plasma gases used are, for example, argon, hydrogen, nitrogen, helium or mixtures of these gases. By heating the plasma gas, a plasma jet sets in, which can reach temperatures of up to 20,000 0 C in the core. The coating material used for coating is injected into the plasma jet using a carrier gas. Furthermore, this coating material to be used for the coating is accelerated to a high speed by the plasma jet. The accelerated in this way material is applied to the workpiece to be coated, that is sprayed. To provide the porous coating, in addition to the coating material, an aggregate material is also sprayed onto the workpiece to be coated. In this case, a spray jet is formed, wherein the spray jet is formed on the one hand by the plasma jet and on the other by the particle beam of the coating material and aggregate material. The particles impinge with high thermal and kinetic energy on a surface of the workpiece to be coated and form a coating there. Depending on the parameters of the injection process, the desired properties of the coating are formed.
Im Sinne der hier vorliegenden Erfindung wird beim thermischen Spritzen ein Zuschlagwerkstoff verwendet, in dem bzw. auf dem ein fluoreszierender Markerwerkstoff festgebunden ist. Beim thermischen Spritzen werden sowohl die Partikel des Beschichtungswerkstoffs als auch die Partikel des Markerwerkstoffs, der in dem bzw. auf dem Zuschlagwerkstoff fest gebunden ist, zum Leuchten angeregt, so dass die in dem Spritzstrahl bzw. Partikelstrahl enthaltenen Partikel des Beschichtungswerkstoffs und die Partikel des Markerwerkstoffs im Sinne einer OnIine-Überwachung erfasst und ausgewertet werden können. Die Anregung des fluoreszierenden Markerwerkstoffs sowie des Beschichtungswerkstoffs kann zum Beispiel über den Plasmastrahl erfolgen. Alternativ kann die Anregung über eine Laserquelle bewerkstelligt werden, welche die Partikel zum Leuchten anregt.For the purposes of the present invention, a supplemental material is used in the thermal spraying, in which or on which a fluorescent marker material is tied. During thermal spraying, both the particles of the coating material and the particles of the marker material, which is firmly bound in or on the aggregate, are made to shine, so that the particles of the coating material and the particles of the marker material contained in the spray jet or particle beam can be recorded and evaluated in terms of on-line monitoring. The excitation of the fluorescent marker material and of the coating material can take place, for example, via the plasma jet. Alternatively, the excitation can be accomplished via a laser source, which excites the particles to glow.
In diesem Zusammenhang soll darauf hingewiesen werden, dass Markerwerkstoffe verwendet werden, die in einem anderen Wellenlängenbereich leuchten als der Beschichtungswerkstoff. Hierdurch wird es möglich, im Partikelstrahl die Partikel des Beschichtungswerkstoffs von den Partikeln des Markerwerkstoffs und damit des Zuschlagwerkstoffs zu unterscheiden. Als Markerwerkstoffe finden insbesondere Laserfarbstoffe Verwendung, deren Fluoreszenz im sichtbaren Wellenlängenbereich liegt. Insbesondere eignet sich als Laserfarbstoff Rhodamin 6G, dessen Fluoreszenz-Emissionsmaximum bei ca. 560 nm liegt. Rhodamin 6G kann in organischen Zuschlagstoffen, wie Polyester, fest gebunden werden, indem zum Beispiel Rhodamin 6G in Polyester eindiffundiert wird.In this context, it should be noted that marker materials are used which shine in a different wavelength range than the coating material. This makes it possible to distinguish in the particle beam, the particles of the coating material from the particles of the marker material and thus the aggregate material. As marker materials are used in particular laser dyes whose fluorescence is in the visible wavelength range. Particularly suitable as a laser dye rhodamine 6G, the fluorescence emission maximum is at about 560 nm. Rhodamine 6G can be firmly bound in organic aggregates, such as polyester, by, for example, diffusing Rhodamine 6G into polyester.
Die Überwachung und Auswertung des Spritzvorgangs erfolgt, wie bereits erwähnt, mit Hilfe von Online-Prozesskontroll- bzw. -regelsystemen. Die Überwachung und Auswertung des Spritzvorgangs wird nachfolgend unter Bezugnahme auf Fig. 1 erläutert. Fig. 1 zeigt stark schematisiert einen sich beim Plasmaspritzen einstellenden Spritzstrahl 10. Der Spritzstrahl 10 wird mit einer Kamera 11 durch ein optisches Filter 12 optisch überwacht. Die Kamera 11 ist im gezeigten Ausführungsbeispiel als CCD-Kamera ausgebildet. Das optische Filter kann als Graufilter oder Farbfilter oder Bandpassfilter ausgeführt sein. Auch können mehrere Kameras und/oder andere Prozesskontrollsysteme, insbesondere ein Spektrometer zur Überwachung des Spritzvorgangs verwendet werden.The monitoring and evaluation of the injection process takes place, as already mentioned, with the aid of online process control systems. The monitoring and evaluation of the injection process will be explained below with reference to FIG. FIG. 1 shows in highly schematic form a spray jet 10 which adjusts during plasma spraying. The spray jet 10 is optically monitored by a camera 11 through an optical filter 12. The camera 11 is in the illustrated embodiment as a CCD camera educated. The optical filter can be embodied as a gray filter or color filter or bandpass filter. It is also possible to use a plurality of cameras and / or other process control systems, in particular a spectrometer for monitoring the injection process.
Das von der Kamera 11 erfasste bzw. ermittelte Bild wird einem im Detail nicht-dargestellten Bildverarbeitungssystem zugeführt. Im Bildverarbeitungssystem werden Eigenschaften des optisch überwachten Spritzstrahls aus den von der Kamera 11 erfassten Daten ermittelt. Die aus der optischen Überwachung des Spritzstrahls ermittelten Eigenschaften des Spritzstrahls 10 werden mit vorgegebenen Sollwerten für diese Eigenschaften verglichen. Wird eine Abweichung der ermittelten Eigenschaften (Istwerte) des Spritzstrahls von den vorbestimmten Werten (Sollwerten) für die Eigenschaften erkannt, so erfolgt eine automatische Anpassung der Prozessparameter für das Plasmaspritzen durch einen Regler.The image acquired by the camera 11 is supplied to an image processing system not shown in detail. In the image processing system, properties of the optically monitored spray jet are determined from the data acquired by the camera 11. The properties of the spray jet 10 determined from the optical monitoring of the spray jet are compared with predetermined desired values for these properties. If a deviation of the determined properties (actual values) of the spray jet from the predetermined values (nominal values) for the properties is detected, the process parameters for the plasma spraying are automatically adapted by a controller.
Das hier beschriebene Verfahren kann selbstverständlich auch in Kombination mit anderen Methoden zur Überwachung des Spritzstrahls, insbesondere der Laser-induzierten Fluoreszenz, angewendet werden.Of course, the method described here can also be used in combination with other methods for monitoring the spray jet, in particular the laser-induced fluorescence.
Abschließend sei darauf hingewiesen, dass die Erfindung zwar bevorzugt bei der Herstellung poröser Beschichtungen verwendet wird, jedoch nicht auf diesen Anwendungsfall beschränkt ist. Vielmehr kann die Erfindung auch bei der Herstellung massiver Beschichtungen angewendet werden, wobei dann der Zuschlagwerkstoff mit dem fluoreszierenden Markerwerkstoff in der Beschichtung verbleibt. So kann zum Beispiel Bornitrid (BN) oder Ben- tonit als Zuschlagstoff in eine massive Beschichtung eingebracht werden, um so eine Sollbruchstelle in der Beschichtung auszubilden. Das Bornitrid ist bei der Beschichtung durch einen auf bzw. in dem Bornitrid gebundenen, fluoreszierenden Markerwerkstoff online erfassbar. Finally, it should be noted that while the invention is preferably used in the production of porous coatings, it is not limited to this application. Rather, the invention can also be used in the production of solid coatings, in which case the aggregate material with the fluorescent marker material remains in the coating. For example, boron nitride (BN) or benzonite can be incorporated as an aggregate in a massive coating so as to form a predetermined breaking point in the coating. The boron nitride can be detected online during the coating by a fluorescent marker material bound to or in the boron nitride.

Claims

Patentansprüche claims
1. Verfahren zur Beschichtung eines Werkstücks, wobei ein Beschich- tungswerkstoff und ein Zuschlagwerkstoff durch thermisches Spritzen auf das Werkstück aufgetragen werden, dadurch gekennzeichnet, dass zusätzlich zu dem Beschichtungswerkstoff ein Zuschlagwerkstoff auf das Werkstück aufgetragen wird, in dem bzw. auf dem ein fluoreszierender Markerwerkstoff fest gebunden ist, wobei der Spritzvorgang dadurch online überwacht wird, dass zumindest die in einem Spritzstrahl befindlichen Partikel des fluoreszierenden Markerwerkstoffs erfasst und ausgewertet werden.1. A method for coating a workpiece, wherein a coating material and a aggregate material are applied by thermal spraying on the workpiece, characterized in that in addition to the coating material, a aggregate material is applied to the workpiece, in which or on a fluorescent marker material is firmly bound, wherein the injection process is monitored online that at least the particles of the fluorescent marker material located in a spray jet are detected and evaluated.
2. Verfahren nach Anspruch 1, dadurch gekennzeichnet, dass nach dem Spritzvorgang der Zuschlagwerkstoff insbesondere durch Wärmebehandlung des beschichteten Werkstücks zersetzt wird, um so die poröse Beschichtung bereitzustellen.2. The method according to claim 1, characterized in that after the injection process, the aggregate material is decomposed, in particular by heat treatment of the coated workpiece, so as to provide the porous coating.
3. Verfahren nach Anspruch 2, dadurch gekennzeichnet, dass nach dem Spritzvorgang der Zuschlagwerkstoff zusammen mit dem fluoreszierenden Markerwerkstoff insbesondere durch Wärmebehandlung des beschichteten Werkstücks zersetzt wird.3. The method according to claim 2, characterized in that is decomposed after the injection process, the aggregate material together with the fluorescent marker material in particular by heat treatment of the coated workpiece.
4. Verfahren nach einem oder mehreren der Ansprüche 1 bis 3, dadurch gekennzeichnet, dass als Zuschlagwerkstoff ein organischer Zuschlagwerkstoff, insbesondere Polyester, verwendet wird.4. The method according to one or more of claims 1 to 3, characterized in that the aggregate material is an organic aggregate, in particular polyester, is used.
5. Verfahren nach einem oder mehreren der Ansprüche 1 bis 4, dadurch gekennzeichnet, dass als fluoreszierenden Markerwerkstoff ein Laserfarbstoff, insbesondere Rhodamin 6G, verwendet wird.5. The method according to one or more of claims 1 to 4, characterized in that a laser dye, in particular rhodamine 6G, is used as the fluorescent marker material.
6. Verfahren nach einem oder mehreren der Ansprüche 1 bis 5, dadurch gekennzeichnet, dass der fluoreszierende Markerwerkstoff beim Spritzvorgang zum Leuchten angeregt und mit einer Kamera erfasst wird. 6. The method according to one or more of claims 1 to 5, characterized in that the fluorescent marker material is excited to illuminate during the injection process and detected by a camera.
EP05820936A 2004-12-10 2005-11-30 Method for coating a workpiece Not-in-force EP1825016B1 (en)

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DE502005004056D1 (en) 2008-06-19

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