EP2576863B1 - Method for producing a layer by means of cold spraying and use of such a layer - Google Patents

Method for producing a layer by means of cold spraying and use of such a layer Download PDF

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Publication number
EP2576863B1
EP2576863B1 EP11723054.0A EP11723054A EP2576863B1 EP 2576863 B1 EP2576863 B1 EP 2576863B1 EP 11723054 A EP11723054 A EP 11723054A EP 2576863 B1 EP2576863 B1 EP 2576863B1
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Prior art keywords
layer
particles
substrate
cold gas
workpiece
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German (de)
French (fr)
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EP2576863A1 (en
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Axel Arndt
Christian Doye
Oliver Stier
Raymond Ullrich
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Siemens AG
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Siemens AG
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D—PROCESSES FOR APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05D1/00—Processes for applying liquids or other fluent materials
    • B05D1/02—Processes for applying liquids or other fluent materials performed by spraying
    • B05D1/12—Applying particulate materials
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles

Definitions

  • the invention relates to a method for producing a layer which is resistant to abrasive wear, for example particle erosion, on a workpiece by cold gas spraying.
  • particles are accelerated towards the surface of the substrate to be coated and remain attached to the substrate at the point of impact.
  • a layer sprayed with cold gas is produced, the invention furthermore relating to the use of such a porous layer.
  • a cold gas spraying system which has a gas heating device for heating a gas.
  • a stagnation chamber is connected to the gas heating device and is connected on the outlet side to a convergent-divergent nozzle, preferably a Laval nozzle.
  • Convergent-divergent nozzles have a converging section and an expanding section which are connected by a nozzle neck. On the output side, the convergent-divergent nozzle generates a powder jet in the form of a gas stream with particles therein at high speed, so that the kinetic energy of the particles is sufficient for them to adhere to the surface to be coated.
  • a layer resistant to abrasive wear is, for example, by RS Lima et al., "Microstructural Characteristics of Cold-Sprayed Nanostructured WC-Co-Coatings", Thin Solid Films 416 (2002), pp. 129-135 described.
  • the wear of such a hard layer depends primarily on how hard the particles are in the abrasive medium. If the abrasive medium itself has a hardness similar to that of WC, wear protection layers containing WC also show a comparatively high abrasive wear. From the EP 1 921 181 A1 describes a method of applying abrasive material to a seal base material to form an abradable seal with a low abrasive wear resistance between rotating and stationary components of turbines, using cold gas spraying to control the density, porosity and thickness of the seal layer.
  • US 2007/0240603 A1 discloses a coated member on which a porous metal coating layer is formed and a method of manufacturing the same.
  • a model study of powder particle size effects in cold spray deposition (D. Helfrich and V. Champagne) an experimental model of the effect of powder size on the deposition efficiency in a cold spray process is presented.
  • the object of the invention is to provide a method for producing a layer which is resistant to abrasive wear and can be used to produce layers which have a comparatively high abrasive wear resistance.
  • the particles made of Zn and / or Sn and / or Cu and / or an alloy containing at least one of these metals as the main component.
  • the speed of the particles hitting the substrate is adjusted so that the layer formed from these particles is porous and the grain size of the layer structure essentially corresponds to the particle size.
  • the pores that form in the structure of the layer thus lie exactly between the particles, while the shape of the particles is largely retained by adjusting the process parameters during cold gas spraying.
  • the comparatively high porosity of the coating result creates a loose metal structure, so to speak, with the selected metals exhibiting ductile behavior.
  • the permanent layer is subsequently stressed, for example, by particle erosion, there is first a plastic deformation of the particles in the layer, which leads to a solidification of the structure and a reduction in its porosity, but ensures that the attack by the abrasive Particles only a small material removal of the layer can be observed.
  • the stress on the permanent layer by the particles can therefore be described as a type of micro-forging, the plastic deformation of the particles in the structure of the permanent layer leading to the fact that material removal is largely avoided.
  • the particles have an average particle size of 2 to 5 ⁇ m.
  • Particle size in the sense of the invention is to be understood as the mean diameter of the particles, which can be determined statistically by known methods. Particles that are not round also have such an average diameter so that their particle size can be specified.
  • the choice of relatively fine particles advantageously leads to a microporosity of the layer, so that it can withstand the particle erosion particularly effectively by plastic deformation of the porous particle composite according to the mechanism described above.
  • an adhesion promoter layer in particular a layer of Ni, is applied to the substrate before the layer is applied, said layer holding the layer in place by forming common diffusion zones or intermetallic phases.
  • This measure in particular also enables the permanent layer to be applied to substrates which in themselves form a poor substrate for the selected metals. The permanent layer with good adhesion can then be deposited on the adhesion promoter layer, which itself adheres well to the substrate.
  • a porous cold gas sprayed layer which consists of Zn and / or Sn and / or Cu and / or an alloy containing at least one of these metals as the main component, as a protective layer on a workpiece to be protected against abrasive wear, with between the cold gas sprayed particles are pores.
  • a porous cold gas sprayed layer which consists of Zn and / or Sn and / or Cu and / or an alloy containing at least one of these metals as the main component, as a protective layer on a workpiece to be protected against abrasive wear, with between the cold gas sprayed particles are pores.
  • the path taken here is that a comparatively soft, ductile layer is used as the resistant layer against abrasive wear and not a hard wear protection layer, whereby the surprising effect is exploited that a soft, ductile layer prevents the attack by the abrasive Medium can evade through plastic deformation, which is why a layer removal is advantageously reduced.
  • the workpiece consists of a metal or a metal alloy that is more noble than the material of the particles.
  • the metal or the metal alloy of the workpiece in the electrochemical series of voltages should have a larger standard hydrogen electrode potential than the material from which the particles are made.
  • the layer according to the invention simultaneously represents a so-called cathodic corrosion protection for the substrate. Even if the layer should be completely removed at some points on the workpiece due to the progressive abrasive wear, so the injured layer continues to provide corrosion protection, since this then acts as a sacrificial anode. In other words, electrochemical attack of the workpiece is prevented by the base metal of the layer dissolving, thereby protecting the material of the workpiece.
  • the Figure 1 the mechanism of how the layer 13 reacts to stress caused by an abrasive particle 16 can also be seen schematically. This plastically deforms the stressed particles 14, at the same time closing the pores between these particles. There remains a depression 17 in the form of a crater or scratch, but here the layer material is not or only barely removed, but avoids the stress caused by the abrasive particle 16 with plastic deformation.
  • HZO paint zinc dust superfine from Norzinco GmbH with particle sizes between 2 and 5 ⁇ m a stable layer was produced by cold gas spraying.
  • the surface produced can be Figure 2 or 5.
  • the particles 14 can still be seen on the surface, and pores between the particles can also be seen.
  • the layer surface produced was treated by sandblasting, using corundum with an average particle size of 120 ⁇ m. How Figure 3 6, the first corundum particles 16 cause the surface strips, scratches 18, which create depressions 17, as in Figure 1 are shown schematically.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Coating By Spraying Or Casting (AREA)

Description

Die Erfindung betrifft ein Verfahren zum Erzeugen einer gegen abrasiven Verschleiß, beispielsweise Partikelerosion, beständigen Schicht auf einem Werkstück durch Kaltgasspritzen. Bei diesem Verfahren werden Partikel zur zu beschichtenden Oberfläche des Substrates hin beschleunigt und bleiben an der Auftreffstelle am Substrat haften. Auf diesem Wege entsteht eine kaltgasgespritzte Schicht, wobei die Erfindung weiterhin eine Verwendung einer solchen porösen Schicht betrifft. Vorzugsweise wird zum Kaltgasspritzen, welches auch als kinetisches Spritzen bezeichnet wird, eine Kaltgasspritzanlage verwendet, die eine Gasheizeinrichtung zum Erhitzen eines Gases aufweist. An die Gasheizeinrichtung wird eine Stagnationskammer angeschlossen, die ausgangsseitig mit einer konvergent-divergenten Düse, vorzugsweise einer Lavaldüse verbunden wird. Konvergent-divergente Düsen weisen einen zusammenlaufenden Teilabschnitt sowie einen sich aufweitenden Teilabschnitt auf, die durch einen Düsenhals verbunden sind. Die konvergent-divergente Düse erzeugt ausgangsseitig einen Pulverstrahl in Form eines Gasstroms mit darin befindlichen Partikeln mit hoher Geschwindigkeit, so dass die kinetische Energie der Partikel ausreicht, damit diese auf der zu beschichtenden Oberfläche haften bleiben.The invention relates to a method for producing a layer which is resistant to abrasive wear, for example particle erosion, on a workpiece by cold gas spraying. In this method, particles are accelerated towards the surface of the substrate to be coated and remain attached to the substrate at the point of impact. In this way, a layer sprayed with cold gas is produced, the invention furthermore relating to the use of such a porous layer. For cold gas spraying, which is also referred to as kinetic spraying, a cold gas spraying system is preferably used which has a gas heating device for heating a gas. A stagnation chamber is connected to the gas heating device and is connected on the outlet side to a convergent-divergent nozzle, preferably a Laval nozzle. Convergent-divergent nozzles have a converging section and an expanding section which are connected by a nozzle neck. On the output side, the convergent-divergent nozzle generates a powder jet in the form of a gas stream with particles therein at high speed, so that the kinetic energy of the particles is sufficient for them to adhere to the surface to be coated.

Die Herstellung einer gegen abrasiven Verschleiß beständigen Schicht ist beispielsweise durch R. S. Lima et al., "Microstructural Characteristics of Cold-Sprayed Nanostructured WC-Co-Coatings", Thin Solid Films 416 (2002), S. 129 - 135 beschrieben. Die dort beschriebene Schicht weist ein feines Gefüge auf, welches als nanostrukturiertes WC-Co-Coating bezeichnet wird. Dieses lässt sich durch Kaltgasspritzen auf einem Substrat abscheiden, wobei wegen des Gefügeanteils WC eine hohe Härte und damit ein hoher Widerstand gegen abrasiven Verschleiß entsteht.The production of a layer resistant to abrasive wear is, for example, by RS Lima et al., "Microstructural Characteristics of Cold-Sprayed Nanostructured WC-Co-Coatings", Thin Solid Films 416 (2002), pp. 129-135 described. The layer described there points a fine structure, which is called nanostructured WC-Coating. This can be deposited on a substrate by cold gas spraying, whereby due to the structural component WC a high hardness and thus a high resistance to abrasive wear arises.

Allerdings ist der Verschleiß einer solchen harten Schicht in erster Linie davon abhängig, wie hart die Teilchen in dem abrasiven Medium sind. Sofern das abrasive Medium selbst eine ähnliche Härte wie WC aufweist, ist bei Verwendung von WC enthaltenen Verschleißschutzschichten ebenfalls ein vergleichsweise hoher abrasiver Verschleiß festzustellen. Aus der EP 1 921 181 A1 ist ein Verfahren zum Auftragen von abrasivem Material auf ein Dichtungsuntermaterial beschrieben, um eine abreibbare Dichtung mit einem niedrigen abrasiven Verschleißwiderstand zwischen rotierenden und stationären Komponenten von Turbinen zu bilden, wobei Kaltgasspritzen zum Steuern der Dichte, Porosität und Dicke der Dichtungsschicht eingesetzt wird.However, the wear of such a hard layer depends primarily on how hard the particles are in the abrasive medium. If the abrasive medium itself has a hardness similar to that of WC, wear protection layers containing WC also show a comparatively high abrasive wear. From the EP 1 921 181 A1 describes a method of applying abrasive material to a seal base material to form an abradable seal with a low abrasive wear resistance between rotating and stationary components of turbines, using cold gas spraying to control the density, porosity and thickness of the seal layer.

US 2007/0240603 A1 offenbart ein beschichtetes Element, auf dem eine poröse Metallüberzugsschicht gebildet wird, und ein Verfahren zu deren Herstellung. In der wissenschaftlichen Arbeit "A model study of powder particle size effects in cold spray deposition" (D. Helfrich und V. Champagne) wird ein experimentelles Modell der Auswirkung der Pulvergröße auf die Abscheidungseffizienz bei einem Kaltspritzverfahren vorgestellt. US 2007/0240603 A1 discloses a coated member on which a porous metal coating layer is formed and a method of manufacturing the same. In the scientific work "A model study of powder particle size effects in cold spray deposition" (D. Helfrich and V. Champagne) an experimental model of the effect of powder size on the deposition efficiency in a cold spray process is presented.

Die Aufgabe der Erfindung liegt darin, ein Verfahren zum Erzeugen einer gegen abrasiven Verschleiß beständigen Schicht anzugeben, mit dem sich Schichten erzeugen lassen, die einen vergleichsweise hohen abrasiven Verschleißwiderstand aufweisen.The object of the invention is to provide a method for producing a layer which is resistant to abrasive wear and can be used to produce layers which have a comparatively high abrasive wear resistance.

Diese Aufgabe wird mit dem eingangs genannten Verfahren erfindungsgemäß dadurch gelöst, dass die Partikel aus Zn und/oder Sn und/oder Cu und/oder einer zumindest eines dieser Metalle als Hauptbestandteil enthaltenen Legierung bestehen. Außerdem wird die Geschwindigkeit der auf das Substrat auftreffenden Partikel so eingestellt, dass die sich aus diesen Partikeln ausbildende Schicht porös ist und die Korngröße des Schichtgefüges im Wesentlichen der Partikelgröße entspricht. Damit liegen die Poren, die sich im Gefüge der Schicht ausbilden, genau zwischen den Partikeln, während die Partikel durch Einstellung der Verfahrensparameter beim Kaltgasspritzen in ihrer Form weitgehend erhalten bleiben. Durch die vergleichsweise hohe Porosität des Beschichtungsergebnisses entsteht sozusagen ein lockeres Metallgefüge, wobei die ausgewählten Metalle ein duktiles Verhalten an den Tag legen. Wird die beständige Schicht im Folgenden beispielsweise durch Partikelerosion beansprucht, so kommt es zunächst zu einer plastischen Verformung der Partikel in der Schicht, die zwar zu einer Verfestigung des Gefüges und zu einer Verringerung von dessen Porosität führt, jedoch gewährleistet, dass durch den Angriff der abrasiven Partikel nur ein geringer Materialabtrag der Schicht zu beobachten ist. Man kann die Beanspruchung der beständigen Schicht durch die Partikel also als eine Art Mikroschmieden bezeichnen, wobei die plastische Verformung der Partikel im Gefüge der beständigen Schicht dazu führt, dass ein Materialabtrag weitgehend vermieden wird.This object is achieved with the method mentioned at the outset in that the particles made of Zn and / or Sn and / or Cu and / or an alloy containing at least one of these metals as the main component. In addition, the speed of the particles hitting the substrate is adjusted so that the layer formed from these particles is porous and the grain size of the layer structure essentially corresponds to the particle size. The pores that form in the structure of the layer thus lie exactly between the particles, while the shape of the particles is largely retained by adjusting the process parameters during cold gas spraying. The comparatively high porosity of the coating result creates a loose metal structure, so to speak, with the selected metals exhibiting ductile behavior. If the permanent layer is subsequently stressed, for example, by particle erosion, there is first a plastic deformation of the particles in the layer, which leads to a solidification of the structure and a reduction in its porosity, but ensures that the attack by the abrasive Particles only a small material removal of the layer can be observed. The stress on the permanent layer by the particles can therefore be described as a type of micro-forging, the plastic deformation of the particles in the structure of the permanent layer leading to the fact that material removal is largely avoided.

Hierin liegt ein überraschender Effekt, der der erfindungsgemäß hergestellten porösen Schicht mit einer hohen Duktilität zugrunde liegt. Anstatt, wie durch R.S. Lima et al. angegeben, eine Verschleißschutzschicht mit einer möglichst hohen Härte zur Verfügung zu stellen, wird gemäß der vorliegenden Erfindung ein gegenteiliger Weg beschritten, nämlich die beständige Schicht so auszuführen, dass eine Beanspruchung durch ein abrasives Medium eine Verformung der Schicht erlaubt, um einen abrasiven Verschleiß dieser Schicht durch ein plastisches Ausweichen der betroffenen Schichtpartikel zu unterbinden.This is a surprising effect that underlies the porous layer with a high ductility produced according to the invention. Instead of as described by RS Lima et al. specified to provide a wear protection layer with the highest possible hardness, according to the present invention an opposite path is followed, namely to carry out the resistant layer in such a way that a Stress caused by an abrasive medium allows the layer to be deformed in order to prevent abrasive wear of this layer by plastic evasion of the affected layer particles.

Gemäß der Erfindung ist vorgesehen, dass die Partikel eine mittlere Partikelgröße von 2 bis 5 µm aufweisen. Als Partikelgröße im Sinne der Erfindung soll der mittlere Durchmesser der Partikel verstanden werden, welcher sich nach bekannten Verfahren statistisch ermitteln lässt. Auch Partikel, die nicht rund sind, weisen einen solchen mittleren Durchmesser auf, so dass deren Partikelgröße angegeben werden kann. Die Wahl von verhältnismäßig feinen Partikeln führt vorteilhaft zu einer Mikroporosität der Schicht, so dass diese nach dem oben beschriebenen Mechanismus durch plastische Verformung des porösen Partikelverbundes besonders wirkungsvoll einer Partikelerosion widerstehen kann.According to the invention it is provided that the particles have an average particle size of 2 to 5 μm. Particle size in the sense of the invention is to be understood as the mean diameter of the particles, which can be determined statistically by known methods. Particles that are not round also have such an average diameter so that their particle size can be specified. The choice of relatively fine particles advantageously leads to a microporosity of the layer, so that it can withstand the particle erosion particularly effectively by plastic deformation of the porous particle composite according to the mechanism described above.

Gemäß einer anderen Ausgestaltung der Erfindung ist vorgesehen, dass vor dem Aufbringen der Schicht eine Haftvermittlerschicht, insbesondere eine Schicht aus Ni, auf das Substrat aufgebracht wird, welche die Schicht durch Ausbildung gemeinsamer Diffusionszonen oder intermetallischer Phasen festhält. Hiermit lässt sich vorteilhaft die Haftung der Schicht auf dem Substrat durch Ausbildung von Diffusionszonen oder intermetallischen Phasen verbessern, damit die Beanspruchung durch das abrasive Medium nicht zu einem Abplatzen der Schicht führt. Diese Maßnahme ermöglicht insbesondere auch die Aufbringung der beständigen Schicht auf Substraten, welche an sich für die ausgewählten Metalle einen schlechten Untergrund bilden. Auf der Haftvermittlerschicht, welche selbst gut auf dem Substrat haftet, lässt sich dann die beständige Schicht mit einer guten Haftung abscheiden.According to another embodiment of the invention, it is provided that an adhesion promoter layer, in particular a layer of Ni, is applied to the substrate before the layer is applied, said layer holding the layer in place by forming common diffusion zones or intermetallic phases. This advantageously allows the adhesion of the layer to the substrate to be improved by forming diffusion zones or intermetallic phases so that the stress caused by the abrasive medium does not lead to the layer flaking off. This measure in particular also enables the permanent layer to be applied to substrates which in themselves form a poor substrate for the selected metals. The permanent layer with good adhesion can then be deposited on the adhesion promoter layer, which itself adheres well to the substrate.

Weiterhin ist es möglich eine poröse kaltgasgespritzte Schicht, die aus Zn und/oder Sn und/oder Cu und/oder einer zumindest eines dieser Metalle als Hauptbestandteil enthaltenen Legierung besteht, als Schutzschicht auf einem gegen abrasiven Verschleiß zu schützenden Werkstück zu verwenden, wobei sich zwischen den kaltgasgespritzten Partikeln Poren befinden. Eine solche Verwendung beinhaltet also, dass die Schicht auf dem betreffenden Werkstück durch Kaltgasspritzen hergestellt wird. Mit der Verwendung der kaltgasgespritzten Schicht im Sinne der Erfindung werden die oben bereits genannten Vorteile erreicht. Hierbei wird, wie bereits erwähnt, der Weg beschritten, dass als beständige Schicht gegen abrasiven Verschleiß eine vergleichsweise weiche, duktile Schicht verwendet wird und nicht eine harte Verschleißschutzschicht, wobei der überraschende Effekt ausgenutzt wird, dass eine weiche, duktile Schicht dem Angriff durch das abrasive Medium durch plastische Verformung ausweichen kann, weswegen ein Schichtabtrag vorteilhaft verringert wird.Furthermore, it is possible to use a porous cold gas sprayed layer, which consists of Zn and / or Sn and / or Cu and / or an alloy containing at least one of these metals as the main component, as a protective layer on a workpiece to be protected against abrasive wear, with between the cold gas sprayed particles are pores. Such use therefore means that the layer on the workpiece in question is produced by cold gas spraying. With the use of the cold gas sprayed layer in the sense of the invention, the advantages already mentioned above are achieved. As already mentioned, the path taken here is that a comparatively soft, ductile layer is used as the resistant layer against abrasive wear and not a hard wear protection layer, whereby the surprising effect is exploited that a soft, ductile layer prevents the attack by the abrasive Medium can evade through plastic deformation, which is why a layer removal is advantageously reduced.

Gemäß einer Ausgestaltung der Erfindung ist vorgesehen, dass das Werkstück aus einem Metall oder einer Metalllegierung besteht, das/die edler ist als das Material der Partikel. Mit anderen Worten soll das Metall oder die Metalllegierung des Werkstücks in der elektrochemischen Spannungsreihe ein größeres Standardwasserstoffelektrodenpotential aufweisen als das Material, aus dem die Partikel sind. Hierdurch wird vorteilhaft erreicht, dass die erfindungsgemäße Schicht gleichzeitig einen sog. kathodischen Korrosionsschutz für das Substrat darstellt. Auch wenn die Schicht durch den fortschreitenden abrasiven Verschleiß an einigen Stellen des Werkstücks vollständig abgetragen sein sollte, so gewährleistet die verletzte Schicht weiterhin einen Korrosionsschutz, da diese dann als Opferanode wirkt. Mit anderen Worten wird ein elektrochemischer Angriff des Werkstücks dadurch verhindert, dass sich das unedlere Metall der Schicht auflöst, wodurch das Material des Werkstücks geschützt wird.According to one embodiment of the invention, it is provided that the workpiece consists of a metal or a metal alloy that is more noble than the material of the particles. In other words, the metal or the metal alloy of the workpiece in the electrochemical series of voltages should have a larger standard hydrogen electrode potential than the material from which the particles are made. This advantageously means that the layer according to the invention simultaneously represents a so-called cathodic corrosion protection for the substrate. Even if the layer should be completely removed at some points on the workpiece due to the progressive abrasive wear, so the injured layer continues to provide corrosion protection, since this then acts as a sacrificial anode. In other words, electrochemical attack of the workpiece is prevented by the base metal of the layer dissolving, thereby protecting the material of the workpiece.

Weitere Einzelheiten der Erfindung werden nachfolgend anhand der Zeichnung beschrieben. Gleiche oder sich entsprechende Zeichnungselemente sind in den einzelnen Figuren mit jeweils den gleichen Bezugszeichen versehen und werden nur insoweit mehrfach erläutert, wie sich Unterschiede zwischen den einzelnen Figuren ergeben. Es zeigen:

Figur 1
einen schematischen Schnitt durch ein Ausführungsbeispiel der erfindungsgemäßen Schicht und
Figuren 2 bis 7
Aufsichten auf die Oberfläche eines Ausführungsbeispiels der erfindungsgemäßen Schicht, die verschiedene Verschleißstadien der Oberfläche Partikelerosion darstellen, jeweils schematisch und als Fotografie.
Further details of the invention are described below with reference to the drawing. Identical or corresponding drawing elements are provided with the same reference numerals in the individual figures and are only explained several times to the extent that differences arise between the individual figures. Show it:
Figure 1
a schematic section through an embodiment of the layer according to the invention and
Figures 2 to 7
Top views of the surface of an embodiment of the layer according to the invention, which represent different stages of wear of the surface of particle erosion, each schematically and as a photograph.

Anhand von Figur 1 lassen sich die Verfahrensschritte eines Ausführungsbeispiels des erfindungsgemäßen Verfahrens darstellen. Auf einem Werkstück 11 ist mittels Kaltgasspritzens zunächst eine Haftvermittlerschicht 12 aufgebracht worden, die aus Nickel besteht. Alternativ könnte diese Schicht auch elektrochemisch aufgebracht werden. In einem weiteren Schritt wird durch Kaltgasspritzen eine beständige Schicht 13 aufgebracht, welche aus Partikeln 14 besteht. Diese lassen sich in ihrer Kontur im Schnitt gemäß Figur 1 noch deutlich erkennen, da die Parameter des Kaltgasspritzens so eingestellt werden, dass die Partikel 14 sich beim Aufprall auf das Werkstück 11 (Substrat) kaum verformen. Allerdings ist der kinetische Energieeintrag in die Partikel genügend groß, damit diese auf der Haftvermittlerschicht 12 bzw. auf benachbarten Partikel 14 haften bleiben. Zwischen den Partikeln bilden sich Poren 15 aus, welche zu einem lockeren Schichtgefüge führen.Based on Figure 1 the method steps of an exemplary embodiment of the method according to the invention can be represented. An adhesion promoter layer 12, which consists of nickel, was first applied to a workpiece 11 by means of cold gas spraying. Alternatively, this layer could also be applied electrochemically. In a further step, a stable layer 13, which consists of particles 14, is applied by cold gas spraying consists. These can be cut according to their contour Figure 1 can still be clearly seen, since the parameters of cold gas spraying are set such that the particles 14 hardly deform when they strike the workpiece 11 (substrate). However, the kinetic energy input into the particles is sufficiently large that they adhere to the adhesion promoter layer 12 or to neighboring particles 14. Pores 15 form between the particles, which lead to a loose layer structure.

Der Figur 1 lässt sich weiterhin schematisch der Mechanismus entnehmen, wie die Schicht 13 auf eine Beanspruchung durch ein abrasives Teilchen 16 reagiert. Dieses verformt die beanspruchten Partikel 14 plastisch, wobei gleichzeitig die Poren zwischen diesen Partikeln geschlossen werden. Es verbleibt eine Vertiefung 17 in Form eines Kraters oder Kratzers, wobei jedoch hierbei das Schichtmaterial nicht oder nur kaum abgetragen wird, sondern der Beanspruchung durch das abrasive Teilchen 16 unter plastischer Verformung ausweicht.The Figure 1 the mechanism of how the layer 13 reacts to stress caused by an abrasive particle 16 can also be seen schematically. This plastically deforms the stressed particles 14, at the same time closing the pores between these particles. There remains a depression 17 in the form of a crater or scratch, but here the layer material is not or only barely removed, but avoids the stress caused by the abrasive particle 16 with plastic deformation.

Unter Verwendung eines sogenannten HZO-Farbenzinkstaubs superfein der Fa. Norzinco GmbH mit Partikelgrößen zwischen 2 und 5 µm wurde durch Kaltgasspritzen eine beständige Schicht hergestellt. Die hergestellte Oberfläche lässt sich Figur 2 bzw. 5 entnehmen. Zu erkennen sind an der Oberfläche noch die Partikel 14, wobei auch Poren zwischen den Partikeln erkennbar sind.Using a so-called HZO paint zinc dust superfine from Norzinco GmbH with particle sizes between 2 and 5 µm, a stable layer was produced by cold gas spraying. The surface produced can be Figure 2 or 5. The particles 14 can still be seen on the surface, and pores between the particles can also be seen.

Die erzeugte Schichtoberfläche wurde durch Sandstrahlen behandelt, wobei Korund mit einer mittleren Partikelgröße von 120 µm verwendet wurde. Wie Figur 3 bzw. 6 zu entnehmen ist, bewirken die ersten Korund-Partikel 16, die die Oberfläche streifen, Kratzer 18, welche Vertiefungen 17 erzeugen, wie sie in Figur 1 schematisch dargestellt sind.The layer surface produced was treated by sandblasting, using corundum with an average particle size of 120 μm. How Figure 3 6, the first corundum particles 16 cause the surface strips, scratches 18, which create depressions 17, as in Figure 1 are shown schematically.

Wird die Oberfläche über einen längeren Zeitraum durch Sandstrahlen beansprucht, so entsteht ein Oberflächenbild gemäß Figur 4 bzw. 7. Es wird deutlich, dass die verschiedenen Kratzer 18, die durch die Korund-Partikel 16 erzeugt werden, sich überlagern und überschneiden. Hierdurch wird deutlich, dass auch eine mehrfache plastische Verformung des Schichtwerkstoffes möglich ist, auch wenn die ursprüngliche Oberflächenbeschaffenheit, bestehend aus Partikeln 14, nach einem längeren Angriff durch das abrasive Medium nicht mehr zu erkennen ist. Dennoch ist auch in diesem Stadium der Beanspruchung der abrasive Abtrag an Zink noch relativ gering.If the surface is exposed to sandblasting over a longer period of time, a surface image is created in accordance with Figure 4 or 7. It is clear that the various scratches 18 which are generated by the corundum particles 16 overlap and overlap. This makes it clear that multiple plastic deformation of the layer material is also possible, even if the original surface texture, consisting of particles 14, can no longer be recognized after a prolonged attack by the abrasive medium. Nevertheless, the abrasive removal of zinc is still relatively low at this stage of the stress.

Claims (3)

  1. Method for generating a layer (13) that is resistant to abrasive wear on a workpiece (11) used as a substrate by cold gas spraying, in which particles (14) are accelerated toward the surface of the substrate to be coated and remain adhering to the substrate at the point of impingement,
    wherein the particles (14) consist of Zn and/or Sn and/or Cu and/or an alloy containing at least one of these metals as a main constituent,
    wherein the parameters of the cold gas spraying are configured such that the particles impinge on the substrate at a speed such that the layer forming is porous and the grain size of the layer structure corresponds substantially to the particle size, and wherein the particles (14) have an average particle size of 2 to 5 µm.
  2. Method according to Claim 1,
    characterized
    in that, before the layer (13) is applied, an adhesion promoting layer (12), in particular a layer of Ni, is applied to the substrate, having the effect of fixing the layer (13) by forming common diffusion zones or intermetallic phases.
  3. Method according to one of the preceding claims,
    characterized
    in that the workpiece (11) consists of a metal or a metal alloy which is electrochemically nobler than the material of the particles (14).
EP11723054.0A 2010-05-31 2011-05-31 Method for producing a layer by means of cold spraying and use of such a layer Active EP2576863B1 (en)

Applications Claiming Priority (2)

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DE102010022597A DE102010022597A1 (en) 2010-05-31 2010-05-31 Method for producing a layer by means of cold gas spraying and use of such a layer
PCT/EP2011/058919 WO2011151313A1 (en) 2010-05-31 2011-05-31 Method for producing a layer by means of cold spraying and use of such a layer

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US8993048B2 (en) 2015-03-31
WO2011151313A1 (en) 2011-12-08
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US20130142950A1 (en) 2013-06-06
EP2576863A1 (en) 2013-04-10

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