JP6480433B2 - 金属皮膜の溶射のために基材を前処理する方法 - Google Patents
金属皮膜の溶射のために基材を前処理する方法 Download PDFInfo
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- 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
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Description
・前縁に接着される金属補強片、
・前縁に塗布されるエロージョン防止塗料、
・前縁に接着される金属またはプラスチックのエロージョン防止フィルム、または、
・上記保護の組合せ。
・皮膜の付着力。OMC部品は、主として、繊維(70%超)、特に炭素繊維、およびより少ない含有量の樹脂(30%未満)、特にエポキシ樹脂で形成されている。これに反して、その構造および製造方法のため、OMC材料の表面は、炭素繊維よりも多くの樹脂で構成されることになり、溶射された皮膜は炭素繊維には付着するものの、樹脂に対する付着力は非常に低い。その結果、皮膜はOMC材料に対して、その表面に存在する炭素繊維材料のみを介してすなわち多くとも表面積の50%を介してしか付着しない。
・OMCに対する溶射による高温の影響。溶射中、エポキシ樹脂は、溶射された溶融金属が生成する熱の影響で劣化する。これは炭素繊維についても言えることであるが、その程度は低い。この欠点は、樹脂および炭素の熱拡散率が低いことから発生する。
・熱膨張差。溶射は、溶融粉末を噴霧することにより部品の表面上に皮膜を被着させることからなる。冷却時点で、皮膜は、熱収縮の結果として収縮を受け、それはより低温の基材の収縮よりも大きい。皮膜と基材の間のこの熱収縮/膨張差は、皮膜内の張力を導き、このとき皮膜は「緊張状態」にあると言われる。この現象は、基材上の皮膜の付着力を劣化させ、それは、皮膜と基材の熱膨張特性間の差の増加と共に増大する。このことは特に、中度の熱膨張係数を有する金属皮膜のものと比べて小さい熱膨張係数を有するOMC基材にあてはまる。
a)被覆すべきゾーン上に、10マイクロメートル(μm)超かつ100μm未満の均一の厚みを有する接着剤層を被着させるステップと、
b)接着剤が乾燥する前に、被覆すべきゾーン上に金属粉末をコールドスプレーして、粉末粒子が前記接着剤層内で少なくとも部分的に包埋された状態になるようにするステップと、
c)前記粉末粒子が内部に捕捉状態で保持され続けている接着剤を乾燥させて、溶射により被着される金属皮膜を受入れるのに好適な下地を形成するステップと、が実施されることを特徴としている。
・基材側で接着剤内に半分包埋され、
・反対側で接着剤層から半分突出し、
こうして、この下地はいつでも溶射層を受入れることができる状態にある。
・10μm超かつ100μm未満でかつ粉末の粒子のメジアン径d50未満の厚みを有する樹脂マトリクス中に少なくとも部分的に包埋させられた金属材料の粉末粒子を提示する、基材上に接着された下地と、
・連続的でかつ金属材料製の、厚み100μm超の摩耗保護層と、を含む摩耗防止用皮膜を含む基材から製造された部品も提供している。
本発明の他の利点および特徴は、添付図面を参照にしながら一例として行なわれる以下の説明を読むことで明らかとなる。
・脱脂ステップ。部品を脱脂する。
・接着剤の塗布に先立つマスキングステップ。サンドブラスティングに対する保護を提供するための接着剤としても使用されるポリ塩化ビニル(PVC)製粘着テープを用いて、マスキングを実施する。これは、接着剤を受けるべきでなく、被覆されるべきでないゾーンを保護する。
・サンドブラスティングステップ。接着剤を受けるべきゾーンを、コランダム(結晶粒サイズ180μmまたは300μm)を用いたサンドブラスティングに付す。このサンドブラスティングによる前処理は、均一な粗度をもつ表面を得るために役立ち、こうして、接着剤は表面全体にわたって規則的に展延することになる(0.8μm〜5μmの範囲内の粗度Raを得ることが望まれる)。
・接着剤を被着させるステップ。この目的で、「Specifix de Struers」エポキシ樹脂接着剤を使用する。樹脂接着剤は、「Specifix Resin」樹脂とその硬化剤「Specifix−40硬化剤」とを混合することによって調製される。
・樹脂接着剤の重合または硬化ステップ、 選択された樹脂接着剤は、90℃の温度で1時間(h)で、または50℃の温度で3時間で硬化する。
・吹付けまたはサンドブラスティングによる仕上げステップ。細かいコランダム(50μm)を用いたサンドブラスティングまたは吹付けにより、接着された金属下地から未接着の余分な粉末を取り除く。
・マスク除去および目視ステップ。マスクを部品から除去し、その外観を目視する。その外観は、接着された下地内に局所的間隙や色の変化が全く無い、厚みが規則的な被着を示さなくてはならない。
・エポキシ樹脂(暗色の方)で被覆された炭素繊維(薄い色の断面として見える)でできたOMC基材11。
・基材11の直上に設置された下地。塗布された接着剤のこの下地は、樹脂接着剤13の半分の深さまで包埋されたNiAlの粉末粒子の単一層12で構成されている。右では(図1および図2、樹脂接着剤13を示す矢印の場所)、粉末粒子が研磨中に剥ぎ取られている、
・ブローアークプラズマトーチにより下地上に溶射された厚み0.2mmのNiAl皮膜層14、および、
・皮膜層14の後続する研磨のための、皮膜14を覆う皮膜樹脂の層15。
Claims (8)
- 溶射による金属皮膜を受けるため、基材の被覆すべきゾーンを前処理するための前処理方法において、
a)被覆すべきゾーン上に、10μm超かつ100μm未満の均一の厚みを有する接着剤層を被着させるステップと、
b)接着剤が乾燥する前に、被覆すべきゾーン上に金属粉末をコールドスプレーして、粉末粒子が前記接着剤層内で少なくとも部分的に包埋された状態になるようにするステップと、
c)前記粉末粒子が内部に捕捉状態で保持され続けている接着剤を乾燥させて、溶射により被着される金属皮膜を受入れるのに好適な下地を形成するステップと、
が実施されること、および、
ステップa)において接着剤を被着させた後、接着剤が塗布された基材は、被覆すべきゾーン全体にわたる接着剤のクリープに対抗するべく動作を開始するミキサーまたは撹拌器内に設置され、この運動は、ステップb)およびステップc)の間継続され、ひとたび接着剤が硬化した時点で停止させられることを特徴とする前処理方法。 - 接着剤層が10μm超かつ50μm未満の厚みを有することを特徴とする、請求項1に記載の方法。
- 前記接着剤層が、前記金属粉末の粒子のメジアン径d50未満の厚みを有することを特徴とする、請求項1又は2に記載の方法。
- 前記接着剤層が、前記ステップa)に先立って混合した樹脂および硬化剤を含むエポキシ接着剤によって形成されていることを特徴とする、請求項1〜3のいずれか一項に記載の方法。
- 前記ステップb)の終りで、被覆すべきゾーンの表面積の70%超かつ95%未満が粉末粒子で覆われていることを特徴とする、請求項1〜4のいずれか一項に記載の方法。
- 前記ステップa)に先立ち、特にサンドブラスティングにより、被覆すべきゾーン内で基材の表面粗度を均一にすることからなるステップa0)が実施されることを特徴とする、請求項1〜5のいずれか一項に記載の方法。
- 前記ステップc)の終りで、未接着粉末粒子を除去することによる仕上げを下地に施す前記ステップc’)が実施されることを特徴とする、請求項1〜6のいずれか一項に記載の方法。
- 有機マトリクス複合材料製の基材を摩耗から保護する方法において、前記ステップc)の後に、溶射により下地上に金属皮膜を被着させて基材上に金属保護層を形成する前記ステップd)をさらに含み、請求項1〜7のいずれか一項に記載の前処理方法が実施される、保護方法。
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