US20140154422A1 - Plasma spraying process - Google Patents

Plasma spraying process Download PDF

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Publication number
US20140154422A1
US20140154422A1 US14/236,049 US201214236049A US2014154422A1 US 20140154422 A1 US20140154422 A1 US 20140154422A1 US 201214236049 A US201214236049 A US 201214236049A US 2014154422 A1 US2014154422 A1 US 2014154422A1
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United States
Prior art keywords
gas
plasma
bore
coating
flow rate
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.)
Abandoned
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US14/236,049
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English (en)
Inventor
Leander Schramm
Clemens Maria Verpoort
David James Cook
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.)
Ford Global Technologies LLC
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Ford Global Technologies LLC
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Filing date
Publication date
Application filed by Ford Global Technologies LLC filed Critical Ford Global Technologies LLC
Assigned to FORD GLOBAL TECHNOLOGIES, LLC reassignment FORD GLOBAL TECHNOLOGIES, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: COOK, DAVID JAMES, SCHRAMM, LEANDER, VERPOORT, CLEMENS MARIA
Publication of US20140154422A1 publication Critical patent/US20140154422A1/en
Abandoned legal-status Critical Current

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    • 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
    • C23C4/14—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying for coating elongate material
    • C23C4/16—Wires; Tubes
    • 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
    • C23C4/127—
    • 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
    • C23C4/131—Wire arc 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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying

Definitions

  • the present invention relates to a process for producing a coating by thermal spraying, in particular by plasma spraying, in which a component, in particular a bore of an internal combustion engine, which is produced for example from a light metal, is coated with an alloy, preferably with an iron alloy, wherein a plasma nozzle, to which a plasma gas and a transporting gas are fed, rotates about a wire and is movable along a longitudinal axis of the bore, such that the bore is coated as seen from the inside all around and in the axial direction of the bore.
  • EP 1 967 601 A2 It is known from EP 1 967 601 A2 to coat, for example, an aluminum engine block, in particular the cylinder bearing surface thereof, with an iron alloy by carrying out arc wire spraying.
  • EP 1 967 601 A2 proposes the use of an iron alloy which contains, inter alia, 5 to 25% by weight chromium. It is essential in the case of EP 1 967 601 A2 that an additional powder, to be precise boron carbide, is additionally fed to the iron melt.
  • the arc wire spraying process of EP 1 967 601 A2 involves what is known as the TWAS process, in which two wires are fed to a spray head in such a manner that the power is transmitted across the wires.
  • an arc which melts the wires is formed by a permanent short circuit.
  • a nozzle from which compressed air or an inert gas such as nitrogen is discharged is located downstream of the nozzle. This gas stream atomizes the molten iron alloy and feeds it together with the molten boron carbide powder to the surface to be coated.
  • DE 44 11 296 A1 and DE 44 47 514 A1 are concerned with coatings provided by means of plasma spraying, in which however a metal powder or a filler wire are melted and in which nitrogen is fed to the material mixture by means of metallic nitrogen compounds in order to harden the coating.
  • EP 0 858 518 B1 is concerned with a process for producing a sliding surface on a light metal body by thermally spraying a coating made of steel and molybdenum, in which the wearing layer is applied by means of plasma spraying.
  • EP 0 858 518 B1 states, however, that a mixture of steel powder with molybdenum powder is used.
  • EP 1 340 834 B1 describes a process for producing a cylinder running surface layer.
  • use is made of a rotating plasma spraying apparatus, and therefore the engine block to be coated can rest during the coating.
  • the proportion of pores can be influenced in a targeted manner depending, for example, on the particle size of the coating powder.
  • FR 2 924 365 A1 is concerned with the plasma spraying of inner walls, with use likewise being made of an additional spraying powder.
  • the capacity of the pores in the coating should be different, which should be achievable by way of a change in the plasma spraying parameters, for example the size, the hardness, the speed and the preheating temperature of the metal particles or of the metal powder.
  • Present-day internal combustion engines and the engine blocks thereof can be cast from a metal or from a light metal, e.g. aluminum or magnesium, light metal blocks in particular having an iron or metal layer on the cylinder bores thereof.
  • the metal layer can be sprayed on by thermal processes.
  • the processes mentioned above are known as thermal spraying processes.
  • the relevant prior art for the present invention includes what is known as the PTWA (Plasma Transferred Wire Arc) internal coating process.
  • bores cylinder bores
  • a wire-like spraying additive by virtue of the fact that a nozzle rotates about the wire in the interior of the bore and is moved along the axis of the bore.
  • the inner wall is thus coated completely as seen all around and in the axial direction.
  • It is essential in the PTWA process that no metal powder is sprayed, but instead a homogeneous wire is melted and the molten droplets thereof are transported to the inner wall to be coated, where they impinge, such that the coating forms.
  • only a single wire-like spraying additive is thus supplied.
  • the plasma impinges on the preheated, wire-like spraying additive.
  • the plasma gas is usually an argon-hydrogen mixture.
  • air or compressed air is used as the transporting gas or atomizer gas.
  • the layers which are produced by this process are distinguished by a low porosity.
  • the PTWA internal coating process has proven suitable to date for the internal coating of cylinder bores, in particular light metal blocks.
  • the coating customarily has pores, which reduce the friction between the piston rings and the cylinder running surface since lubricant can accumulate in the pores.
  • EP 1 340 834 B1, EP 0 858 518 B1 and FR 2 924 365 A1 deal with influencing the appearance of pores in the coating.
  • the invention is based on the object of specifying a process of the type mentioned in the introduction which makes it possible to produce a coating which is improved in this respect.
  • the invention proposes a process for producing a coating by thermal spraying, in particular by plasma spraying, preferably by means of the PTWA internal coating process, in which a component, in particular a bore of an internal combustion engine, which is produced for example from a light metal, is coated with an alloy, preferably with an iron alloy, wherein a plasma nozzle, to which a plasma gas and a transporting gas are fed, rotates about a wire and is movable along a longitudinal axis of the bore, such that the bore is coated as seen from the inside all around and in the axial direction of the bore, in which process a variable gas stream or a variable flow rate of the plasma gas and/or of the transporting gas can be set over the axial length of the bore to be coated.
  • the gas stream can have different magnitudes during the coating operation at different positions along the longitudinal axis of the inner wall to be coated. If the flow rate of the gases is variable over the axial length of the bore, different pore proportions can be established in the coating depending on the flow rate value. With the invention, it has advantageously been identified that a low gas flow rate produces a high pore proportion in the coating and a relatively high gas flow rate produces a low pore proportion in the coating.
  • the internal coating can of course also be subsequently machined, for example honed, and/or lapped, in order to name just a few subsequent machining processes merely by way of example.
  • Pistons are moved to and fro in a known manner in the cylinder bore.
  • the piston rings are in contact with the cylinder running surface, i.e. with the coating.
  • the gas flow rate in the region of the top dead center has a low value, so that a high pore proportion forms.
  • the pore proportion can be reduced, and therefore a relatively high flow rate can be set.
  • the plasma spraying apparatus is movable to and fro in the axial direction along the bore.
  • an extensive internal coating can be produced.
  • the spraying procedure can be started at a top region of the bore.
  • the coating can have a small pore proportion, and therefore the flow rate of the gas can be set to a high value of e.g. 1100 l/min.
  • the plasma spraying apparatus is moved along the longitudinal axis toward the opposite end of the bore, and reaches the top dead center region, it is expediently provided to reduce the flow rate and to change it to a low value of e.g. 450 l/min, in order to produce a high pore proportion in the coating.
  • a relatively low flow rate causes a relatively low impact energy of the molten wire droplets on the inner wall.
  • the plasma spraying apparatus left the top dead center region toward the opposite end of the bore, it is possible in turn for a flow rate with a high value of e.g. 1100 l/min to be set, such that a coating with a low pore proportion is similarly achievable. The remainder of the inner wall of the bore can then be coated at this high flow value.
  • the flow rate of the transporting gas can be set variably. It is also conceivable that the flow rate of the plasma gas together with the transporting gas or per se can be set variably.
  • the flow rate can be set variably by way of a control element, which receives appropriate signals for setting the desired or most advantageous flow rate for the respective position of the spraying apparatus along the bore to be coated.
  • the control element can be a rapidly operable solenoid valve, which preferably controls the flow steplessly.
  • the control element is arranged in the respective feed line for the respective gas.
  • FIG. 1 shows a schematic view of a plasma spraying apparatus for carrying out the process
  • FIG. 2 shows a schematic section through a cylinder bore with a coating produced by the process.
  • FIG. 1 shows a nozzle unit 1 of a PTWA internal coating apparatus.
  • the PTWA (Plasma Transferred Wire Arc) coating system is a system for coating bores, in particular cylinders in engine blocks of internal combustion engines.
  • the nozzle unit 1 consists of a cathode 2 , a plasma nozzle 3 and the electrically conductive alloy wire 4 as anode, which is fed perpendicularly to the plasma nozzle 3 .
  • the material used for the cathode 2 is preferably tungsten, which may also be doped with thorium, for example.
  • the plasma gas 5 for example a mixture of argon and hydrogen, is fed through bores made in the nozzle body 6 and lying tangentially to the circumference.
  • the cathode holder 7 isolates the cathode 2 from the nozzle body 6 .
  • the alloy wire 4 is guided in the wire feed 15 such that it can move in rotation and be displaced longitudinally.
  • the process is started by a high-voltage discharge, which ionizes and dissociates the plasma gas 5 between alloy wire 4 , nozzle body 6 and cathode 2 .
  • the thus produced plasma flows through the plasma nozzle 3 at high speed.
  • the plasma gas 5 is transported toward the alloy wire 4 fed continuously perpendicularly to the nozzle 3 , as a result of which the electric circuit is completed.
  • a transporting gas 9 or an atomizer gas 9 is fed via feed ducts 10 and auxiliary nozzles 11 to the plasma jet 8 emerging from the plasma nozzle 3 .
  • the melting and the atomization of the alloy wire 4 are influenced in this case by two phenomena.
  • the wire 4 is firstly resistance heated by large current intensities, which are typically 65-90 amperes.
  • the impact of the plasma jet 8 on the preheated wire 4 ensures that the latter melts at the wire end 12 .
  • a plasma is generated inside the plasma nozzle 3 by means of high-voltage discharge.
  • a targeted nitrogen gas flow, i.e. the transporting gas 9 along the discharge path transports the plasma and the molten spraying material 13 onto the surface 14 of the cylinder bore to be coated.
  • the flow rate of the plasma gas 5 and/or of the transporting gas 9 is, according to the invention, variable along the longitudinal axis of the bore.
  • FIG. 2 shows a schematic section through a cylinder bore 16 with a coating 14 , in which the coating 14 has been produced with a flow rate of the gas or gases which was varied over the axial length X.
  • the coating is split into five regions, the dimensions of the regions shown, i.e. the axial extent thereof, merely being exemplary.
  • the spraying procedure using the PTWA internal coating process began in a top cover region 17 .
  • the spraying apparatus was moved from the top cover region 17 toward the opposite end 18 , the nozzle unit 1 rotating as described above.
  • a top dead center region 19 adjoining the top cover region 17 can be seen.
  • the top dead center region 19 is adjoined by a central region 20 , which is adjoined by a bottom dead center region 21 . This is adjoined by a bottom foot region 22 .
  • Spraying was performed at a high flow rate in the top cover region 17 but also in the central region 20 and also in the bottom foot region 22 , and therefore the coating has a low pore proportion in the respective region.
  • spraying was performed at a low flow rate in the top dead center region 19 and in the bottom dead center region 21 , and therefore the coating has a high pore proportion in the respective region.
  • the region 21 is optional, and therefore the coating may also include only the regions 17 , 19 and 20 , where the central region 20 continues as far as the end 18 , and where spraying was performed at a high flow rate, and therefore the coating can then have a low pore proportion in the respective region 17 and 20 (as far as the end 18 ).

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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)
US14/236,049 2011-10-27 2012-10-02 Plasma spraying process Abandoned US20140154422A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102011085324.3 2011-10-27
DE102011085324A DE102011085324A1 (de) 2011-10-27 2011-10-27 Plasmaspritzverfahren
PCT/EP2012/069420 WO2013060552A1 (de) 2011-10-27 2012-10-02 Plasmaspritzverfahren

Publications (1)

Publication Number Publication Date
US20140154422A1 true US20140154422A1 (en) 2014-06-05

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Application Number Title Priority Date Filing Date
US14/236,049 Abandoned US20140154422A1 (en) 2011-10-27 2012-10-02 Plasma spraying process

Country Status (7)

Country Link
US (1) US20140154422A1 (de)
EP (1) EP2771496A1 (de)
CN (1) CN103890222A (de)
DE (1) DE102011085324A1 (de)
IN (1) IN2014CN02960A (de)
RU (1) RU2608247C2 (de)
WO (1) WO2013060552A1 (de)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP2963142A1 (de) * 2014-06-30 2016-01-06 United Technologies Corporation Systeme und verfahren zur plasmasprühbeschichtung
JP2018040360A (ja) * 2016-09-08 2018-03-15 ドクター エンジニール ハー ツェー エフ ポルシェ アクチエンゲゼルシャフトＤｒ． Ｉｎｇ． ｈ．ｃ． Ｆ． Ｐｏｒｓｃｈｅ Ａｋｔｉｅｎｇｅｓｅｌｌｓｃｈａｆｔ 内燃機関のシリンダをコーティングするための方法、および内燃機関のためのシリンダ
US11638958B2 (en) * 2014-03-11 2023-05-02 Tekna Plasma Systems Inc. Process and apparatus for producing powder particles by atomization of a feed material in the form of an elongated member

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DE102013112809A1 (de) * 2013-11-20 2015-05-21 Ks Aluminium-Technologie Gmbh Verfahren zur Herstellung einer gespritzten Zylinderlauffläche eines Zylinderkurbelgehäuses einer Verbrennungskraftmaschine sowie derartiges Zylinderkurbelgehäuse
CN105986919B (zh) * 2015-01-28 2019-08-27 代卫东 一种改进的发动机缸体及其制造工艺
DE102021106846A1 (de) 2021-03-19 2022-09-22 Rolls-Royce Solutions GmbH Zylinderlaufbahn mit Teilbereichen und Verfahren zur Herstellung der Zylinderlaufbahn, sowie Zylinder und Brennkraftmaschine
DE102022105774A1 (de) 2022-03-11 2023-09-14 Bayerische Motoren Werke Aktiengesellschaft Verfahren zum Bearbeiten eines Kurbelgehäuses sowie Kurbelgehäuse

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US5296667A (en) * 1990-08-31 1994-03-22 Flame-Spray Industries, Inc. High velocity electric-arc spray apparatus and method of forming materials
US5808270A (en) * 1997-02-14 1998-09-15 Ford Global Technologies, Inc. Plasma transferred wire arc thermal spray apparatus and method
FR2924365A1 (fr) * 2007-12-03 2009-06-05 Peugeot Citroen Automobiles Sa Procede de fabrication d'un revetement comportant des pores aptes a retenir un lubrifiant et piece comportant un tel revetement
JP2010190200A (ja) * 2009-02-20 2010-09-02 Honda Motor Co Ltd シリンダライナ

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Publication number Priority date Publication date Assignee Title
US4122327A (en) * 1975-07-17 1978-10-24 Metco Inc. Automatic plasma flame spraying process and apparatus
US5296667A (en) * 1990-08-31 1994-03-22 Flame-Spray Industries, Inc. High velocity electric-arc spray apparatus and method of forming materials
US5808270A (en) * 1997-02-14 1998-09-15 Ford Global Technologies, Inc. Plasma transferred wire arc thermal spray apparatus and method
FR2924365A1 (fr) * 2007-12-03 2009-06-05 Peugeot Citroen Automobiles Sa Procede de fabrication d'un revetement comportant des pores aptes a retenir un lubrifiant et piece comportant un tel revetement
JP2010190200A (ja) * 2009-02-20 2010-09-02 Honda Motor Co Ltd シリンダライナ

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11638958B2 (en) * 2014-03-11 2023-05-02 Tekna Plasma Systems Inc. Process and apparatus for producing powder particles by atomization of a feed material in the form of an elongated member
US11951549B2 (en) 2014-03-11 2024-04-09 Tekna Plasma Systems Inc. Process and apparatus for producing powder particles by atomization of a feed material in the form of an elongated member
EP2963142A1 (de) * 2014-06-30 2016-01-06 United Technologies Corporation Systeme und verfahren zur plasmasprühbeschichtung
JP2018040360A (ja) * 2016-09-08 2018-03-15 ドクター エンジニール ハー ツェー エフ ポルシェ アクチエンゲゼルシャフトＤｒ． Ｉｎｇ． ｈ．ｃ． Ｆ． Ｐｏｒｓｃｈｅ Ａｋｔｉｅｎｇｅｓｅｌｌｓｃｈａｆｔ 内燃機関のシリンダをコーティングするための方法、および内燃機関のためのシリンダ

Also Published As

Publication number Publication date
CN103890222A (zh) 2014-06-25
IN2014CN02960A (de) 2015-07-03
WO2013060552A1 (de) 2013-05-02
RU2014121305A (ru) 2015-12-10
EP2771496A1 (de) 2014-09-03
DE102011085324A1 (de) 2013-05-02
RU2608247C2 (ru) 2017-01-17

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