US20170114439A1 - Coating and surface repair method - Google Patents

Coating and surface repair method Download PDF

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Publication number
US20170114439A1
US20170114439A1 US15/317,804 US201515317804A US2017114439A1 US 20170114439 A1 US20170114439 A1 US 20170114439A1 US 201515317804 A US201515317804 A US 201515317804A US 2017114439 A1 US2017114439 A1 US 2017114439A1
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US
United States
Prior art keywords
coating
repair method
hvaf
hardened steel
surface repair
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
Application number
US15/317,804
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English (en)
Inventor
Ibibia Altraide
Tapas K. Mukherji
Michael F. Mullen
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.)
Sikorsky Aircraft Corp
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Sikorsky Aircraft Corp
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 Sikorsky Aircraft Corp filed Critical Sikorsky Aircraft Corp
Priority to US15/317,804 priority Critical patent/US20170114439A1/en
Assigned to SIKORSKY AIRCRAFT CORPORATION reassignment SIKORSKY AIRCRAFT CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: MUKHERJI, TAPAS K., MULLEN, MICHAEL F., ALTRAIDE, Ibibia
Publication of US20170114439A1 publication Critical patent/US20170114439A1/en
Abandoned legal-status Critical Current

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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
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P6/00—Restoring or reconditioning objects
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/123—Spraying molten metal
    • 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
    • C23C4/129—Flame spraying

Definitions

  • the subject matter disclosed herein relates to a coating and surface repair method and, more particularly, to a coating and surface repair method for shafts, bearings and gears having hardened steel surfaces exhibiting certain types of damages.
  • Aircraft such as helicopters of varying configurations, include many components that contact one another at high speeds and at high temperatures. These components include shafts, bearings and bearing races and gears that register with complementary gears. The repeated contact between bearings and bearing races and between gears and other gears leads to damage to various surfaces of those features over time. This damage can be exacerbated by exposure and corrosion.
  • the requirements include, but are not limited to, the requirement that the repaired surfaces maintain high hardness, the requirement that deposited materials be thermally and galvanically compatible with substrate steel, the requirement that the adhesion of the small repair volumes be adequate and assessable, the requirement that heat induced by the repair processes cannot over-temper the substrate steel, the requirement that a heat affected zone (HAZ) at an interface of the repair be small and cannot occur within the first 0.008-0.010′′ depth of the active load bearing surface of the component and the requirement that the fatigue and mechanical strength properties of the repaired surfaces be comparable to that of the original surfaces.
  • HZ heat affected zone
  • a coating and surface repair method includes positioning a high velocity air fuel (HVAF) gun proximate to a damaged hardened steel surface and forming a ceramic metallic coating on the damaged hardened steel surface by executing an HVAF thermal spray process using the HVAF gun.
  • HVAF high velocity air fuel
  • the hardened steel surface includes carburized steel.
  • the hardened steel surface includes carburized steel, nitridized steel, borided steel, cyanided steel, carbo-nitrided steel or a combination thereof.
  • the damaged hardened steel surface is pitted.
  • the forming results in a repaired surface with fatigue and mechanical strength properties comparable to that of the original damaged hardened steel surface.
  • the damaged hardened steel surface has defects of sizes between 0.005-0.040 inches in diameter and depth.
  • the executing of the thermal spray process includes maintaining combustion temperatures within a range of 1900-2300° C.
  • the ceramic metallic coating includes a Tungsten-Carbide (WC) material.
  • WC Tungsten-Carbide
  • ceramic metallic coating includes a Tungsten-Carbide Cobalt (WC/Co) material.
  • the ceramic metallic coating includes a Tungsten-Carbide Cobalt-Chromium (WC/Co—Cr) material.
  • a coating and surface repair method includes positioning a high velocity air fuel (HVAF) gun proximate to a carburized steel surface exhibiting pitting damage, executing an HVAF thermal spray process using the HVAF gun with respect to the carburized steel surface and forming a ceramic metallic coating including a Tungsten-Carbide (WC) material on the carburized steel surface as a result of the executing of the HVAF thermal spray process.
  • HVAF high velocity air fuel
  • WC Tungsten-Carbide
  • the forming results in a repaired surface with fatigue and mechanical strength properties comparable to that of the original carburized steel surface.
  • the damaged hardened steel surface has defects of sizes between 0.005-0.040 inches in diameter and depth.
  • the executing of the thermal spray process includes maintaining combustion temperatures within a range of 1900-2300° C.
  • the ceramic metallic coating includes at least one of a Tungsten-Carbide Cobalt (WC/Co) material and a Tungsten-Carbide Cobalt-Chromium (WC/Co—Cr) material.
  • WC/Co Tungsten-Carbide Cobalt
  • WC/Co—Cr Tungsten-Carbide Cobalt-Chromium
  • FIG. 1 is a flow diagram illustrating a surface repair method in accordance with embodiments
  • FIG. 2 is a perspective view of an aircraft component to be repaired in accordance with embodiments
  • FIG. 3 is a schematic illustrating of a system for conducting a repair method in accordance with embodiments
  • FIG. 4 is an enlarged view of the encircled portion of the surface of the system of FIG. 3 ;
  • FIG. 5 is an enlarged view of the portion of the surface of FIG. 4 in a repaired condition.
  • the description provided below relates to a method for the coating and repair of hardened steel (e.g., carburized steel, nitridized steel, borided steel, cyanided steel, carbo-nitrided steel or a combination thereof) shafts, gears and bearing surfaces through a high velocity air fuel (HVAF) thermal spray process using a ceramic metallic (CERMET) material as a coating so that damaged surfaces of the affected parts can be repaired.
  • HVAF high velocity air fuel
  • CERMET ceramic metallic
  • the method can repair a carburized stainless steel SS9310 surface with defects of sizes between at least about 0.005-0.040 inches, while maintaining a defect-free interfacial bond with no reduction in substrate hardness, low coating porosity, high coating and substrate hardness, acceptable microstructure and surface finish.
  • the method is inexpensive compared to D-Gun or high velocity oxy fuel (HVOF) processes and has a better resulting surface finish than alternative methods, a smaller repair area with a greater deposit depth than alternative methods and minimal hardness changes to interfacial heat affected zones (HAZ) due to relatively lower temperatures.
  • the method also permits the formation of coating thicknesses of about 0.005-0.040 inches, which are thicker than what is otherwise possible with alternative methods, and also requires no additional expensive grinding processes (e.g., no need for final surface grinding or initial grit blasting) as with processes in which D-Gun coatings of WC/Co are formed.
  • a coating and surface repair method in accordance with embodiments is provided.
  • the method includes positioning a high velocity air fuel (HVAF) gun 10 proximate to a damaged hardened steel surface 20 (operation 100 ), executing an HVAF thermal spray process using the HVAF gun 10 with respect to the damaged hardened steel surface 20 (operation 110 ) while maintaining combustion temperatures within a range of 1900-2300° C. (operation 115 ) and a standoff distance of at least 7 inches and thereby forming a ceramic metallic coating 30 on the damaged hardened steel surface 20 (operation 120 ).
  • HVAF high velocity air fuel
  • the ceramic metallic coating 30 may include at least one or more of a Tungsten-Carbide (WC) material, a Tungsten-Carbide Cobalt (WC/Co) material and a Tungsten-Carbide Cobalt-Chromium (WC/Co—Cr) material.
  • the hardened steel surface 20 may include at least one or more of carburized steel (e.g., a carburized SS9310 coupon surface), borided steel, cyanided steel, nitridized steel or some combination thereof.
  • the forming of operation 120 results in a repaired surface 40 . This repaired surface 40 has fatigue and mechanical strength properties that are comparable to that of the original damaged hardened steel surface 20 .
  • the damaged hardened steel surface 20 may be a bearing journal surface 21 or an integral raceway 22 of a gear 200 .
  • the damaged hardened steel surface 20 may exhibit pitted-type damage, such as corrosion induced pitting, in which the surface includes recesses or pits 23 that are recessed from a normal plane P thereof.
  • the pits 23 may have a defect size of about 0.005-0.040 inches in depth and/or diameter.
  • the repaired surface 40 includes the ceramic metallic coating 30 in the pits 23 .
  • the HVAF gun 10 is at least initially positioned at a distance from the damaged hardened steel surface 20 and includes a body 11 having a rear side 110 and a forward side 111 .
  • the body 11 includes an outer hull 112 and an inner hull 113 that are separated from one another to define a flow path 114 , a ceramic baffle 115 and Hydrogen (H 2 ) or Nitrogen (N2), powder and fuel nozzles 116 .
  • the outer hull 112 is formed to define an inlet 117 by which air enters the flow path 114 and thus travels toward the rear side 110 .
  • the inner hull 113 is formed to define an interior, which is divided by the baffle 115 into a mixing chamber 118 in which the air, Hydrogen, powder and fuel are mixed to form a combustible mixture and a combustion chamber 119 in which the mixture is combusted.
  • the combustion chamber 119 is tapered at the forward side to form an outlet nozzle 120 through which the combustion products are exhausted toward the damaged hardened steel surface 20 as a supersonic jet.
  • the HVAF gun 10 sprays powders, which are heated and accelerated by combustion products of hot compressed air and fuel gas.
  • the fuel gas can be propane, propylene or natural gas.
  • a mixture of air and fuel gas flows into the combustion chamber 119 through orifices defined in the baffle 115 , which may be formed of a ceramic insert.
  • Initial ignition of the mixture by a spark plug results in heating of the baffle 115 above an auto-ignition temperature of the mixture.
  • the heat of the baffle 115 continuously ignites the mixture providing stable combustion within a range of air-to-fuel ratios and gas pressures.
  • Cooling of the HVAF gun 10 may be provided by air or water or other types of coolants.
  • spray powder is injected axially into the combustion chamber 119 , whereby the spray powder is heated at a pressure of about 2-5 bars.
  • a high heat conductivity gas e.g., hydrogen
  • a powder carrier gas such that the powder is propelled into the outlet nozzle 120 where it is accelerated to supersonic velocities (over 1200 ft/s) to impact a substrate and to thereby form the ceramic metallic coating 30 .
  • air-fuel combustion temperatures are only slightly higher than the melting temperatures of most coating metals/alloys.
  • HVAF allows for the heating of spray powder particles near or slightly above their melting point but still within the plastic state.
  • Such heat transfer regimes prevent excessive overheating of the particle surface allowing for better particle deformation and coating upon deposition.
  • flow velocities and particle temperatures can be controlled and tuned for targeted coating coality.
  • the execution of the thermal spray process of operation 110 requires that certain parameters be tightly controlled so as to avoid further damage to the damaged hardened steel surface 20 .
  • Such parameters may include those of the following Table:
  • the use of the HVAF thermal spray process of operation 110 actually leads to surprising, unexpected results in that the repaired surface 40 has fatigue and mechanical strength properties that are comparable to that of the original damaged hardened steel surface 20 in spite of the fact that the temperature range of HVAF processes are normally about 1900-2300° C.
  • the repaired surface 40 has about HRC 60-64 hardness without affected interfacial surface hardness, and about 2-3 RA surface finish without the need for surface grinding or grit blasting, and a coating thickness of about 0.005-0.040 inches.
  • the temperature of the damaged hardened steel surface 20 is generally maintained below 400° F. in order to avoid over-tempering the damaged hardened steel surface 20 at the normal HVAF temperature ranges noted above.
  • the sub-400° F. temperatures may be achieved through some combination of time limiting of the execution of the HVAF thermal spray process of operation 110 , a focusing of the HVAF thermal spray process of operation 110 on a particular area of the damaged hardened steel surface 20 and a cooling operation.
  • the HVAF gun 10 may be position relatively close to the damaged hardened steel surface 20 or the jet generated by the HVAF gun 10 may be passed through a focusing element such as a tube or focusing nozzle.
  • a coolant e.g., water or air
  • a cooling jacket maybe provided around the HAZ that prevents the HAZ from spreading over a large area of the damaged hardened steel surface 20 .
  • the coolant may be provided by a coolant source 50 as shown in FIG. 3 .
  • the coolant source 50 may be disposed proximate to (i.e., in front of or behind relative to the HVAF gun 10 ) the hardened steel surface 20 and the coolant may be provided at a predefined temperature and velocity and with a predefined heat transfer coefficient.
  • the temperature of the powder and hence the temperature of the ceramic metallic coating 30 assuming no heat generation or storage, has a linear relationship with the coolant temperature and the predefined heat transfer coefficient.
  • a required powder temperature with respect to the coolant temperature and coolant convection coefficient can be determined.
  • L i.e., ceramic metallic coating width
  • k i.e., heat conduction factor of powder
  • hardened steel surface 20 temperature that may not be exceeded.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
US15/317,804 2014-06-16 2015-04-16 Coating and surface repair method Abandoned US20170114439A1 (en)

Priority Applications (1)

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US15/317,804 US20170114439A1 (en) 2014-06-16 2015-04-16 Coating and surface repair method

Applications Claiming Priority (3)

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US201462012634P 2014-06-16 2014-06-16
US15/317,804 US20170114439A1 (en) 2014-06-16 2015-04-16 Coating and surface repair method
PCT/US2015/026131 WO2016003522A2 (en) 2014-06-16 2015-04-16 Coating and surface repair method

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EP (1) EP3154714A4 (de)
WO (1) WO2016003522A2 (de)

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210078108A1 (en) * 2019-09-13 2021-03-18 Rolls-Royce Corporation Additive manufactured ferrous components

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP3502302B1 (de) 2017-12-22 2022-03-02 Ge Avio S.r.l. Nitrierverfahren zum aufkohlen von ferrium-stählen

Family Cites Families (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6004372A (en) * 1999-01-28 1999-12-21 Praxair S.T. Technology, Inc. Thermal spray coating for gates and seats
JP2007507604A (ja) * 2003-09-29 2007-03-29 ゼネラル・エレクトリック・カンパニイ ナノ構造化コーティング系、部品及び関連製造方法
US8261444B2 (en) * 2009-10-07 2012-09-11 General Electric Company Turbine rotor fabrication using cold spraying
CN102343497A (zh) * 2011-11-23 2012-02-08 马鞍山市恒意机械有限责任公司 一种修复轧辊表面的方法

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20210078108A1 (en) * 2019-09-13 2021-03-18 Rolls-Royce Corporation Additive manufactured ferrous components
US11865642B2 (en) * 2019-09-13 2024-01-09 Rolls-Royce Corporation Additive manufactured ferrous components

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WO2016003522A2 (en) 2016-01-07
EP3154714A2 (de) 2017-04-19
WO2016003522A3 (en) 2016-03-03
EP3154714A4 (de) 2017-12-20

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