WO1993008315A1 - Fabrication d'un revetement anti-usure - Google Patents

Fabrication d'un revetement anti-usure Download PDF

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Publication number
WO1993008315A1
WO1993008315A1 PCT/AU1992/000553 AU9200553W WO9308315A1 WO 1993008315 A1 WO1993008315 A1 WO 1993008315A1 AU 9200553 W AU9200553 W AU 9200553W WO 9308315 A1 WO9308315 A1 WO 9308315A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
bonding material
wear
hard material
tungsten
Prior art date
Application number
PCT/AU1992/000553
Other languages
English (en)
Inventor
Harold Leroy Harford
Original Assignee
Harold Leroy Harford
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 Harold Leroy Harford filed Critical Harold Leroy Harford
Publication of WO1993008315A1 publication Critical patent/WO1993008315A1/fr

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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
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas

Definitions

  • the present invention relates to a method of producing a wear-resistant coating.
  • FIELD OF THE INVENTION Many different processes and techniques are widely known have been extensively used in regard to obtaining coatin high hardness to render a metal substrate or more particularly, a machine part, more resistant to wear.
  • Fusion processes can be used to obtain wear-resistant coatings which are both of high hardness and relatively thick, but such processes have several disadvantages associated therewith. Fusion processes may result in a substantial dilution of the coating material with the met substrate which it is being applied to.
  • Diffusion methods such as powder welding, pack diffusion, physical vapour deposition (PVD) , chemical vapour depositi (CVD) and many others can be used to produce wear-resistan coatings of high hardness and integrity, but are limited a to the attainable thickness of the coating material.
  • wear-resistant coatings produced by diffusion methods are limited to thicknesses in the range of 1 mil t mils.
  • Thermal spray processes such as powder gas spraying and electric arc spraying are advantageous in that generally lower costs are possible in applying a wear-resistant coati to a metal substrate or a machine part, and in that the thermal spray process makes it possible to be able to apply wear-resistant coating to a broad range of different metal substrate materials.
  • wear-resistant coatings produced by thermal spray processes are porous to the order of 10 — 15% of the coating material, and so coatings of ver high hardness are usually not obtainable.
  • the high velocity oxygen fuel (HVOF) and high velocity air fuel (HVAF) thermal spray processes are recent developments in regard to thermal spray processes and methods.
  • Wear-resistant coatings having a high density, high hardnes excellent particle co-hesion, a very low porosity and good microstructure with regard to volume and hardness of the har constituents and their even distribution within the matrix can be produced using this process.
  • the hard phase of the micro constituents of the wear-resistant coating applied using this process is typically greater in volume as compare with metal alloys used for fusion processes.
  • the HVOF or HVAF thermal spray processes can be used to apply an 88/12 tungsten-carbide alloy to a metal substrate to achieve a wear coating with a diamond pyramid hardness DPH 300 of 1200 and a density of 13 to 13.7 gm/cm 3 .
  • the HVOF and HVAF thermal spraying processes have a disadvantage in that the wear resistant coating applied to the metal substrate at this particular hardness has a thickness limitation of the order of 10 to mils.
  • attempts to apply a wear-resistant coati with a thickness greater than 10 to 15 mils using the HVOF HVAF thermal spray processes will result in the formation cracks in the wear-resistant coating.
  • a further disadvantage associated with the HVOF and HVAF technology is that a sprayed tungsten-carbide layer has a pronounced surface roughness. This roughness, in the orde of 150 rms, limits the use of the tungsten-carbide layer i the as sprayed condition. For example, if the tungsten-carbide layer is used as a bearing surface this will produce galling on the other member, such as a seal or bearing surface and seizure occu rapidly.
  • the present invention provides a method of obtaining a wear-resistant coating which at least reduces one or more the above entioned problems of prior art methods.
  • a method of obtaining a wear-resistant coating comprising the steps of: - applying a layer of a bonding material to a surface of a substrate; - applying a layer of a hard material to the layer of bonding material; - applying a further layer of the bonding material to the layer of hard material, the further layer being easily grindable; and - optionally applying further sequential layers of hard material and bonding material, wherein the or each layer o bonding material acts to limit stress in the or each layer of hard material.
  • the hard material is applied to the bonding material using a high velocity spray process.
  • a method of obtaining a wear-resistant coating comprising the steps of: - applying a layer of a bonding material to a surface of a substrate; - applying a layer of a hard material to the layer of bonding material; and - repeatedly applying the bonding material and hard materia in sequential layers until a desired thickness of the wear-resistant coating is obtained.
  • the wear-resistant coating is applied to a met substrate.
  • the bonding material and hard material are metals or metal alloys.
  • FIG. 1 is a partial sectional view of a wear-resistant coating produced in accordance with the method of the present invention
  • Figure 2 is a schematic diagram of the thermal spray coati method as used in accordance with the present invention
  • Figure 3 is a partial sectional view of a wear-resistant coating of greater thickness than that of Figure 1 produce in accordance with the method of the present invention
  • Figure 4 is a schematic diagram of the microstructure of a thermally sprayed coating
  • Figure 5 is a schematic representation of an electric arc metal spraying system
  • Figure 6 is a schematic representation of a high velocity oxygen fuel (HVOF) thermal spraying system.
  • HVOF high velocity oxygen fuel
  • substrate 12 are typically best removed by grit blasting
  • the oxide coating thereon may be simply removed by way of 9 hand grinding or a similar manual operation after 0 pre-heating the surface 14 of the metal substrate 12.
  • the 1 aforementioned technique for removing oxide from the surfa 2 14 may also be used if the surface 14 of the metal substra 3 12 is unable to undergo blasting due to the size thereof. 4
  • the metal substrate 12 may be re-heated to about 50°C 6 and sprayed with a chlorinated hydrocarbon type solvent.
  • An electric arc metal spraying system 40 as shown in Figur 8 2, 4 and 5 may be subsequently arranged to apply a porous 9 coating of a ductile bonding material 16 to the surface 14 0 of the metal substrate 12.
  • the electric arc metal spraying system 40 generally comprises the steps of a solid or powder starting materi 30, this material being melted in an arc 32, the melted particles being accelerated in a gas stream 34, the particles splattering on the substrate 36 followed by th cooling and coalescence 38, as is shown in Figure 2.
  • Th resulting layer 16 comprises voids, oxidized particles a unmelted particles together with fully melted and coales particles, as shown in Figure 4.
  • the electric arc metal spraying system 40 typically comprises an arc gun 42, a power source 44, an air suppl and wire stock 48. Each of the elements of the electric metal spraying system 40 are interconnected therebetween operation in known manner. A schematic representation o this system 40 is shown in Figure 5.
  • the operational parameters of the electric arc metal spraying system 40 are appropriately set after considera of the type of alloy that is to be applied to surface 14
  • a layer of a nickel-aluminium a 16 is to be applied and the relevant operational paramet are preferably as follows:- Volts - 32 Amps - 120 Air Pressure - 50 Psi Wire Diameter - 1/16 inch
  • the porous layer of the nickel-aluminium alloy 16 is app to the surface 14 of the treated metal substrate 12 to a thickness of, for example, 6 mils using the appropriatel arranged electric arc metal spraying system 40. It is t noted that the nature of the alloy 16 used determines th 2 extent of the bond strength to the metal substrate 12 and the resulting surface roughness of the bond material 16.
  • the nickel-aluminium alloy coating 16 used in this example will bond to the metal substrate 12 with a tensile bond strength of approximately 7000 - 8000 psi.
  • the nickel-aluminium alloy 16 will also provide a surface roughness of 200 - 300 micro inches.
  • the nickel-aluminium alloy 16 provides a coating that is both porous and ductil 0
  • a high velocity oxygen fuel system (HVOF) thermal spraying 1 system 50 as shown in Figure 6 may be subsequently used to 2 apply a dense layer of a hard material 18 to an exposed 3 upper surface 20 of the bonding material 16.
  • the HVOF thermal spraying system 50 typically comprises a 5 HVOF torch 52, heat exchanger 54, regulated gas supply 56, 6 gas control console 58 and a powder feeder 60.
  • the layer of the tungsten-carbide alloy powder 18 is preferably applied without undue delay to the surface 20 the nickel-aluminium alloy layer 16 using the appropriatel set HVOF thermal spraying system 50.
  • the tungsten-carbide alloy powder layer 18 may be applied from a minimum thickness of 10 mils to a maximum thickness of 15 mils.
  • the temperature of the metal substrate 12 shou preferably not exceed 120°C. Cooling jets and interrupted application of the HVOF thermal spraying system 50 may be used as necessary in this regard.
  • the porosity and ductility of the bonding alloy layer 16 enables the hard material 18 to be applied to the surface 20 of the bonding alloy layer 16 to thickness exceeding what is usually obtainable using the HVOF thermal spraying systems 50.
  • a subsequent layer 22 of the bonding alloy may be now electric arc sprayed over the first hard material coating using the aforementioned operational parameters of the electric arc metal spraying system 40.
  • a further layer 22 of nickel-aluminium alloy may sprayed over the first tungsten-carbide layer 18.
  • the thickness of this second layer 22 may be of the order o mils.
  • the nickel-aluminium alloy layer 22 used in the example will bond with the tungsten-carbide layer 18 wi tensile bond strength of approximately 5000 - 6000 psi the tungsten-carbide layer interface 24.
  • This second nickel-aluminium alloy layer 22 will also provide the suitable roughness for a subsequent hard material layer that is, a second tungsten-carbide layer.
  • the subsequent layer of hard material 26 is now applied the second bonding alloy layer 22 using the HVOF therma spraying system 50 having the operational parameters therefor set as hereinbefore detailed.
  • a further layer 26 of tungsten-carbide alloy powder is applied to second nickel-aluminium alloy layer 22.
  • the two processes of electric arc spraying a porous bond alloy and subsequently applying a hard material using th HVOF thermal spraying process to the previously applied bonding alloy may be repeated in sequence several times until a desired thickness of wear-resistant coating 10 h been deposited, as shown in Figure 3.
  • the final resistant coating 10 is a composite coating obtained usi the two different density alloys or materials, the compo coating 10 comprising a laminated structure having at le 2 layers of a softer and less dense bonding material and layer of hard material.
  • these two processes may be repea until ten layers of tungsten carbide have been deposited.
  • the final laminate coating will have a total thickness of 133 mils comprising ten tungsten-carbide layers of 10 mils each, 9 layers of nickel-aluminium alloy of 3 mils each plus the original layer of nickel-aluminium alloy of 6 mils thickness.
  • a 100 mil thick tungsten-carbide coating has been applied to the metal substrate without the occurrence of any micro-cracking anywhere in the composite coating. Examples of the use of the composite coating in industry provided in Table 2 as examples A, B, C and D. Note shou
  • HVAF system may be substituted for the HVOF system described hereinabove.
  • the method can be used to create a final composite coating which possesses the characteristic of being easily machinable or grindable using conventional grinding wheels and not requiring diamond wheels.
  • a nickel-aluminium alloy layer is preferably
  • a layer of hard material is preferably
  • the hard material layer is allowed to cool to below 50°C at
  • the tungsten-carbide layer has a surface roughness in the
  • the electric arc metal spraying system 40 is now arranged t 1 spray a layer of a different alloy onto the hard material 2 layer and hence the operational parameters are set 3 accordingly.
  • a layer of chrome 4 iron alloy is to be applied and the relevant operational 5 parameters are preferably as follows:- 6 Volts - 38 Amps - 250 7 Air pressure 65 psi 8 Wire diameter-1/16 inch 9
  • the chrome-iron alloy layer is applied to the surface of the 0 tungsten-carbide alloy powder layer using the electric arc metal spraying system 40. Sufficient spraying is carried out to obtain a chrome-iron alloylayer of, for example 20 mils thickness.
  • the machine part can now be machined or ground to the required size using conventional tools or grinding wheels.
  • the chrome-iron alloy layer is ground down so that the tungsten-carbide layer will be 0.5 mils below the surface of the finished top alloy layer. It has been observed that the layer of porous soft final alloy material does not inhibit the performance of the denser, hard material upon which it has been applied when the machine part is placed in service.
  • the present invention it is possible to obtain a wear-resistant coating of high hardness which is able to be finished without the use of diamond grinding apparatus. Further, it is also possible to obtain a wear-resistant coating, of high hardness and thickness without loss of integrity of the coating.
  • the bonding layer is porous and provides ductility and effectively destresses the laminate thereby preventing cracking.
  • the bonding layers 16 and 22 may also be applied using a thermal spray of molybdenum, either powder or wire stock.
  • plasma sprayed tungsten-carbide using a low speed flame and large particle sizes in stock powder can give the required porosity in the bonding layers 16 and 22.
  • HVOF or HVAF sprayed tungsten-carbide using a low speed flame and larger particle sizes in stock powder can also give the required porosity in the bonding layers 16 and 22.
  • the plasma sprayed or HVOF and HV sprayed tungsten-carbide under the above conditions is dense than the HVOF or HVAF sprayed tungsten-carbide described previously.
  • each bonding layer is a less dense and more porous layer than the or each hard layer.
  • the layer of hard material alternatively comprise titanium nitride and other carbid and nitrides of a similar chemical nature.
  • eac should be applied using the HVOF or HVAF thermal sprayin systems. It is further envisaged that the wear-resistant coating be post-heat treated. This heat treatment may be at approximately 850°C and could heal micro-cracks in the o each layer of hard material. Modifications and variations such " as would be apparent t skilled addressee are deemed within the scope of the pre invention.

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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)

Abstract

Procédé permettant d'obtenir un revêtement anti-usure (10) et comportant: l'application d'une couche (16) d'un matériau adhésif à la surface (14) d'un substrat (12); l'application d'une couche (18) d'un matériau dur sur la couche (16) de matériau adhésif; l'application d'une nouvelle couche (22) de matériau adhésif, identique ou non, sur la couche (18) de matériau dur, cette couche (22) étant facilement broyable; et l'application éventuelle de nouvelles couches alternées de matériau dur (26) et adhésif (22), ces dernières (22) limitant les contraintes portant sur la ou les couches (18, 26) de matériau dur.
PCT/AU1992/000553 1991-10-18 1992-10-16 Fabrication d'un revetement anti-usure WO1993008315A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AUPK8971 1991-10-18
AUPK897191 1991-10-18

Publications (1)

Publication Number Publication Date
WO1993008315A1 true WO1993008315A1 (fr) 1993-04-29

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/AU1992/000553 WO1993008315A1 (fr) 1991-10-18 1992-10-16 Fabrication d'un revetement anti-usure

Country Status (1)

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WO (1) WO1993008315A1 (fr)

Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2769063A1 (fr) * 1997-09-29 1999-04-02 Exedy Corp Mecanisme amortisseur, notamment pour ensemble formant disque d'embrayage et ensemble formant volant
EP1805344B1 (fr) * 2004-10-16 2011-03-16 MTU Aero Engines AG Procede de fabrication d'une piece pourvue d'un revetement de protection contre l'usure
CN114437647A (zh) * 2021-12-15 2022-05-06 清华大学 柔性耐磨超疏水材料及其制备方法和应用

Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4044217A (en) * 1975-05-07 1977-08-23 Kawasaki Jukogyo Kabushiki Kaisha Sliding surface working method using wire-explosion coating
GB2121780A (en) * 1982-06-14 1984-01-04 Eutectic Corp Ceramic flame spray powder
JPS5996273A (ja) * 1982-11-26 1984-06-02 Toshiba Corp 耐熱部品
US4481237A (en) * 1981-12-14 1984-11-06 United Technologies Corporation Method of applying ceramic coatings on a metallic substrate
US4612256A (en) * 1983-04-29 1986-09-16 Goetze Ag Wear-resistant coating
US4731253A (en) * 1987-05-04 1988-03-15 Wall Colmonoy Corporation Wear resistant coating and process
JPH03207847A (ja) * 1990-01-08 1991-09-11 Sumitomo Metal Ind Ltd 高耐食性複合被覆鋼材およびその製造方法
JPH03207848A (ja) * 1990-01-08 1991-09-11 Nippon Steel Corp 意匠性に優れた耐食性金属被覆鋼の製造方法
JPH04128359A (ja) * 1990-09-17 1992-04-28 Mitsubishi Heavy Ind Ltd 金属溶射皮膜形成方法
JPH04131363A (ja) * 1990-09-20 1992-05-06 Japan Atom Energy Res Inst 下地用プラズマ溶射膜

Patent Citations (10)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4044217A (en) * 1975-05-07 1977-08-23 Kawasaki Jukogyo Kabushiki Kaisha Sliding surface working method using wire-explosion coating
US4481237A (en) * 1981-12-14 1984-11-06 United Technologies Corporation Method of applying ceramic coatings on a metallic substrate
GB2121780A (en) * 1982-06-14 1984-01-04 Eutectic Corp Ceramic flame spray powder
JPS5996273A (ja) * 1982-11-26 1984-06-02 Toshiba Corp 耐熱部品
US4612256A (en) * 1983-04-29 1986-09-16 Goetze Ag Wear-resistant coating
US4731253A (en) * 1987-05-04 1988-03-15 Wall Colmonoy Corporation Wear resistant coating and process
JPH03207847A (ja) * 1990-01-08 1991-09-11 Sumitomo Metal Ind Ltd 高耐食性複合被覆鋼材およびその製造方法
JPH03207848A (ja) * 1990-01-08 1991-09-11 Nippon Steel Corp 意匠性に優れた耐食性金属被覆鋼の製造方法
JPH04128359A (ja) * 1990-09-17 1992-04-28 Mitsubishi Heavy Ind Ltd 金属溶射皮膜形成方法
JPH04131363A (ja) * 1990-09-20 1992-05-06 Japan Atom Energy Res Inst 下地用プラズマ溶射膜

Non-Patent Citations (5)

* Cited by examiner, † Cited by third party
Title
PATENT ABSTRACTS OF JAPAN, C-244, page 47; & JP,A,59 096 273 (TOSHIBA KK), 2 June 1984. *
PATENT ABSTRACTS OF JAPAN, C-891, page 150; & JP,A,3 207 847 (SUMITOMO METAL IND LTD), 11 September 1991. *
PATENT ABSTRACTS OF JAPAN, C-891, page 150; & JP,A,3 207 848 (NIPPON STEEL CORP), 11 September 1991. *
PATENT ABSTRACTS OF JAPAN, C-976, page 48; & JP,A,4 128 359 (MITSUBISHI HEAVY IND LTD), 28 April 1992. *
PATENT ABSTRACTS OF JAPAN, C-977, page 73; & JP,A,4 131 363 (JAPAN ATOMIC ENERGY INST), 6 May 1992. *

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2769063A1 (fr) * 1997-09-29 1999-04-02 Exedy Corp Mecanisme amortisseur, notamment pour ensemble formant disque d'embrayage et ensemble formant volant
EP1805344B1 (fr) * 2004-10-16 2011-03-16 MTU Aero Engines AG Procede de fabrication d'une piece pourvue d'un revetement de protection contre l'usure
US8920881B2 (en) 2004-10-16 2014-12-30 MTU Aero Engines AG Method for producing a component covered with a wear-resistant coating
CN114437647A (zh) * 2021-12-15 2022-05-06 清华大学 柔性耐磨超疏水材料及其制备方法和应用

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