WO2023025438A1 - Procédé d'application d'un revêtement résistant à l'usure sur un cylindre sécheur yankee - Google Patents

Procédé d'application d'un revêtement résistant à l'usure sur un cylindre sécheur yankee Download PDF

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Publication number
WO2023025438A1
WO2023025438A1 PCT/EP2022/068132 EP2022068132W WO2023025438A1 WO 2023025438 A1 WO2023025438 A1 WO 2023025438A1 EP 2022068132 W EP2022068132 W EP 2022068132W WO 2023025438 A1 WO2023025438 A1 WO 2023025438A1
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WIPO (PCT)
Prior art keywords
weight percent
wear
coating layer
coating
resistant coating
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Application number
PCT/EP2022/068132
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English (en)
Inventor
Daren J. Gansert
Andrew Cross
Original Assignee
Valmet Ab
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Filing date
Publication date
Application filed by Valmet Ab filed Critical Valmet Ab
Publication of WO2023025438A1 publication Critical patent/WO2023025438A1/fr

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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
    • C23C4/04—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
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C19/00—Alloys based on nickel or cobalt
    • C22C19/03—Alloys based on nickel or cobalt based on nickel
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/46—Ferrous alloys, e.g. steel alloys containing chromium with nickel with vanadium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/50—Ferrous alloys, e.g. steel alloys containing chromium with nickel with titanium or zirconium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
    • 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
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • 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
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/082—Coating starting from inorganic powder by application of heat or pressure and heat without intermediate formation of a liquid in the layer
    • 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
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/082—Coating starting from inorganic powder by application of heat or pressure and heat without intermediate formation of a liquid in the layer
    • C23C24/085—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • C23C24/087—Coating with metal alloys or metal elements only
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
    • C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
    • C23C28/022—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer with at least one MCrAlX layer
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/321—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer with at least one metal alloy layer
    • 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
    • C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • C23C28/30—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer
    • C23C28/32—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer
    • C23C28/322—Coatings combining at least one metallic layer and at least one inorganic non-metallic layer including at least one pure metallic layer only coatings of metal elements only
    • 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
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • 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
    • 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
    • C23C4/067—Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
    • 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
    • C23C4/073—Metallic material containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-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
    • C23C4/129—Flame 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
    • C23C4/131—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
    • 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
    • C23C4/18—After-treatment

Definitions

  • the present disclosure relates in general to a method of applying a wear-resistant coating on a Yankee drying cylinder.
  • a fibrous web that has been formed in a forming section is typically dried on a Yankee drying cylinder typically constructed of cast iron or steel or a combination of both, which is normally heated from within by hot steam.
  • Yankee drying cylinder typically constructed of cast iron or steel or a combination of both, which is normally heated from within by hot steam.
  • These drums which expand and contract with the internal steam heat and pressure carry the moisture containing paper web partway around their circumference to a take-off point marked by a separation or creping doctor blade which acts to separate the fibrous tissue or paper web from the drum for collection on a take-up roll.
  • Yankee dryer drums are subject to wear from friction, i.e. tribological wear, as well as from chemical wear or erosion caused by chemical action, e.g.
  • the methods of improving the tribological and erosive wear resistance of Yankee dryer drums including thermal arc spraying the drum have been a long standing proven Valmet process technology for over 3.5 decades, mostly using iron based raw materials and certain thermal arc processes that use a wire comprised of an iron based superalloy (a super alloy is an alloy with the ability to operate at a high fraction of its melting point) to form an amorphous and / or microcrystalline coating which can be subsequently ground to shape.
  • the coated Yankee dryer drum has a hard, wear resistant coating that wears at a lower rate than the original surface . The coating is homogenous and wears slowly - it has a consistent composition throughout its thickness.
  • the present disclosure relates to a method of applying a wear-resistant coating on the outer surface of a Yankee drying cylinder shell (also known as a drum).
  • the present method is applicable to either new or refurbished Yankee dryers, such as Yankee dryers comprising a cylindrical shell made of cast iron and/or steel materials.
  • the Yankee dryer drum is trued and either set in a jig or the existing machine frame is used for application of the coating onto the typical drum body.
  • the drum body may be rotated in front of a thermal spray apparatus and the material for the coating, supplied in wire or powder form, is heated to become plastic and/or semi-molten and/or molten and sprayed onto the drum surface.
  • thermal spray coating processes that may be used in the application method.
  • an arc spray device for example a twin wire arc spray, a wire is melted in an electric arc forming microdroplets which are blown at high velocity onto the drum surface.
  • a powder of the desired coating material is introduced into an oxygen and fuel mix.
  • the oxygen and fuel mix is combusted.
  • the powder is heated by the combustion process and the expansion of the exhaust gas accelerates the powder to very high speeds.
  • the heated powder particles are in a plastic and/or semi-molten and/or molten state and are directed towards the Yankee drum surface. Upon impact with the drum surface the energy of the impact causes the powder particles to deform and form a dense coating.
  • the thermal spraying conditions are adapted to each different composition and size of powder or wire so that the dense coating is non-homogeneous in structure and is a porous coating with microcracks and particle boundary layers between the re-solidified particles which act as stress relievers, thereby increasing the durability and reducing the brittleness of the coating. It is believed that such a porous coating comprises un-melted particles, lamella of re-solidified particles, voids, and oxide inclusions.
  • thermal spray coating processes may be used such as plasma spraying, water stabilized plasma spraying and combustion powder or wire spraying.
  • the powder or wire feedstock can be heated by combustion e.g. in the exhaust gas stream of a fuel (e.g. hydrogen, propane, propylene, kerosene) mixed with air or oxygen or by electricity.
  • a fuel e.g. hydrogen, propane, propylene, kerosene
  • the feedstock enters the heated gas and is heated to become plastic and/or semi-molten and/or molten to form droplets which are transported at high velocity onto the surface to be coated.
  • Porosity in the coating should preferably be limited to being equal to or less than 5% and preferably is greater than or equal to 1% as determined by inspection using A STM Standard E2109 - 01 (Reapproved 2014) “Standard Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings). Flexing of the Yankee drum walls occurs during use as the cylinder walls bow out locally under centrifugal forces as well as internal pressures caused by pressurized steam used to heat the Y ankee.
  • a Yankee dryer drum that has been coated in accordance with the herein described method can be installed, or reinstalled, in the tissue or papermaking line where it carries the papermaking web around a portion of its circumference while heating the web to substantial dryness, so it can be taken off at the doctor blade device for rolling on a take-up roll. It is in the increased longevity of the doctor blade, reduced wear rate of the yankee dryer shell and the consequent reduced downtime that the present Yankee dryer drums prove their value. While not wishing to be bound to a particular theory, it is believed that the coating provided by the present method maintains its composition substantially constant through the coating depth in contrast to prior art coating materials which change in composition through depth, sometimes through loss of an element such as chromium.
  • wear of the coating does not adversely affect the coating properties.
  • Resistance to tribological wear, chemical wear and erosive wear remains effective over time.
  • Continuing effective wear resistance means that the coating surface will not become rough as wear progresses or because of compositional changes.
  • a lack of increase in surface roughness means that the doctor blade at the take-off location does not wear unduly or irregularly, which in turn prolongs the service life of the doctor blade.
  • the present disclosure provides a coating interposed between the tissue or papermaking web and the Yankee dryer drum surface which coating enables some or all of the above-described advantages.
  • a coated Yankee dryer drum affording these same advantages is further provided.
  • Selection of the coating alloy raw material (the coating “feedstock”) and the thermal spraying process, gas types, pressures and flows in accordance with this invention substantially reduces or eliminates any off gassing of Hexavalent Chromium into the air during thermal spraying and subsequent grinding, and there are substantially no emissions of Hexavalent chromium to the floor of the site.
  • the coating feedstock used for forming the wear-resistant coating layer in accordance with the present disclosure consists of:
  • impurities should be considered to mean unavoidable impurities resulting from the raw material(s) used for, or resulting from, the manufacturing process for producing the coating feedstock, unless explicitly stated otherwise.
  • the coating feedstock used for forming the wear-resistant coating layer consists of: from 1.40 to 2.02 weight per cent Al, from 0.00 to 10.00 weight percent Ti, from 0.10 to 10.08 weight percent Si, from 1.80 to 10.00 weight percent B, from 15.00 to 16.10 weight percent Mo, from 10.00 to 11.36 weight percent V, from 2. 10 to 2.50 weight percent C, from 0.000 to 0.020 weight percent Cr, from 0. 10 to 0.30 weight percent Mn, from 0.00 to 0.10 weight percent Mg, from 0.00 to 1.00 weight percent Ni, from 0.00 to and 0.50 weight percent Nb, the remainder being iron and impurities.
  • the present disclosure further provides a method of forming a substantially homogeneous coating against tribological wear on a Yankee dryer drum, including thermal spraying the coating onto the web contacting surfaces of the dryer drum. Since during use of a Yankee drum there is continual wear, the capacity of a coating according to the present disclosure to maintain a high degree of uniformity of composition continuous through the coating thickness, rather than have the coating composition vary and possibly vary the method, quality and efficiency of tissue or papermaking with a Yankee dryer, including passing a tissue or paper formed web over a Yankee dryer drum in drying relation, and interposing between the paper-making web and the dryer drum a tribological and erosive wear limiting coating becomes paramount. Tribological wear will cause development of surface imperfections, manifested generally as roughness, loss of doctor blade efficiency, and deterioration in efficiency and productivity.
  • the present disclosure further provides a coated Yankee dryer comprising a drum, the drum having a tribological and erosive wear limiting iron alloy coating wherein the iron alloy coating has the composition:
  • a bond coating layer may be interposed between the outer surface of the cylindrical shell of the Yankee drying cylinder and the wear-resistant coating layer.
  • Such a bond coating layer may further facilitate the bonding of the wear-resistant coating to the outer surface of the drum.
  • Such a bond coating may stabilize the underlying cast iron or steel substrate and cover any small defects - especially with a cast iron shell that can have areas of harder and softer material / more or less porosity / inclusions / other defects that result from the casting process.
  • the final coating (that is, any bond coating layer and the wearresistant coating layer after machining) preferably has a thickness of 100 pm - 3990 pm wherein the wear-resistant coating layer is equal to or greater than 100 pm and equal to or less than 1990 pm thick, and if a bonding coating is applied then the bond coating layer is equal to or greater than 1.00 and equal to or less than 2000 pm thick, the coating preferably has a porosity which is equal to or less than 5% and preferably is greater than or equal to 1% as determined by A STM Standard E2109 - 01 (Reapproved 2014) “Standard Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings), the coating preferably has a diamond pyramid hardness (DPH) determined by ASTM E384-10, “Standard Test Method for Knoop and Vickers Hardness of Materials”, which is equal to or greater than 650 and equal to or less than 1004; the coating preferably is either low Chrome (that is, equal to or less than
  • the wear-resistant coating layer is equal to or greater than 650 pm and equal to or less than 850 thick and the final coating is thermally sprayed onto the drum to form a coating in which the layer of wear resistant coating has a hardness from 650-1004 DPH.
  • the wear resistant coating has homogenous coating properties throughout the thickness of the wear resistant coating. The porosity of the wear resistant coating helps liquid chemical coatings which are applied to the exposed surface of the wear resistant coating to stick to the wear resistant coating. Such porosity remains as the wear resistant coating wears, which is in contrast to prior art devices which relied on surface roughness to help the liquid chemical coating to stick to the wear resistant coating of the Yankee.
  • a method according to the invention comprises providing a Yankee drying cylinder having a cylindrical shell or drum with a circular cross-section and an outer surface and performing a thermal spray operation to form a wear-resistant coating layer on the outer surface of the Yankee drying cylinder during which thermal spray operation coating feedstock according to the present invention is fed to one or more spray devices, heated to become plastic and/or semi-molten and/or molten and sprayed onto the outer surface of the shell of the Yankee drying cylinder to form the wear-resistant coating layer.
  • the coating feedstock for the thermal spray operation preferably comprises no Chromium or only a small amount of Chromium which is equal to or greater than 0.000 and equal to or less than 0.050 weight percent, preferably equal to or less than 0.020 weight percent, and more preferably is equal to or less than 0.010 weight percent.
  • the outer surface of the shell may be sprayed until the wear-resistant coating layer has obtained a thickness of 680 pm - 2000 pm, preferably 800 pm to 1000 pm. Subsequently, on the now coated outer surface, a grinding operation may be performed, and the outer surface may then be polished. Preferably, any grinding and polishing operations are carried out such that, after the grinding operation and the polishing operation, the wearresistant coating layer has a residual thickness from 100 pm - 1990 pm, preferably 650 pm to 850 pm.
  • an optional bond coating layer to the outer surface of the circular cylindrical shell before the wear-resistant coating is applied.
  • the bond coating layer is intended to stabilize the outer surface of the steel shell, to pacify imperfections from the casting process for a cast iron shell and to improve adherence of the wear-resistant coating layer to the circular cylindrical shell .
  • the application of the wear-resistant coating layer may be preceded by the steps of: performing an initial first grinding operation on the outer surface of the shell; grit blasting the outer surface after the initial grinding operation; optionally coating the ground and grit blasted outer surface to form a bond coating layer on the ground and grit blasted surface.
  • Said coating operation to form a bond coating layer may for example be performed by an initial spraying operation.
  • a bond coating feedstock is fed to one or more thermal spray devices, heated to become plastic and/or semimolten and/or molten and sprayed onto the ground and grit blasted outer surface to form the bond coating layer.
  • the bond coating feedstock for any such initial thermal spraying operation is preferably a Ni-Al mixture or alloy consisting essentially of Ni and Al and unavoidable impurities comprising Ni at an amount equal to or greater than 85.00 percent by weight and less than or equal to 98.00 percent by weight and Al at an amount equal to or less than 15.00 percent by weight and equal to or greater than 2.00 percent by weight.
  • the wear-resistant coating layer according to the invention is subsequently applied on top of the bond coating layer.
  • the thickness of the bond coating layer is preferably equal to or greater than 1.00 pm and equal to or less than 2000 pm and more preferably 10 pm to 30 pm.
  • each pass of the thermal spraying device, commonly called a “gun” adds 10- 20 pm additional bond coat thickness.
  • the method may optionally comprise the step of applying a sealant, for example mono ammonium phosphate or di ammonium phosphate dissolved in water, to the wear-resistant coating layer over the surface of the wear-resistant coating layer.
  • a sealant for example mono ammonium phosphate or di ammonium phosphate dissolved in water
  • ADP ammonium dihydrogen phosphate
  • MAP mono ammonium phosphate
  • MAP has a moderately low pH that remains almost constant at different concentrations.
  • Diammonium phosphate (DAP) chemical formula (NH4)2HPO4 is one of a series of water-soluble ammonium phosphate salts that can be produced when ammonia reacts with phosphoric acid.
  • MAP and DAP create a uniform bonding surface on the Yankee dryer to help protect the finished surface and to assist it to accept the blended chemical coating added during the paper and tissue making processes.
  • MAP was originally used in the metal plating industry to prep the metal surfaces to accept the plating metals.
  • MAP and DAP do a similar job for Yankee coating - it assists the blended chemical coating applied during the paper making process to more readily adhere to the Yankee surface and to adhere in a uniform and even manner.
  • MAP and DAP also forms a hard-micro surface on cast iron Yankees that will over time create a harder surface.
  • Cast iron has a Rockwell hardness of 23 - but, for example, when continuously exposed to MAP the Rockwell hardness increases to 35. This harder micro-surface helps protect the Yankee from damage.
  • MAP and DAP not only spread the coating uniformly it also can assist in accelerating the cross linking of the organic polymer used in the chemical coating applied to the Yankee surface.
  • MAP and DAP will help prevent corrosion by interfering with electron transfer across the water phase and the Yankee surface. This is especially important in mills susceptible to Yankee cylinder edge crevasse build-up.
  • phosphate coatings serve as a surface preparation for further coating. A function they perform effectively with excellent adhesion and electric isolation. The porosity allows the additional materials to seep into the phosphate coating after drying and become mechanically interlocked. The dielectric nature electrically isolates anodic and cathodic areas on the surface, minimizing under-film corrosion that sometimes occurs at the interface of the coating and substrate; it also minimizes the risk for graphitic corrosion in cast iron.
  • MAP and DAP can be very beneficial in protecting the Yankee surface and establishing a good Yankee organic coating.
  • Other benefits of using MAP and DAP are that scratches and porosity can be somewhat filled and a level of corrosion resistance can be achieved. Due to the combination of hydrophobic and hydrophilic properties between the wet pulp or web to the coated surface, the contact and release-ability are key factors to allow the “pickup” of the web and “release” of the tissue during tissue paper manufacturing.
  • This feature of porosity also called, “Surface Texturing” enhances the ability to speed up tissue paper operations for paper making and realizing a more economical product and also allows for the reduction of wear on both the Yankee and doctor blade surfaces allowing tissue operations to continue for long periods without interruption.
  • the polishing operation may be performed until the surface of the wear-resistant layer has obtained a surface roughness Ra in the range of 0. 1 pm - 1.2 pm, preferably in the range of 0.2 pm - 0.8 pm.
  • the wear-resistant coating on the surface of the Yankee cylinder consists of:
  • the coating has an ASTM E384-10 DPH hardness equal to or greater than 650 and equal to or less than 1004.
  • the wear-resistant coating according to the present disclosure consists of: from 1.40 to 2.02 weight per cent Al, from 0.00 to 10.00 weight percent Ti, from 0. 10 to 10.08 weight percent Si, from 1.80 to 10.00 weight percent B, from 15.00 to 16. 10 weight percent Mo, from 10.00 to 11.36 weight percent V, from 2. 10 to 2.50 weight percent C, from 0.000 to 0.020 weight percent Cr, from 0. 10 to 0.30 weight percent Mn, from 0.00 to 0.10 weight percent Mg, from 0.00 to 1.00 weight percent Ni, from 0.00 to and 0.50 weight percent Nb, the remainder being iron and impurities, and has preferably an ASTM E384-10 hardness equal to or greater than 650 and equal to or less than 1004.
  • the coating feedstock used to form the wear-resistant coating layer comprises from 16.00 to 16.10 weight percent Mo, from 10.85 to 10.98 weight percent V, from 1.81 to 1.85 weight percent B, from 2.17 to 2. 19 weight percent C, from 0.00 to 0. 10 weight percent Ti, from 0.00 to 0.10 weight percent Mg, from 0.00 to 0. 10 weight percent Ni, from 0.00 to 0.50 weight percent Nb, and from 0.000 to 0.020 weight percent Cr.
  • Such a coating feedstock may essentially consist of from 16.00 to 16.10 weight percent Mo, from 10.85 to 10.98 weight percent V, from 1.81 to 1.85 weight percent B, from 2.17 to 2.19 weight percent C, from 0.00 to 0. 10 weight percent Ti, from 0.00 to 0.10 weight percent Mg, from 0.00 to 0. 10 weight percent Ni, from 0.00 to 0.50 weight percent Nb, from 0.000 to 0.020 weight percent Cr with the balance being iron and impurities.
  • the coating feedstock according to the first exemplifying embodiment comprises from 16.00 to 16.04 weight percent Mo, from 10.85 to 10.98 weight percent V, from 1.81 to 1.85 weight percent B, from 2.17 to 2.19 weight percent C, and from 0.000 to 0.010 weight percent Cr.
  • the coating feedstock used to form the wear-resistant coating layer comprises from 15.00 to 15.20 weight percent Mo, from 11.26 to 11.40 weight percent V, from 1.80 to 1.90 weight percent B, from 2.19 to 2.29 weight percent C, from 0.00 to 0.01 weight percent Ti, from 0.00 to 0.01 weight percent Mg, from 0.00 to 0.03 weight percent Ni, from 0.00 to 0.03 weight percent Nb, and from 0.000 to 0.010 weight percent Cr.
  • Such a coating feedstock may essentially consist of from 15.00 to 15.20 weight percent Mo, from 11.26 to 11.40 weight percent V, from 1.80 to 1.90 weight percent B, from 2.19 to 2.29 weight percent C, from 0.00 to 0.01 weight percent Ti, from 0.00 to 0.01 weight percent Mg, from 0.00 to 0.03 weight percent Ni, from 0.00 to 0.03 weight percent Nb, from 0.000 to 0.010 weight percent Cr with the balance being iron and impurities.
  • the coating feedstock for the wear-resistant coating layer according to the second exemplifying embodiment comprises 15.01 weight percent Mo, 11.36 weight percent V, 1.85 weight percent B, 2.24 weight percent C, from 0.00 to 0.01 weight percent Ti, from 0.00 to 0.01 weight percent Mg, from 0.00 to 0.03 weight percent Ni, from 0.00 to 0.03 weight percent Nb, and from 0.0000 to 0.0005 weight percent Cr with the balance being iron and impurities.
  • the coating feedstock used to form the wear-resistant coating layer comprises from 15.00 to 16.10 weight percent Mo, from 0.00 to 2.10 weight percent Al, from 0.00 to 0.30 weight percent Mn, from 0.00 to 10.20 weight percent Si, from 0.00 to 10.00 weight percent Ti, from 0.00 to 0.20 weight percent Mg, from 0.00 to 1.00 weight percent Ni, from 0.00 to 0.50 weight percent Nb, and, from 0.000 to 0.020 weight percent Cr.
  • Such a coating feedstock may essentially consist of from 15.00 to 16.10 weight percent Mo, from 0.00 to 2.10 weight percent Al, from 0.00 to 0.30 weight percent Mn, from 0.00 to 10.20 weight percent Si, from 0.00 to 10.00 weight percent Ti, from 0.00 to 0.20 weight percent Mg, from 0.00 to 1.00 weight percent Ni, from 0.00 to 0.50 weight percent Nb, and, from 0.000 to 0.020 weight percent Cr with the balance being iron and impurities.
  • the coating feedstock for the wear-resistant coating layer according to the third exemplifying embodiment consists of from 15.00 to 16.00 weight percent Mo, 1.40 to 2.02 weight percent Al, 0.10 to 0.30 weight percent Mn, 0.10 to 10.10 weight percent Si, from 0. 10 to 10.00 weight percent Ti, from 0.00 to 0. 10 weight percent Mg, from 0.00 to 1.00 weight percent Ni, from 0.00 to 0.50 weight percent Nb, and from 0.000 to 0.020 weight percent Cr with the balance being iron and impurities.
  • the at least one or more thermal spray devices that act against a part of the outer surface of the shell to apply coating for the wear-resistant coating layer to that part of the outer surface is operated at a distance from that part of the outer surface which is in the range of 50 mm - 260 mm and preferably at a distance in the range of 60 mm - 225 mm. More specifically, the outlet (where the feedstock exits the spray device) of the thermal spray device may be arranged at said distance from that part of the outer surface. In embodiments where a bond coating layer is applied by usage of a thermal spray device, such a spray device may be operated at a similar distance from the outer surface as in the case of the thermal spraying to form the wear-resistant coating.
  • the plastic and/or semiplastic and/or molten feedstock is sprayed onto the outer surface of the shell at an angle of 30° - 90° with respect to that part of the outer surface, preferably at an angle of 45° - 90° and even more preferred at an angle in the range of 75° - 90°.
  • the initial thermal spraying operation may be initiated less than or equal to 90 minutes after the grit blasting has been completed, preferably less than or equal to 45 minutes and even more preferred less than or equal to 5 minutes after the grit blasting has been completed-
  • the initial thermal spraying operation is carried out at such a rate that the entire outer surface has been covered in less than or equal to 3 hours after the grit blasting has been completed.
  • thermal spray devices may be arranged in banks of thermal spray devices, for example one or two or three or more, thermal spray devices, and there may be a plurality of banks of thermal spray devices, for example three, banks of two or three or more thermal spray devices. Even more than 9 thermal spray devices arranged in banks may be used, for example for large cylinders, to reduce the process time.
  • a single thermal spray gun may be used, or one, two or three or more in groups or banks of thermal spray devices may be used simultaneously during at least one of the thermal spray operations, each group comprising one or more spray devices.
  • the wear resistant coating layer is substantially inert, in order to prevent rusting, oxidation or damage, preferably the grinding and/or polishing operation that follows the forming of the wearresistant coating layer is initiated less than or equal to 15 minutes, preferably less than or equal to 10 minutes after the thermal spraying of the wear-resistant coating layer has been completed.
  • the coating feedstock that is fed to the at least one spray device to form the wear-resistant coating layer may come in the shape of two wires, each wire having a diameter in the range of 1.1 mm - 3.8 mm.
  • At least one thermal spray device is an arc spray gun.
  • all thermal spray devices may optionally be arc spray guns.
  • Different thermal spray devices and different types of thermal spray devices may be used for applying the bond coating layer and for applying the wear resistant coating layer.
  • At least one thermal spray device is a HVOF spray device.
  • all thermal spray devices may optionally be HVOF guns.
  • At least one thermal spray device is a HVAF spray device.
  • all thermal spray devices may optionally be HVAF guns.
  • At least one thermal spray device is a plasma spray gun.
  • all thermal spray devices may optionally be plasma spray guns.
  • At least one thermal spray device is a water stabilized plasma spray gun. When more than one thermal spray device is used, all thermal spray devices may optionally be water stabilized plasma spray guns. In an embodiment of the invention, at least one thermal spray device is a combustion powder spray device. When more than one thermal spray device is used, all thermal spray devices may optionally be combustion powder spray devices.
  • At least one thermal spray device is a wire spray device.
  • all thermal spray devices may optionally be wire spray devices.
  • the thermal spraying operation for forming the wear-resistant coating layer may be carried out such that, during the thermal spraying operation, each wire is fed to the at least one spray device at a rate of 40 mm/second - 90 mm/second, while the at least one spray device operates at a voltage in the range of 28 - 40 Volts, preferably 32-33 Volts and an amperage in the range of 100 Amps - 350 Amps, preferably 125-250 A.
  • the invention further contemplates the method of forming a coating on a Yankee dryer drum surface for protection against tribological and erosive wear by thermal spraying a composition onto said surface, said composition establishing a drum coating; with a ASTM E384-10 DPH hardness equal to or greater than 650 and equal to or less than 1004 whereby erosive wear of said drum dryer surface caused by chemical action of chloride, fluoride, and sulfite ions during papermaking is resisted.
  • This is achieved by thermal spraying an iron based alloy coating feedstock according to the present disclosure onto the web-contacting surface.
  • special thermal arc parameters are adapted to eliminate or reduce any Hexavalent chromium emissions.
  • iron based alloy coating feedstocks according to the present disclosure are sprayed using athermal arc process using the following parameters;
  • the iron based alloy coating feedstock according to the present disclosure can be applied in the form of a powder using a combustion spraying method such as HVOF spraying, HVAF spraying, or combustion powder spraying.
  • a combustion spraying method such as HVOF spraying, HVAF spraying, or combustion powder spraying.
  • the exhaust gas temperature into which the powder is injected is of the order of 3000 0 C and the powder is accelerated to initial speeds preferably equal to or greater than 100 m/s and equal to or less than 500 m/s.
  • Preferred median particle diameters are equal to or greater than 5 pm and less than or equal to 70 pm, more preferably equal to or greater than 10 pm and less than or equal to 65 pm.
  • the temperature of the exhaust gas, initial speed of the particles and the size of the particles are controlled by the process parameters which can be adjusted to achieve the desired porosity of the wear-resistant coating.
  • the end effect of the process parameters are deliberate in order to achieve the desired structure of the coated and finish ground coating. Typically, increasing particle size alone leads to increased porosity.
  • Figure 1 is a schematic representation of a Yankee drying cylinder during operation to produce paper.
  • Figure 2 is a schematic representation in perspective of a Yankee drying cylinder.
  • Figure 3 is a schematic representation of a step in the process of applying a coating layer to the surface of a Y ankee drying cylinder.
  • Figure 4 is a schematic representation of a further step in the process of applying a coating layer to the surface of a Yankee drying cylinder.
  • Figure 5 is a schematic representation of how coating material is thermally sprayed onto the surface of the shell of the Yankee drying cylinder.
  • Figure 6 is a schematic representation of how several spray devices may be used simultaneously to apply a coating layer to the outer surface of the Yankee drying cylinder.
  • Figure 7 is a schematic representation of how a spray device may be oriented relative to the shell of the Y ankee drying cylinder during application of a coating layer.
  • Figure 8 is a schematic cross-sectional representation of a Yankee drying cylinder that has been coated in accordance with one embodiment of the present invention.
  • Figure 9 is a schematic representation of a possible initial spraying step that precedes the step in which thermal spraying is used to form a wear-resistant coating layer.
  • Figure 10 is a schematic cross-sectional representation of a Yankee drying cylinder that has been coated with a coating in accordance with the invention.
  • Figure 11 is a schematic representation of a polishing step.
  • Figure 12 is a schematic representation of a possible step at the end of the process of providing a wearresistant coating layer.
  • a Yankee drying cylinder 1 is shown in operation during manufacture of a paper web such as a tissue paper web.
  • a wet fibrous web W which comes from the forming section (not shown in Fig. 1) of a paper making machine is carried by a fabric such as a water-receiving felt 15 to a transfer nip formed between a transfer roll (or press roll) 16 and a Yankee drying cylinder 1.
  • the transfer roll (or press roll) 16 may be lightly loaded against the Yankee drying cylinder 1, just sufficiently to form a transfer nip.
  • the roll 16 may be loaded with a considerable force against the Yankee drying cylinder 1 and form a dewatering nip with the Yankee drying cylinder 1 such that water is pressed out of the fibrous web W.
  • Water can also be removed by use of an internal vacuum box combined with a transfer roll (or press roll) with a perforated shell.
  • the fibrous web W is transferred from the fabric 15 to the outer surface 3 of the Yankee drying cylinder that is rotating in the direction of arrow R about its axis of rotation A which is also the longitudinal axis of symmetry of the Yankee drying cylinder 1.
  • the Yankee drying cylinder 1 is heated to a high temperature, normally by means of hot steam that is supplied to the interior of the Yankee drying cylinder.
  • the fibrous web W is ready-dried on the outer surface 3 of the Yankee drying cylinder 1 and creped off from the Yankee drying cylinder by a doctor 14. While not shown in the figures, it should be understood that the Yankee drying cylinder 1 normally has internal grooves from which condense water is evacuated during operation.
  • the Yankee drying cylinder may a cast iron Yankee or a Yankee drying cylinder made of welded steel.
  • FIG. 2 shows an example of a Yankee drying cylinder in perspective.
  • the Yankee drying cylinder 1 comprises a circular cylindrical shell 2 which is designed to be capable of receiving hot steam.
  • the cylindrical shell with a circular cross-section has an outer surface 3.
  • the internal grooves of the Yankee drying cylinder 1 (if present) are located on an internal surface of the shell 2.
  • the Yankee drying cylinder also has end walls 17 of which only one can be seen in Fig. 2.
  • the end walls 17 may be connected to the shell 2 by means of, for example, welding, screws or bolts.
  • a spray device 5 a thermal spray device 5 which may be, for example, an arc spray gun or HVOF or HVAF or plasma spray gun or water stabilized plasma spray gun, combustion powder spray device or wire spray device or combinations thereof or the like thereof of , are used to apply a wear-resistant coating layer 4 (shown in fig. 8) to the outer surface 3 of a circular cylindrical shell 2 which is part of a Yankee drying cylinder 1.
  • a coating feedstock 6 is fed to the spray device 5, heated to become plastic and/or semi -molten and/or molten and sprayed onto the outer surface 3 of the shell 2.
  • the coating feedstock 6 may comprise two separate wires 6a, 6b.
  • the wires 6a, 6b are electrically charged - one being positive and the other being negative.
  • the wires 6a, 6b are molten when they come into close proximity or are in contact with each other and, as schematically indicated in Fig. 5, air (or gas) is used to blow the molten feedstock onto the outer surface 3 in a spray 18 that lands as small droplets on the outer surface These droplets form a wear-resistant coating layer 4 on the circular cylindrical shell 2.
  • the coating feedstock 6 that is fed to at least one spray device 5 and that is used for the thermal spray operation is formed by a material that consists of:
  • the feedstock of this invention consists of: from 1.40 to 2.02 weight per cent Al, from 0.00 to 10.00 weight percent Ti, from 0. 10 to 10.08 weight percent Si, from 1.80 to 10.00 weight percent B, from 15.00 to 16. 10 weight percent Mo, from 10.00 to 11.36 weight percent V, from 2. 10 to 2.50 weight percent C, from 0.000 to 0.020 weight percent Cr, from 0. 10 to 0.30 weight percent Mn, from 0.00 to 0. 10 weight percent Mg, from 0.00 to 1.00 weight percent Ni, from 0.00 to and 0.50 weight percent Nb, the remainder being iron and impurities.
  • the sum of Al + Mn + Si is equal to or greater than 5.00 and equal to or less than 10.00 weight percent.
  • the coating feedstock used to form the wearresistant coating layer consists of from 15.00 to 16. 10 weight percent Mo, from 10.85 to 10.98 weight percent V, from 1.81 to 1.85 weight percent B, from 2.17 to 2. 19 weight percent C, from 0.00 to 0. 10 weight percent Ti, from 0.00 to 0. 10 weight percent Mg, from 0.00 to 0.10 weight percent Ni, from 0.00 to 0.50 weight percent Nb, from 0.000 to 0.020 weight percent Cr with the balance being iron and impurities.
  • the coating feedstock for the wear-resistant coating layer 4 consists of from 16.00 to 16.04 weight percent Mo, from 10.85 to 10.98 weight percent V, from 1.81 to 1.85 weight percent B, from 2.17 to 2.19 weight percent C, from 0.000 to 0.010 weight percent Cr and the balance being iron and impurities.
  • the coating feedstock used to form the wearresistant coating layer consists of from 15.00 to 15.20 weight percent Mo, from 11.26 to 11.40 weight percent V, from 1.80 to 1.90 weight percent B, from 2.19 to 2.29 weight percent C, from 0.00 to 0.01 weight percent Ti, from 0.00 to 0.01 weight percent Mg, from 0.00 to 0.03 weight percent Ni, from 0.00 to 0.03 weight percent Nb, from 0.000 to 0.010 weight percent Cr with the balance being iron and impurities.
  • the coating feedstock for the wear-resistant coating layer of this exemplified embodiment consists of 15.01 weight percent Mo, 11.36 weight percent V, 1.85 weight percent B, 2.24 weight percent C, from 0.00 to 0.01 weight percent Ti, from 0.00 to 0.01 weight percent Mg, from 0.00 to 0.03 weight percent Ni, from 0.00 to 0.03 weight percent Nb, from 0.000 to 0.005 weight percent Cr with the balance being iron and impurities.
  • the coating feedstock [Oct 21 ranges] used to form the wear-resistant coating layer consists of from 15.00 to 16.10 weight percent Mo, from 0.00 to 2.10 weight percent Al, from 0.00 to 0.30 weight percent Mn, from 0.00 to 10.20 weight percent Si, from 0.00 to 10.00 weight percent Ti, from 0.00 to 0.20 weight percent Mg, from 0.00 to 1.00 weight percent Ni, from 0.00 to 0.50 weight percent Nb, and from 0.000 to 0.020 weight percent Cr with the balance being iron and impurities.
  • the coating feedstock for the wear-resistant coating layer of this exemplified embodiment consists of from 15.00 to 16.00 weight percent Mo, 1.40 to 2.02 weight percent Al, 0.10 to 0.30 weight percent Mn, 0.10 to 10.10 weight percent Si, from 0.10 to 10.00 weight percent Ti, from 0.00 to 0. 10 weight percent Mg, from 0.00 to 1.00 weight percent Ni, from 0.00 to 0.50 weight percent Nb, and from 0.000 to 0.020 weight percent Cr with the balance being iron and impurities.
  • the outer surface of the shell 2 should also be sprayed until the wear-resistant coating layer 4 has obtained a thickness equal to or greater than 680 pm and equal to or less than 2000 pm, more preferably equal to or greater than 800 pm and equal to or less than 1000 pm.
  • a grinding operation is performed on the wear-resistant coating layer.
  • a grinding operation is symbolically indicated in Fig. 3 in which a grinding tool 7 acts on the now coated outer surface 3.
  • the grinding operation is followed by polishing of the coated outer surface such that, after the grinding operation and the polishing operation, the wear-resistant coating layer 4 has a thickness equal to or greater than 100 pm and equal to or less than 1990 pm, preferably equal to or greater than 650 pm and equal to or less than 850 pm.
  • the polishing operation is indicated schematically/symbolically in Fig. 11 in which a polishing device 8 acts on the coated surface 3.
  • the polishing operation should preferably (but not necessarily) be carried out until the surface of the wear-resistant layer 4 has obtained a surface roughness Ra equal to or greater than 0.1pm and equal to or less than 1.2 pm, more preferably equal to or greater than 0.2 pm and equal to or less than 0.8 pm.
  • the wear-resistant coating layer 4 indicated in Fig. 8 is not to scale.
  • each wire may advantageously have a diameter preferably equal to or greater than 1.1 mm and equal to or less than 3.8 mm.
  • the thermal spraying operation is preferably (but not necessarily) carried out such that each wire is fed to the at least one spray device 5 at a rate preferably equal to or greater than 40 mm/second and equal to or less than 90 mm/second.
  • the at least one spray device 5 preferably (but not necessarily) operates at a voltage preferably equal to or greater than 28 and equal to or less than 40 Volts and an amperage preferably equal to or greater than 100 Amps and equal to or less than 350 Amps.
  • thermal spray devices 5 may be used and several spray devices may be arranged in groups.
  • six spray devices 5a - 5f are used simultaneously and three spray devices 5a, 5b and 5c are operating together in a group 19 while three spray devices 5d, 5e and 5f are arranged in a group 20.
  • each group may comprise of one, two, three or more than three spray devices and more than one group may be used simultaneously with other groups of spray devices.
  • two, three, four or five groups of spray devices could be used.
  • two spray devices 5 could also be arranged in a pair and operate together.
  • several pairs of spray devices could also be used simultaneously.
  • one, two, three or four pairs could be used or more than four pairs. While the method may be carried out with only one spray device 5, the simultaneous use of several spray devices makes it possible to form the coating layer in a shorter time. The use of spray devices operating close to each other in pairs or groups can result in a more even coating result.
  • the at least one spray device 5 (or several spray devices 5) such that, when the at least one spray device 5 acts against a part of the outer surface of the shell to apply coating to that part of the outer surface, the molten feedstock is sprayed onto the outer surface of the shell 2 at an angle R with respect to that part of the outer surface.
  • the angle R is preferably in the range of 30° - 90°, preferably in the range of 45° - 90° and even more preferred in the range of 75° - 90°.
  • the at least one spray device 5 is operated at a distance L from that part of the outer surface 3 against which it acts at a given moment which is in the range of 50 mm - 260 mm and preferably at a distance in the range of 60 mm - 225 mm.
  • Fig. 3 An advantageous embodiment of the inventive method will now be explained with reference to Fig. 3; Fig. 4; Fig. 9: and Fig. 10.
  • the bond layer is intended to improve adherence of the wear-resistant coating layer to the circular cylindrical shell 2.
  • the procedure may suitably be as follows.
  • An initial grinding operation (as symbolically indicated in Fig. 3) is performed on the outer surface 3 of the shell 2.
  • the outer surface 3 may be simply a surface formed by cast iron or by steel.
  • the outer surface 3 is grit blasted by a grit blasting device 9 as shown in Fig. 4.
  • the ground and grit blasted surface 3 is then coated in an initial thermal spraying operation in substantially the same way as previously described with reference to the forming of the wear-resistant coating layer except that a different coating feedstock is used.
  • the initial thermal spraying operation will form a bond coating layer 10 for the subsequently applied wear resistant coating layer.
  • this bond coating layer will temporarily form the (new) outer surface 3 of the shell 2.
  • coating feedstock in the shape of two wires 1 la, 1 lb is fed to a thermal spray device 5.
  • the coating feedstock 1 la, 1 lb is heated to become plastic and/or semi-molten and/or molten and is sent in a spray 22 onto the surface of the shell 2.
  • air or gas as indicated by the arrow in Fig. 9 may be used to force the molten feedstock towards the surface 3 of the shell 2.
  • the coating feedstock 1 la, 1 lb that is used in the initial thermal spraying operation surface to form the bond coating layer 10, consists of from 85 to 98 percent by weight Ni and from 2 to 15 percent by weight Al and unavoidable impurities.
  • the wear-resistant layer 4 will subsequently be applied/formed on top of the bond coating layer 10.
  • the circular cylindrical shell now has two coating layers, a bond layer 10 and a top layer 4 which is the wear-resistant layer.
  • the inventors have found that the bond layer 10, when formed with the feedstock described above, significantly improves adherence of the wear-resistant layer.
  • the initial thermal spraying operation to form the bond coating layer is suitably initiated less than or equal to 90 minutes after the grit blasting has been completed, preferably less than or equal to 45 minutes and even more preferred less than or equal to 5 minutes after the grit blasting has been completed.
  • time intervals may also be considered.
  • the initial thermal spraying operation is preferably carried out at such a rate that the entire outer surface has been covered less than or equal to 3 hours after the grit blasting has been completed to prevent oxidation of the exposed outer surface.
  • the grinding operation that follows the forming of the wear-resistant coating layer 4 is preferably initiated less than or equal to 15 minutes after the thermal spraying operation has been completed, in particular less than or equal to 10 minutes.
  • the method can suitably comprise an optional step of applying a sealant such as mono ammonium phosphate or di ammonium phosphate dissolved in water to the wear-resistant coating layer 4 evenly over the surface of the wear-resistant coating layer 4.
  • a device 12 for the application of mono ammonium phosphate or di ammonium phosphate sends a spray or jet of mono ammonium phosphate or di ammonium phosphate dissolved in water onto the shell 2 (and thereby also onto the wearresistant coating layer 4 which now forms the outer surface 3 of the circular cylindrical shell 2).
  • MAP and DAP create a uniform bonding surface on the Yankee dryer to help protect the finished surface and to assist it to accept the blended chemical coating added during the paper and tissue making processes.
  • MAP was originally used in the metal plating industry to prep the metal surfaces to accept the plating metals.
  • MAP and DAP do a similar job for Yankee coating - it assists the blended chemical coating applied during the paper making process to more readily adhere to the Y ankee surface and to adhere in a uniform and even manner.
  • a wear-resistant coating can be formed with minimal or no use of chromium.
  • the amount of chromium is equal or less than 0.020 % by weight, more preferably up to or less than 0.010 %, even more preferably equal to or less than 0.005% and most preferably zero.
  • a wear-resistant coating layer can be formed which has a hardness in the range of 650 - 1004 DPH .
  • the wear-resistant layer formed by the present method will be porous to some extent and the porosity is preferably equal to or less than 5% and preferably is greater than or equal to 1% % as determined by ASTM Standard E2109 - 01 (Reapproved 2014) “Standard Test Methods for Determining Area Percentage Porosity in Thermal Sprayed Coatings”.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Inorganic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

L'invention concerne un procédé d'application d'un revêtement durable résistant à l'usure sur un cylindre sécheur Yankee (1), le procédé comprenant : l'étape consistant à fournir un cylindre de séchage Yankee (1) ayant une enveloppe cylindrique (2) comprenant une section transversale circulaire et une surface externe (3) ; l'étape consistant à réaliser une opération de pulvérisation thermique pour former une couche de revêtement résistante à l'usure (4) sur la surface externe du cylindre de séchage Yankee (1) au cours de laquelle une charge d'alimentation de revêtement d'opération de pulvérisation thermique (6) est acheminée vers au moins un dispositif de pulvérisation (5), chauffée pour devenir plastique et/ou semi-fondue et/ou fondue et pulvérisée sur la surface externe (3) du cylindre de séchage Yankee (1) pour former la couche de revêtement résistante à l'usure (4), la charge d'alimentation de revêtement (6) pour l'opération de pulvérisation thermique étant constituée : de 0,0 à 2,1 pour cent en poids d'Al, de 0,0 à 10,0 pour cent en poids de Ti, de 0,0 à 10,2 pour cent en poids de Si, de 1,7 à 10,1 pour cent en poids de B, de 15,0 à 16,1 pour cent en poids de Mo, de 9,5 à 11,4 pour cent en poids de V, de 2,0 à 4,2 pour cent en poids de C, de 0,000 à 0,020 pour cent en poids de Cr, de 0,0 à 0,3 pour cent en poids de Mn, de 0,0 à 0,2 pour cent en poids de Mg, de 0,0 à 1,0 pour cent en poids de Ni, de 0,0 à 0,5 pour cent en poids de Nb, le reste étant du fer et des impuretés. L'invention divulgue également des revêtements et des cylindres Yankee ayant de tels revêtements.
PCT/EP2022/068132 2021-08-26 2022-06-30 Procédé d'application d'un revêtement résistant à l'usure sur un cylindre sécheur yankee WO2023025438A1 (fr)

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US20230064090A1 (en) * 2021-08-26 2023-03-02 Valmet Aktiebolag Method of applying a wear-resistant coating on a yankee drying cylinder, such coatings and yankee cylinders with such coatings
CN117904572B (zh) * 2024-01-15 2024-07-02 东北大学 一种车削处理提高疏水涂层耐磨性的方法

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EP2256227A1 (fr) * 2008-03-19 2010-12-01 Mitsubishi Heavy Industries, Ltd. Procédé de réparation d'un élément
US20170016105A1 (en) * 2014-03-11 2017-01-19 Daimler Ag Method for Coating a Substrate, in Which a Wire-Like Spray Material is Melted in an Electric Arc and is Isolated as a Layer on the Substrate and Electric Arc Wire Sprayed Layer
WO2017040775A1 (fr) * 2015-09-04 2017-03-09 Scoperta, Inc. Alliages résistant à l'usure sans chrome et à faible teneur en chrome

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US6171657B1 (en) 1995-12-18 2001-01-09 Bender Machine, Inc. Method of coating yankee dryers against wear
EP2256227A1 (fr) * 2008-03-19 2010-12-01 Mitsubishi Heavy Industries, Ltd. Procédé de réparation d'un élément
US20170016105A1 (en) * 2014-03-11 2017-01-19 Daimler Ag Method for Coating a Substrate, in Which a Wire-Like Spray Material is Melted in an Electric Arc and is Isolated as a Layer on the Substrate and Electric Arc Wire Sprayed Layer
WO2017040775A1 (fr) * 2015-09-04 2017-03-09 Scoperta, Inc. Alliages résistant à l'usure sans chrome et à faible teneur en chrome

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