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ADVANCEMENTS IN SURFACE ENGINEERING PROCESSES.pptx

The document provides an overview of surface engineering processes and their timeline of development. It discusses various nitriding, plating, thermal spraying, and coating processes such as gas nitriding, plasma nitriding, hard chrome plating, electroless nickel plating, physical vapor deposition, chemical vapor deposition, high-velocity oxy-fuel spraying, high-velocity air-fuel spraying, detonation gun spraying, plasma spraying, and cold spraying. It provides details on the process, applications, advantages, and issues with some of these surface modification techniques.

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ADVANCEMENTS INSURFACE ENGINEERING PROCESSES 1 S U R F A C E C O AT IN G
SURFACEENGINEERINGPROCESSES:TIMELINE 2 1908 Nitriding 1910 Wire Spray( M U Schoop Switzerland ) 1923 Anodizing1924 Hard chrome Plating 1930 Physical Vapor deposition (PVD) 1955 Detonation Gun 1960 Plasma Spray ( Metco NY) 1965 Co2 Laser Cladding 1970 Chemical vapor deposition ( CVD) Widia Germany 1980 High Velocity Oxy Fuel ( HVOF) 1990 Cold Spray ( Russia to NCMS) 2000 High Velocity Air Fuel ( HVAF) 2005 Fibre laser cladding 2003 Cold spray commercial equipment 2017 EHLV(High speed laser spray cladding )
GAS NITRIDING 3
GAS NITRIDINGPROCESS 4  Gas Nitriding  In gas Nitriding the donor is a nitrogen rich gas, usually ammonia (NH3),  When ammonia comes into contact with the heated work piece it dissociates into nitrogen and hydrogen.  The nitrogen then diffuses onto the surface of the material creating a nitride layer. This process has existed for nearly a century  Recent developments have led to a process that can be accurately controlled. The thickness and phase constitution of the resulting Nitriding layers can be selected and the process optimized for the particular properties required.
PLASMA NITRIDING 5 Schematic Representation of Plasma Nitriding
PLASMA NITRIDINGPROCESS  Plasma Nitriding, also known as ion Nitriding, plasma ion Nitriding or glow-discharge Nitriding, is an industrial surface hardening treatment for metallic materials.  In plasma Nitriding, the reactivity of the Nitriding media is due to the gas in ionized state. In this technique intense electric fields are used to generate ionized molecules of the gas around the surface to be nitrided. Such highly active gas with ionized molecules is called plasma, naming the technique. The gas used for plasma Nitriding is usually pure nitrogen, since no spontaneous decomposition is needed (as is the case of gas Nitriding with ammonia). 6
APPLICATIONS OF NITRIDING 7 Plasma Ion Nitriding on Gears Gas Nitride coating on Screws AND GEARS
HARDCHROME PLATING 8
HARD CHROME PLATING • Chrome Discovered 1798,, first successful electrolytic • plating 1856, commercial utilization late 1920’s • Advantages –Resists most chemicals, oxygen, and moisture in air – Does not tend to seize,, gall,, or cold weld – Hard surface typical 62 Rc, 0.003”--0..015” typical thickness – Simple technology – Excellent wear resistance – Historically relatively inexpensive
ISSUES WITH HARD CHROME PLATING – The process produces large amounts of hydrogengas in the gas bubbles burst throwing hexavalentchrome solution into the air as fine mist. – Hexavalentchrome is a know carcinogen. – The process produces large volumes of toxic waste.. – EPA and OSHA have mandated more stringent stack emission levels and lowering of permissible exposure limitsfor workers. – T h i s results in increased costs and business risks..
ENP (ELECTROLESSNICKELPLATING) 11
ADVANTAGES OF ENP 12  Even coating on parts surface can be achieved.  No sophisticated jigs or racks are required.  There is flexibility in plating volume and thickness.  The process can plate recesses and blind holes with stable thickness.  Chemical replenishment can be monitored automatically.  Complex filtration method is not required  Matte, semi-bright or bright finishes can be obtained.
APPLICATIONOF ENPCOATING 14 ENP Coated Bolts Wheel Rims ENP Coated
15
 PVD is characterized by a process in which the material goes from a condensed phase to a vapor phase and then back to a thin film condensed phase. The most common PVD processes are sputtering and evaporation. PVD is used in the manufacture of items which require thin films for mechanical, optical, chemical or electronic functions. Examples include semiconductor devices such as thin film solar panels, aluminized PET film for food packaging and balloons, and titanium nitride coated cutting tools for metalworking. Besides PVD tools for fabrication, special smaller tools (mainly for scientific purposes) have been developed.  The source material is unavoidably also deposited on most other surfaces interior to the vacuum chamber, including the fixturing used to hold the part 16
17 PVD Coating on Drill Bits & Ornaments
18 Schematic of CVD Coating Process
CVD (CHEMICAL VAPOR DEPOSITION) 19  Chemical vapor deposition (CVD) is a chemical process used to produce high quality, high-performance, solid materials. The process is often used in the semiconductor industry to produce thin films.  In typical CVD, the wafer (substrate) is exposed to one or more volatile precursors, which react and/or decompose on the substrate surface to produce the desired deposit. Frequently, volatile by-products are also produced, which are removed by gas flow through the reaction chamber.
APPLICATIONSOF CVD COATING 20 Typical CVD Coating Equipment CVD Coated Parts
CVD V/SPVD 21
22 HP/HVOF HVAF Axial plasma Wire spray Metco 2E Cold spray NCMS Laser cladding Cold spray commercial guns wire s
23
xtausraxx Various surface Modification processes
Particle velocity V ~ 800- 1200m/sec Spray dist 6-15 inches – No heat transfer to base D -- = 3.5 d Gun- Flsme/Plasma/HV OF Flame Temp 3000- 15000*C Heated particles propelled Concept and Schematic of THERMAL SPRAY Grit blasted surface Layer by layer coating builds up
26 Chemical Composition Manufacture Method Particle Shape Particle Size Distribution Hall Flow Apparent Density Liquid- or Gas- Fuel Spray Gun Choice Fuel Used Spray Parameter Kinetic Energy Thermal INPUT MATL/POWDER SPRAY PROCESS / GUN COATING PROPERTIES Wear Resistance Corrosion Resistance Phase Composition Bond strength Hardness Porosity Deposition Efficiency
PLASMA SPRAYING • Most versatile process in terms of range of coatings •plasma temperature: up to 15000 ºC. • virtually all existing materials including ceramics. Flame spray 32 57 0- 500m/sec
DETONATION GUN SPRAYING • Flame temperature: 4000 ºC •Particle Velocity : 1000 m/Sec. •Bond Strength: 100 Mpa 28
HIGH-VELOCITYOXY FUELSPRAYING (HVOF) 29
HVOF Porosity 0.5-1% Hardness 1100-1250 HV0.3 Harder coatings are overstressed ±150-200 HV deviation 4-5 kg/h, 5-10 µm per pass HVAF Gas impermeable @50 µm 1200, 1350 or 1600+ HV0.3 Ductile and cavitation resistant ±50-60 HV deviation 15-33+ kg/h, 50 µm per pass
HVAF Jet Kote Kermetico C6, C7 1700- 2100 °C DJ 2600 JP 5000 2982 °C 2982 °C Opt Tc + Axial ↓ Opt heating Long nozzle ↓ Opt velocity
THE RESULT kermetico.com jrienecker@kermetico.com Gu n Hardness, HV300 Poro -sity, % Fracture Tough- ness K1C Ratio W2C to WC AK 1,326 ± 98 0.3 5.97 ±0.7 0 JP 1,289 ± 108 0.6 4.87 ±0.6 0.12 JK 1,047 ± 112 1.7 3.01 ±0.6 0.7 Source: Wear and corrosion performance of WC-10Co-4Cr coatings deposited by different HVOF and HVAF spraying processes Qun Wang etc., Hunan University, 2013 JP 5000 AK7 Jet Kote
EROSIONRATEVS. AN ATTACK ANGLE: WC-10CO-4CR HVAF COATINGS PERFORM AS A DUCTILEMATERIAL Midwest Thermal Spray (MI, USA) 0.000 0.050 0.100 0.150 0.200 0.250 0.300 AK06-HVAF: WC-Co-Cr HVOF MTS: WC-Co-Cr SHS8000, fused Volume loss, mm3/min Dry erosion rate of hard coatings Angle 30 deg. Angle 90 deg.
UNIFORMITYOF HVAF COATING PROPERTIES: HARDNESS OF HVOF AND KERMETICO HVAF WC-10CO-4CR COATINGS (SCHLUMBERGER, UK) kermetico.com jrienecker@kermetico.com HVAF OF Relative standard deviation, % HVAF: 3.9 % HVOF: 15.7-17.8%
KERMETICOHVAF: YOUR CHOICE OF COST AND QUALITY kermetico.com jrienecker@kermetico.com HVAF-E (Economy) – meets HVOF specs HVAF-B (Balanced) – exceeds HVOF specs HVAF-U (Ultra) – Coatings beyond the limits HV spraying = deposition + blasting Well bonded particles will stay, poor bonded will go away Higher velocity => more blasting => ↑quality ↑cost
36 Spray Particle Temperature Vs. Wc & W2C Phase CompositionB HVAF working zone (1600-1800 C )
HVAF COATINGS PERFORM BETTER THAN HVOF HVAF tungsten carbide coatings are harder and stronger than HVOF ones, yet they are ductile. These are the reasons why they resist wear and cavitation combined. 37
Suspension HVOF-spraying
39 Power and aero turbine areas where coatings are applied. Cold zone and Hot zone and abradables
SEVERESERVICEAPPLICATIONS 40 Plug Valve TC Coating Control Valve Stem-Stellite 6 Coating Ball Valve TC Coating Mud Rotor TC Coating & Super Polish
APPLICATIONSOF HVOF &HVAF INCOATING OF FRANCIS T U R B I N EHEAD COVER kermetico.com jrienecker@kermetico.com
WC-Co-Cr 1 mm thick Conveyor Screws
ROTOR SHAFT REPAIR – CHROME CARBIDE Repair of turbine casing Applications of TC Coating in Power Turbines
PUMPAND VALVE APPLICATIONS P u m p a n d v a l v e a p p l i c a t i o n s C a g e c a r b i d e c o a t e d K n i f e G a t e v a l v e b o d y c a r b i d e c o a t e d I m p e l l e r c e r a m i c c o a t e d S l e e v e c e r a m i c c o a t e d & G r o u n d C e r a m i c c o a t e d s l e e v e s F o r F o o d i n d u s t r y 44 H a r d f a c e d p u m p s l e e v e
BRIDLE ROLL CARBID E COATING Application of HVOF Coating- Steel Mill CRM Roll
46 Spray Particle Temperature Vs. Wc & W2C Phase CompositionB HVAF working zone (1600-1800 C )
47
Compressed gas Powder feeder Substrate The gas dynamic cold spray coating is based on the projection of solid powder at high velocity. De Laval Nozzle Principle of cold spray 1. A compressed gas is heated before entering in a DE Laval Nozzle. 2. The gas is accelerated in the nozzle. 3. Powder is injected in the gas stream and accelerated as well. 4. The powder reaches velocity up to 1200 m/s. 5. The powder is plastically deformed and the coating is building up.
COLD SPRAYING • Gas temperature: under the phase transition temperature ~ 800,1000C • sprayed materials: pure Al, Zn, Cu, Ni Alloys : NiCr, Cr- Carbide/NiCr 49
Assadi et al., Bonding mechanismin cold gas spraying, Acta Materialia, 51, 4379-4394, 2003 Bonding mechanism T. Schmidt et al., From Particle Acceleration to Impact and Bonding in Cold Spraying, Journal of Thermal Spray Technology, 18, 5-6, 794-808, 2009 Typical surface around the critical velocity Q. Blochet, Influence of substrate surface roughness on cold-sprayed coating-substrate bond strength in aluminum- based systems, PhD Thesis, Mines ParisTech, 2015
51
Cold spray advantages and limitations Advantages: • No powder melting No phase change No grain growth Low heating of the substrate • No significant impact on the oxide content w.r.t. initial material • Powder mixture possible • Compressive residual stress (fatigue life increase) • Nozzle geometry can be tuned for a given jet size • Thick coating • High deposition rate Limitations: • One constituent has to be ductile • Accessibility to the surface to be coated • Limited materials for coating as of now
53
54 SPRAYMET S U R F A C E C O AT IN G
55 Hot Process ( Cladding ) Spray and fuse Plasma Transferred Arc ( PTA) cladding Laser Cladding
56 C l e a n t h e s u r f a c e w i t h s o l v e n t s S h o t b l a s t w i t h s t e e l g r i t s ( D o n o t u s e A l u m i n u , o x i d e g r i t s ) P r e h e a t t h e j o b i n r o t a t i o n t o ~ 2 0 0 d e g ( f l a t j o b s c a n b e s t a t i o n e r y w i t h f i r m f i x t u r e ) S p r a y t h e a l l o y ( # 4 5 , 5 5 , 6 0 , ) a p p r o x 3 0 0 m i c o r n s t o a v o i d s u r f a c e o x i d t i o n I n c r e a s e t h e t e m p o f j o b t o ~ 6 5 0 C w i t h t o r c h a n d w h e n j o b i s h o t s p r a y a g a i n t o b u i l d u p . F u s e t o t a l t h i c k n e s s ( 1 . 5 m m – 2 m m ) t o g e t h e r w i t h u n i f o r m o r a n g e c o l o r o n j o b . ( 9 0 0 - 1 0 5 0 * C ) A l l o w j o b t o r o t a t e f o r s o m e t i m e t ill o r a n g e c o l o r d i s a p p e a r s . E l s e b e n d w i l l c o m e i n j o b . S l o w c o o l t h e j o b b y k e e p i n g i n r o c k w o o l o r v e r m i c u l i t e t ill r o o m t e m p e r a t u r e A f t e r s p r a y b r i c s a r e k e p t a r o u n d j o b t o c o n t a i n h e a t f o r f a s t e r t o r c h f u s i o n B i g j o b s n e e d s t w o o r t h r e e t o r c h e s f o r f u s i o n . L o n g j o b s c a n b e g r a d u a l l y f u s e d i n r o t a t i o n .
PLASMA TRANSFEREDARC SPRAYING(PTA) • Fe, Ni, Co, Cr based alloys, stainless steels, cermets •Dilution ~ 2 % Schematic of PTA
58 Hard Surfacing PTAW is well suited to apply hard alloys for wear resistance. Stellite, Colmonoy, Hastelloy, and Tungsten Carbide can all be successfully applied with PTAW. Corrosion Resistant Overlays The localize heat input characteristics of PTAW allow corrosion resistant alloys to be applied with very little dilution into the base material. PTAW can achieve subsea chemistry requirements of <5% Fe in as little as 0.040” of overlay thickness. Flow Controls Valve Bores, Gates, Seats, Seat Pockets, Ring Grooves, Valve Stems. Power Industry Turbine Blades, Shafts, Bearing Surfaces, etc.
Rock Bit Journal Overlayed with Stellite 6 Crack Free Typical PTA depositon
60 • virtually all metal alloys, cermets and ceramics. Dilution < 1 % Schematic of Laser Cladding.
Laser cladding : Metallurgical Bonding HVOF/HVAF : Mechanical Bonding WC+NiCrB Si WcCoCR V low dilution / 100% clear bond line Nil dilution / 90% clear bond line Laser Cladding VS HVOF/HVAF coatings : Metallurgically speaking :
62 • Best technique for coating any shape increase life-time of wearing parts. • Particular dispositions for repairing parts (ideal if the mould of the part no longer exist or too long time needed for a new fabrication). • Most suited technique for graded material application. • Well adapted for near-net-shape manufacturing.(DLAM) • Low dilution between track and substrate (unlike other welding processes and strong metallurgical bond. • Low deformation of the substrate and small heat affected zone (HAZ). • High cooling rate fine microstructure. • Built part is free of crack and porosity. • 100% metallurgical bond line
63 Laser Cladding Head Co Axial Laser Head
64 Common Base Material Grades Common materials utilized in manufacture of oilfield MWD/LWDCollars. 17-4PH, INCONEL 718/925,P550, Duplex Stainless Steel and AISI41XX. Common Weld Overlay Grades Tungsten carbide/ Nickel-Chrome composite, Nickel alloy 625/C-276, Cobalt Alloys, Copper alloys and various other stainless steel grades. Laser Cladding Applications (Drilling tools) Hard facing of MWD/LWDdrill collars, Stabilizer sleeves, Wear bands. Laser Cladding Applications (Engineering) Hardfacing of Guides and rollers for steel works. Cladding of bearing surfaces on transmission shafts, pump shafts, drive shafts, hydraulic cylinder rods Laser Cladding Applications Cladding of thermo wells for chemical process plants and refineries. Hard facing of wear parts for brick and clay works,pulp and paper, mining and agriculture industries.
65 Before Laser Cladding Stabilizer Rollers After Laser Cladding Process on Stabilizer Rollers
Laser cladding process Dilution/distortion negligible Laser cladded stabilizer Cladding of Hydraulic Ram & Piston Guides Rotor Repair by Laser Cladding
ULTRAHIGHSPEEDLASERCLADDING (EHLA) Fraunhofer’s EHLA process has been adopted for applying protective coatings to hydraulic cylinders for maritime use Using this technique, coating speeds can reportedly be accelerated from 0.5-2 m per minute to as many as 5 m per minute. The use of EHLA also reduces minimum layer thickness from 500 μm to 25-250 μm, and layers are reported to be smoother, with roughness reduced to a tenth of typical values for Laser Material Deposition.
⯈ Hard trivalent chrome ⯈ THERMAL SPRAY ⯈ Plasma spray ceramic ⯈ High velocity oxy-fuel (HVOF)/High velocity air-fueled (HVAF) ⯈ Twin wire arc spray ( low cost high C- High Cr ) ⯈ PLATING ALTERNATIVES TO HEXAVALENT CHROME ⯈ Electro less nickel plating/ Electroless nickel with boron / Teflon composites ⯈ Electrodeposited Nano crystalline cobalt-phosphorus coatings ⯈ Nickel-cobalt alloy coatings ⯈ OTHERS ⯈ Explosive bonding ⯈ Laser cladding ⯈ Physical vapor deposition (PVD) ⯈ Electro-spark deposition ALTERNATIVES TO HARD CHROME PLATING SOUGHT
COMPARISON OF HARD CHROME PLATING TO HVOF ⯈ Micro cracks Micro porosity max 1 % (No through passage) Superior Corrosion Resistance :Hard chrome plating however contains micro- cracks within its structure which forms a weakness against corrosion versus thermal spray, as shown in the picture below. Hard chrome plate Chrome Plating HVOF/HVAF Spray
Results form Komatsu paper 2016
PROCESS BENEFITS : HVOF VS. HARD CHROME Specifications Hard Chrome Plating HVOF Surface Hardness 62 Rc 71 Rc Time required to coat Komatsu 830E first stage 7 hours (0.002” per hour to get 0.007”/side 1 hour (12 lbs at 12 lbs/hour to get 0.007”/side Work Piece Temp 145 F 300-350F Post Plate H2 Relief 275-425 F for 2-4 hours Not required Desired Surface Finish 0.4-0.8 um 16-32u in 2-6 u in
BOSCH REXROTHOEM CYLINDERS Endutorq 1000 laser cladded Endutorq 2000 HVOF coated
EATON USA Eatonite anti-corrosion laser cladding is a high performance, field repairable, 3rd party certified, hydraulic cylinder rod coating designed for the most demanding fresh and salt water applications and harshest operating environments. Eatonite anti- corrosion laser cladding extends the life of hydraulic cylinders and reduces costs of unplanned maintenance and equipment downtime.
SUMMATION • Hard chrome has the COST advantage that it is a single material and deposition method that can be used for a wide variety of applications • HVOF/HVAF is a single technology, with a wide variety of materials that can be used to achieve the right combination of properties for many purposes. Butmechanical Bonding • COLD SPRAY is a emerging technology presently limited to SOFTmaterials • Laser Cladding is now a approved and widely used depostion process with low heat input and dilution. Replacing hard chrome in many applications where impact is involeved

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ADVANCEMENTS IN SURFACE ENGINEERING PROCESSES.pptx

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    SURFACEENGINEERINGPROCESSES:TIMELINE 2 1908 Nitriding 1910 WireSpray( M U Schoop Switzerland ) 1923 Anodizing1924 Hard chrome Plating 1930 Physical Vapor deposition (PVD) 1955 Detonation Gun 1960 Plasma Spray ( Metco NY) 1965 Co2 Laser Cladding 1970 Chemical vapor deposition ( CVD) Widia Germany 1980 High Velocity Oxy Fuel ( HVOF) 1990 Cold Spray ( Russia to NCMS) 2000 High Velocity Air Fuel ( HVAF) 2005 Fibre laser cladding 2003 Cold spray commercial equipment 2017 EHLV(High speed laser spray cladding )
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    GAS NITRIDINGPROCESS 4  GasNitriding  In gas Nitriding the donor is a nitrogen rich gas, usually ammonia (NH3),  When ammonia comes into contact with the heated work piece it dissociates into nitrogen and hydrogen.  The nitrogen then diffuses onto the surface of the material creating a nitride layer. This process has existed for nearly a century  Recent developments have led to a process that can be accurately controlled. The thickness and phase constitution of the resulting Nitriding layers can be selected and the process optimized for the particular properties required.
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    PLASMA NITRIDINGPROCESS  PlasmaNitriding, also known as ion Nitriding, plasma ion Nitriding or glow-discharge Nitriding, is an industrial surface hardening treatment for metallic materials.  In plasma Nitriding, the reactivity of the Nitriding media is due to the gas in ionized state. In this technique intense electric fields are used to generate ionized molecules of the gas around the surface to be nitrided. Such highly active gas with ionized molecules is called plasma, naming the technique. The gas used for plasma Nitriding is usually pure nitrogen, since no spontaneous decomposition is needed (as is the case of gas Nitriding with ammonia). 6
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    APPLICATIONS OF NITRIDING 7 PlasmaIon Nitriding on Gears Gas Nitride coating on Screws AND GEARS
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    HARD CHROME PLATING •Chrome Discovered 1798,, first successful electrolytic • plating 1856, commercial utilization late 1920’s • Advantages –Resists most chemicals, oxygen, and moisture in air – Does not tend to seize,, gall,, or cold weld – Hard surface typical 62 Rc, 0.003”--0..015” typical thickness – Simple technology – Excellent wear resistance – Historically relatively inexpensive
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    ISSUES WITH HARDCHROME PLATING – The process produces large amounts of hydrogengas in the gas bubbles burst throwing hexavalentchrome solution into the air as fine mist. – Hexavalentchrome is a know carcinogen. – The process produces large volumes of toxic waste.. – EPA and OSHA have mandated more stringent stack emission levels and lowering of permissible exposure limitsfor workers. – T h i s results in increased costs and business risks..
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    ADVANTAGES OF ENP 12 Even coating on parts surface can be achieved.  No sophisticated jigs or racks are required.  There is flexibility in plating volume and thickness.  The process can plate recesses and blind holes with stable thickness.  Chemical replenishment can be monitored automatically.  Complex filtration method is not required  Matte, semi-bright or bright finishes can be obtained.
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    APPLICATIONOF ENPCOATING 14 ENP CoatedBolts Wheel Rims ENP Coated
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     PVD ischaracterized by a process in which the material goes from a condensed phase to a vapor phase and then back to a thin film condensed phase. The most common PVD processes are sputtering and evaporation. PVD is used in the manufacture of items which require thin films for mechanical, optical, chemical or electronic functions. Examples include semiconductor devices such as thin film solar panels, aluminized PET film for food packaging and balloons, and titanium nitride coated cutting tools for metalworking. Besides PVD tools for fabrication, special smaller tools (mainly for scientific purposes) have been developed.  The source material is unavoidably also deposited on most other surfaces interior to the vacuum chamber, including the fixturing used to hold the part 16
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    17 PVD Coating onDrill Bits & Ornaments
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    18 Schematic of CVDCoating Process
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    CVD (CHEMICAL VAPORDEPOSITION) 19  Chemical vapor deposition (CVD) is a chemical process used to produce high quality, high-performance, solid materials. The process is often used in the semiconductor industry to produce thin films.  In typical CVD, the wafer (substrate) is exposed to one or more volatile precursors, which react and/or decompose on the substrate surface to produce the desired deposit. Frequently, volatile by-products are also produced, which are removed by gas flow through the reaction chamber.
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    APPLICATIONSOF CVD COATING 20 TypicalCVD Coating Equipment CVD Coated Parts
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    Particle velocity V~ 800- 1200m/sec Spray dist 6-15 inches – No heat transfer to base D -- = 3.5 d Gun- Flsme/Plasma/HV OF Flame Temp 3000- 15000*C Heated particles propelled Concept and Schematic of THERMAL SPRAY Grit blasted surface Layer by layer coating builds up
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    26 Chemical Composition Manufacture Method Particle Shape ParticleSize Distribution Hall Flow Apparent Density Liquid- or Gas- Fuel Spray Gun Choice Fuel Used Spray Parameter Kinetic Energy Thermal INPUT MATL/POWDER SPRAY PROCESS / GUN COATING PROPERTIES Wear Resistance Corrosion Resistance Phase Composition Bond strength Hardness Porosity Deposition Efficiency
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    PLASMA SPRAYING • Mostversatile process in terms of range of coatings •plasma temperature: up to 15000 ºC. • virtually all existing materials including ceramics. Flame spray 32 57 0- 500m/sec
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    DETONATION GUN SPRAYING •Flame temperature: 4000 ºC •Particle Velocity : 1000 m/Sec. •Bond Strength: 100 Mpa 28
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    HVOF Porosity 0.5-1% Hardness 1100-1250HV0.3 Harder coatings are overstressed ±150-200 HV deviation 4-5 kg/h, 5-10 µm per pass HVAF Gas impermeable @50 µm 1200, 1350 or 1600+ HV0.3 Ductile and cavitation resistant ±50-60 HV deviation 15-33+ kg/h, 50 µm per pass
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    HVAF Jet Kote Kermetico C6,C7 1700- 2100 °C DJ 2600 JP 5000 2982 °C 2982 °C Opt Tc + Axial ↓ Opt heating Long nozzle ↓ Opt velocity
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    THE RESULT kermetico.com [email protected] Gu n Hardness, HV300 Poro -sity, % Fracture Tough- ness K1C Ratio W2C to WC AK1,326 ± 98 0.3 5.97 ±0.7 0 JP 1,289 ± 108 0.6 4.87 ±0.6 0.12 JK 1,047 ± 112 1.7 3.01 ±0.6 0.7 Source: Wear and corrosion performance of WC-10Co-4Cr coatings deposited by different HVOF and HVAF spraying processes Qun Wang etc., Hunan University, 2013 JP 5000 AK7 Jet Kote
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    EROSIONRATEVS. AN ATTACKANGLE: WC-10CO-4CR HVAF COATINGS PERFORM AS A DUCTILEMATERIAL Midwest Thermal Spray (MI, USA) 0.000 0.050 0.100 0.150 0.200 0.250 0.300 AK06-HVAF: WC-Co-Cr HVOF MTS: WC-Co-Cr SHS8000, fused Volume loss, mm3/min Dry erosion rate of hard coatings Angle 30 deg. Angle 90 deg.
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    UNIFORMITYOF HVAF COATINGPROPERTIES: HARDNESS OF HVOF AND KERMETICO HVAF WC-10CO-4CR COATINGS (SCHLUMBERGER, UK) kermetico.com [email protected] HVAF OF Relative standard deviation, % HVAF: 3.9 % HVOF: 15.7-17.8%
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    KERMETICOHVAF: YOUR CHOICE OFCOST AND QUALITY kermetico.com [email protected] HVAF-E (Economy) – meets HVOF specs HVAF-B (Balanced) – exceeds HVOF specs HVAF-U (Ultra) – Coatings beyond the limits HV spraying = deposition + blasting Well bonded particles will stay, poor bonded will go away Higher velocity => more blasting => ↑quality ↑cost
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    36 Spray Particle TemperatureVs. Wc & W2C Phase CompositionB HVAF working zone (1600-1800 C )
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    HVAF COATINGS PERFORMBETTER THAN HVOF HVAF tungsten carbide coatings are harder and stronger than HVOF ones, yet they are ductile. These are the reasons why they resist wear and cavitation combined. 37
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    39 Power and aeroturbine areas where coatings are applied. Cold zone and Hot zone and abradables
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    SEVERESERVICEAPPLICATIONS 40 Plug Valve TCCoating Control Valve Stem-Stellite 6 Coating Ball Valve TC Coating Mud Rotor TC Coating & Super Polish
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    APPLICATIONSOF HVOF &HVAFINCOATING OF FRANCIS T U R B I N EHEAD COVER kermetico.com [email protected]
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    ROTOR SHAFT REPAIR – CHROMECARBIDE Repair of turbine casing Applications of TC Coating in Power Turbines
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    PUMPAND VALVE APPLICATIONS Pu m p a n d v a l v e a p p l i c a t i o n s C a g e c a r b i d e c o a t e d K n i f e G a t e v a l v e b o d y c a r b i d e c o a t e d I m p e l l e r c e r a m i c c o a t e d S l e e v e c e r a m i c c o a t e d & G r o u n d C e r a m i c c o a t e d s l e e v e s F o r F o o d i n d u s t r y 44 H a r d f a c e d p u m p s l e e v e
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    BRIDLE ROLL CARBID E COATING Applicationof HVOF Coating- Steel Mill CRM Roll
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    46 Spray Particle TemperatureVs. Wc & W2C Phase CompositionB HVAF working zone (1600-1800 C )
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    Compressed gas Powder feeder Substrate The gas dynamiccold spray coating is based on the projection of solid powder at high velocity. De Laval Nozzle Principle of cold spray 1. A compressed gas is heated before entering in a DE Laval Nozzle. 2. The gas is accelerated in the nozzle. 3. Powder is injected in the gas stream and accelerated as well. 4. The powder reaches velocity up to 1200 m/s. 5. The powder is plastically deformed and the coating is building up.
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    COLD SPRAYING • Gastemperature: under the phase transition temperature ~ 800,1000C • sprayed materials: pure Al, Zn, Cu, Ni Alloys : NiCr, Cr- Carbide/NiCr 49
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    Assadi et al.,Bonding mechanismin cold gas spraying, Acta Materialia, 51, 4379-4394, 2003 Bonding mechanism T. Schmidt et al., From Particle Acceleration to Impact and Bonding in Cold Spraying, Journal of Thermal Spray Technology, 18, 5-6, 794-808, 2009 Typical surface around the critical velocity Q. Blochet, Influence of substrate surface roughness on cold-sprayed coating-substrate bond strength in aluminum- based systems, PhD Thesis, Mines ParisTech, 2015
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    Cold spray advantagesand limitations Advantages: • No powder melting No phase change No grain growth Low heating of the substrate • No significant impact on the oxide content w.r.t. initial material • Powder mixture possible • Compressive residual stress (fatigue life increase) • Nozzle geometry can be tuned for a given jet size • Thick coating • High deposition rate Limitations: • One constituent has to be ductile • Accessibility to the surface to be coated • Limited materials for coating as of now
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    54 SPRAYMET S U RF A C E C O AT IN G
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    55 Hot Process (Cladding ) Spray and fuse Plasma Transferred Arc ( PTA) cladding Laser Cladding
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    56 C l ea n t h e s u r f a c e w i t h s o l v e n t s S h o t b l a s t w i t h s t e e l g r i t s ( D o n o t u s e A l u m i n u , o x i d e g r i t s ) P r e h e a t t h e j o b i n r o t a t i o n t o ~ 2 0 0 d e g ( f l a t j o b s c a n b e s t a t i o n e r y w i t h f i r m f i x t u r e ) S p r a y t h e a l l o y ( # 4 5 , 5 5 , 6 0 , ) a p p r o x 3 0 0 m i c o r n s t o a v o i d s u r f a c e o x i d t i o n I n c r e a s e t h e t e m p o f j o b t o ~ 6 5 0 C w i t h t o r c h a n d w h e n j o b i s h o t s p r a y a g a i n t o b u i l d u p . F u s e t o t a l t h i c k n e s s ( 1 . 5 m m – 2 m m ) t o g e t h e r w i t h u n i f o r m o r a n g e c o l o r o n j o b . ( 9 0 0 - 1 0 5 0 * C ) A l l o w j o b t o r o t a t e f o r s o m e t i m e t ill o r a n g e c o l o r d i s a p p e a r s . E l s e b e n d w i l l c o m e i n j o b . S l o w c o o l t h e j o b b y k e e p i n g i n r o c k w o o l o r v e r m i c u l i t e t ill r o o m t e m p e r a t u r e A f t e r s p r a y b r i c s a r e k e p t a r o u n d j o b t o c o n t a i n h e a t f o r f a s t e r t o r c h f u s i o n B i g j o b s n e e d s t w o o r t h r e e t o r c h e s f o r f u s i o n . L o n g j o b s c a n b e g r a d u a l l y f u s e d i n r o t a t i o n .
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    PLASMA TRANSFEREDARC SPRAYING(PTA) •Fe, Ni, Co, Cr based alloys, stainless steels, cermets •Dilution ~ 2 % Schematic of PTA
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    58 Hard Surfacing PTAW iswell suited to apply hard alloys for wear resistance. Stellite, Colmonoy, Hastelloy, and Tungsten Carbide can all be successfully applied with PTAW. Corrosion Resistant Overlays The localize heat input characteristics of PTAW allow corrosion resistant alloys to be applied with very little dilution into the base material. PTAW can achieve subsea chemistry requirements of <5% Fe in as little as 0.040” of overlay thickness. Flow Controls Valve Bores, Gates, Seats, Seat Pockets, Ring Grooves, Valve Stems. Power Industry Turbine Blades, Shafts, Bearing Surfaces, etc.
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    Rock Bit JournalOverlayed with Stellite 6 Crack Free Typical PTA depositon
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    60 • virtually allmetal alloys, cermets and ceramics. Dilution < 1 % Schematic of Laser Cladding.
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    Laser cladding : Metallurgical Bonding HVOF/HVAF: Mechanical Bonding WC+NiCrB Si WcCoCR V low dilution / 100% clear bond line Nil dilution / 90% clear bond line Laser Cladding VS HVOF/HVAF coatings : Metallurgically speaking :
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    62 • Best techniquefor coating any shape increase life-time of wearing parts. • Particular dispositions for repairing parts (ideal if the mould of the part no longer exist or too long time needed for a new fabrication). • Most suited technique for graded material application. • Well adapted for near-net-shape manufacturing.(DLAM) • Low dilution between track and substrate (unlike other welding processes and strong metallurgical bond. • Low deformation of the substrate and small heat affected zone (HAZ). • High cooling rate fine microstructure. • Built part is free of crack and porosity. • 100% metallurgical bond line
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    63 Laser Cladding Head CoAxial Laser Head
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    64 Common Base MaterialGrades Common materials utilized in manufacture of oilfield MWD/LWDCollars. 17-4PH, INCONEL 718/925,P550, Duplex Stainless Steel and AISI41XX. Common Weld Overlay Grades Tungsten carbide/ Nickel-Chrome composite, Nickel alloy 625/C-276, Cobalt Alloys, Copper alloys and various other stainless steel grades. Laser Cladding Applications (Drilling tools) Hard facing of MWD/LWDdrill collars, Stabilizer sleeves, Wear bands. Laser Cladding Applications (Engineering) Hardfacing of Guides and rollers for steel works. Cladding of bearing surfaces on transmission shafts, pump shafts, drive shafts, hydraulic cylinder rods Laser Cladding Applications Cladding of thermo wells for chemical process plants and refineries. Hard facing of wear parts for brick and clay works,pulp and paper, mining and agriculture industries.
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    65 Before Laser CladdingStabilizer Rollers After Laser Cladding Process on Stabilizer Rollers
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    Laser cladding process Dilution/distortionnegligible Laser cladded stabilizer Cladding of Hydraulic Ram & Piston Guides Rotor Repair by Laser Cladding
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    ULTRAHIGHSPEEDLASERCLADDING (EHLA) Fraunhofer’s EHLA processhas been adopted for applying protective coatings to hydraulic cylinders for maritime use Using this technique, coating speeds can reportedly be accelerated from 0.5-2 m per minute to as many as 5 m per minute. The use of EHLA also reduces minimum layer thickness from 500 μm to 25-250 μm, and layers are reported to be smoother, with roughness reduced to a tenth of typical values for Laser Material Deposition.
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    ⯈ Hard trivalentchrome ⯈ THERMAL SPRAY ⯈ Plasma spray ceramic ⯈ High velocity oxy-fuel (HVOF)/High velocity air-fueled (HVAF) ⯈ Twin wire arc spray ( low cost high C- High Cr ) ⯈ PLATING ALTERNATIVES TO HEXAVALENT CHROME ⯈ Electro less nickel plating/ Electroless nickel with boron / Teflon composites ⯈ Electrodeposited Nano crystalline cobalt-phosphorus coatings ⯈ Nickel-cobalt alloy coatings ⯈ OTHERS ⯈ Explosive bonding ⯈ Laser cladding ⯈ Physical vapor deposition (PVD) ⯈ Electro-spark deposition ALTERNATIVES TO HARD CHROME PLATING SOUGHT
  • 69.
    COMPARISON OF HARDCHROME PLATING TO HVOF ⯈ Micro cracks Micro porosity max 1 % (No through passage) Superior Corrosion Resistance :Hard chrome plating however contains micro- cracks within its structure which forms a weakness against corrosion versus thermal spray, as shown in the picture below. Hard chrome plate Chrome Plating HVOF/HVAF Spray
  • 70.
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    PROCESS BENEFITS : HVOFVS. HARD CHROME Specifications Hard Chrome Plating HVOF Surface Hardness 62 Rc 71 Rc Time required to coat Komatsu 830E first stage 7 hours (0.002” per hour to get 0.007”/side 1 hour (12 lbs at 12 lbs/hour to get 0.007”/side Work Piece Temp 145 F 300-350F Post Plate H2 Relief 275-425 F for 2-4 hours Not required Desired Surface Finish 0.4-0.8 um 16-32u in 2-6 u in
  • 72.
    BOSCH REXROTHOEM CYLINDERS Endutorq1000 laser cladded Endutorq 2000 HVOF coated
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    EATON USA Eatonite anti-corrosionlaser cladding is a high performance, field repairable, 3rd party certified, hydraulic cylinder rod coating designed for the most demanding fresh and salt water applications and harshest operating environments. Eatonite anti- corrosion laser cladding extends the life of hydraulic cylinders and reduces costs of unplanned maintenance and equipment downtime.
  • 74.
    SUMMATION • Hard chromehas the COST advantage that it is a single material and deposition method that can be used for a wide variety of applications • HVOF/HVAF is a single technology, with a wide variety of materials that can be used to achieve the right combination of properties for many purposes. Butmechanical Bonding • COLD SPRAY is a emerging technology presently limited to SOFTmaterials • Laser Cladding is now a approved and widely used depostion process with low heat input and dilution. Replacing hard chrome in many applications where impact is involeved