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VTT Powder Piloting Service: Thermal spraying development (TS)

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For more information please visit our website: www.vtt.fi/powder. We are material experts specialized on powder based materials. With Powder Piloting Service we can boost up your development needs and adoption of resource efficient manufacturing and alternative materials for substitution.

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VTT Powder Piloting Service: Thermal spraying development (TS)

  1. 1. 1 Powder Piloting Service Material solutions, from powder to product. VTT Technical Research Centre of Finland Ltd Thermal spraying development (TS) www.vtt.fi/powder
  2. 2. 2 Service for introducing new material compositions to thermal spraying from materials to performance validated product.  Powder piloting of ceramic, metallic and composite materials including materials design  State of art selection of thermal spray techniques available in Thermal Spray Center Finland TSCF www.vtt.fi/powder Thermal spraying (TS) TSCF Thermal Spray Center Finland
  3. 3. 321/12/2017 3  Selection of material composition meeting demands of component operation conditions  Specification of powder characteristics in respect of spraying method and material properties 2 1 3 4 5 Material selection and design Powder processing, modification and characterization Thermal spraying parameters Coating samples spraying and testing Pilot component spraying  Raw materials selection  Preconditioning of the composition  Powder processing  Modification of powders to meet process demands  Powder characterization  Design of experiment (DoE) for process parameter mapping  DoE based processing parameter optimization  Online monitoring  Coating characterization  Sample preparation for coating performance tests  Application and material specific tests and analyses  Design and optimization of component spraying  Manufacturing and post treating of component  Component performance testing (lab and/or field testing) www.vtt.fi/powder Development steps from powder to product: Thermal spraying (TS)
  4. 4. 421/12/2017 4 Is it possible to produce a coating to serve in the application? GATE2. Performance testing reveal actual potential and need for development. GATE3. Commercial availability of suitable material and powder, evaluation of tailoring possibility. GATE1. www.vtt.fi/powder Development steps from powder to product: Thermal spraying (TS) 2 1 3 4 5 Material selection and design Thermal spraying parameters Coating samples spraying and testing Pilot component spraying Powder processing, modification and characterization
  5. 5. 521/12/2017 5  Demands and restrictions from operation conditions  Wear resistance, ductility, corrosion resistance, grindability, polishability  Demands and restrictions of thermal spray process  Stability in spraying, melting temperature  Powder properties, flowability, particle size distribution, dust fraction, density  Evaluation of the suitability of material and powder to different TS processes STEP 1. Material selection & design TSCF Thermal Spray Center Finland www.vtt.fi/powder
  6. 6. 621/12/2017 6 STEP 1. Material selection & design TSCF Thermal Spray Center Finland www.vtt.fi/powder  Tailored material solutions  Wear resistance  High temperature and aqueous corrosion resistance  Low coefficient of friction  Electrical properties  Thermal properties  Surface functionality
  7. 7. 721/12/2017 7  Commercial powder availability with needed properties?  If not, is tailoring possible  Processing technologies  Selection of processing method based on material composition, spraying method and desired particle size distribution  Agglomeration, gas atomization, milling, air classification, plasma spheroidization etc.  Characterization of properties  Particle size distribution and morphology,  Chemical composition and phase structure STEP 2. Powder processing, modification and characterization TSCF Thermal Spray Center Finland www.vtt.fi/powder
  8. 8. 821/12/2017 8 Design of experiments Parameter optimization with on-line monitoring and process mapping Coating characterization STEP 3: Thermal spraying parameters Example of Process Map for WC-CoCr: Young modulus against particle temperature – velocity TSCF Thermal Spray Center Finland www.vtt.fi/powder TS technology selection Sample selection Test matrix design Sample preparation Redesign according to process mapping and characterization Modification of the powder
  9. 9. 921/12/2017 9  Test sample spraying using optimized parameters  Residual stresses and elastic constant  Hardness, microstructure, corrosion resistance, wear resistance, microstructure etc. STEP 4: Coating samples spraying and testing Online Particle diacnostics of HVOF process TSCF Thermal Spray Center Finland www.vtt.fi/powder
  10. 10. 1021/12/2017 10TSCF Thermal Spray Center Finland www.vtt.fi/powder STEP 5: Pilot component spraying
  11. 11. 111121/12/2017 Protection against high temperature corrosion TSCF Thermal Spray Center Finland www.vtt.fi/powder Probe before exposure Probe after exposure
  12. 12. 12 Dispersion strengthened ceramics Improved strength, toughness and hardness and tailored wear performance Nano Ceramic powders Nano oxide-oxide composite powder composition enabling amorphous coating structure Praxair HV 2000 HVOF sprayed Al2O3-ceramic coating Coatings for extreme conditions HVOF spraying Improved abrasion wear performance by using nano SiC addition on Al2O3 TSCF Thermal Spray Center Finland www.vtt.fi/powder Utilizing nanostructures in thermal spraying - Ceramic coatings 0 20 40 60 80 100 120 140 160 AbrasionWearResistance[mg/30min]
  13. 13. 13 0 2 4 6 8 10 12 14 16 18 Nano Sub-micron Conventional Tailored wear performance Conventional: carbide size 1-3 µm Nano: carbide size 100-200 nm Nanostructured: carbide size 1-3 µm, crystal size 100-200 nm a) b) c) Improved wear resistance by using sub-micron carbide WC-CoCr -coating in fine particle wet abrasion wear Improved cavitation resistance of tailored nano- WC-CoCr -coating Nano WC-powders HVOF spraying a) Conventional carbide b) Nanocarbide Agglomerated & sintered nano tungsten carbide (50 nm) powder for thermal spraying Thermico CJS HVOF Nano WC-CoCr coating 1 µm TSCF Thermal Spray Center Finland www.vtt.fi/powder Coatings for extreme conditions Utilizing nanostructures in thermal spraying - CerMet Composite coatings 0 5000 10000 15000 20000 25000 30000 35000 40000 Parameter A Parameter B Parameter A Parameter B Conventional Sub-micron VolumeLoss-μm3 WC-CoCr WeightLoss–(mg/120min)
  14. 14. 14TSCF Thermal Spray Center Finland Wear of system Wear test Coating properties Applied method Spray condition  ICP data  T–V plot Powder type  Porosity  Size Material composition  Cermets  Ceramics www.vtt.fi/powder  Erosion  Adhesion  Dry abrasion  Slurry abrasion  Lamella adhesion  Coating adhesion  Stresses & Young’s Modulus  Hardness  Fracture toughness  Crack density  Feature size  Phases  Porosity  HVOF  HVAF  CJS  Plasma  Shape  Metals  Cold spray Powder production methods  Gas atomization  Spray drying  Plasma spheroidization Microstructure
  15. 15. 15 For more information please visit our website. Interested? VTT Technical Research Centre of Finland Ltd www.vtt.fi/powder TSCF Thermal Spray Center Finland

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