36877575 nano hvof-thermico-1-1

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36877575 nano hvof-thermico-1-1

  1. 1. A D V A N C E D C O A T I N G S O L U T I O N S
  2. 2. nanoHVOF - for the most demanding OD and ID Applications with ® OD and ID Applications with WC-CoCr 86 10 4 nanoHVOF powder – System Technology and Application Know-How ® Götz Matthäus – General Manager Thermico GmbH & Co. KG, Germany Michael Molnar – President Thermico USA , Inc.
  3. 3. Outline 1. Thermico performance profile 2. NANO HVOF R&D Project - advantages of spraying fine powders2. NANO HVOF R&D Project - advantages of spraying fine powders 3. Problematic of spraying fine powder materials 4. nanoHVOF powder 5. nanoHVOF is a system ® ® 6. Applications
  4. 4. Thermico Research and Development All scientific processes which lead to innovative products are realized in our shop located in Dortmund - Germany Performance profile located in Dortmund - Germany Spherodized Powder material, Coating and Technology development System manufacturing A reliable Spare Part and component production to build up Turnkey Systems for HVOF and Plasma is done in our shop located in Dortmund - Germany. ID and OD torches, Powder Feeder, Monitored and computer based Visualization and Controller Units International Spray ShopInternational Spray Shop Located in Dortmund – Germany and Greensboro, NC – USA* we have nanoHVOF coating Shops for the most demanding OD and ID Applications Aerospace, Landing Gear, Oil & Gas, Paper Rolls * under construction
  5. 5. EU R&D Project NANO HVOF (4/2000 – 10/2003) The NANO HVOF EU project shows the idea and the high potential of HVOF coatings sprayed with fine, 5 - 15 µm powders. The research and development work of the NANO HVOF EU project only Micrograph of a dense WC-CoCr 86 10 4 coatingSEM of a 5-15µm agglomerated, sintered and crushed WC-CoCr powder The research and development work of the NANO HVOF EU project only focused an improvement of coating quality concerning high density and submicron splat-thickness. All coatings of this R&D Project where produced with conventional agglomerated, sintered and crushed powders.
  6. 6. What are the advantages of spraying powders with particle ? sizes less than 15 µm?
  7. 7. Advantages of spraying fine powders Diagram shows that particle velocity depends on particle size
  8. 8. Advantages of spraying fine powders Kinetic energy depends on particle velocity 30µm 5 µm Ek (30µm) ½ m v2 1 ------------------- = ------------ = ------------ Ek (5µm) ½ m v2 6,25 400 m/s 1000 m/s Under constant mass flow conditions a comparison between 5 µm and 30 µm particles shows, the smaller the particle size, the higher the particle velocity. Due to high particle velocity the kinetic energy increases exponentially (EK = ½ mv 2 ).
  9. 9. Advantages of spraying fine powders HVOF standard powder Agglomerated, sintered and crushed powder WC-CoCr 86 10 4 For melting a small particle less thermal energy is needed Particle size Particle sizeParticle size -45 +20 µm HVOF Process energy 100 – 250 kW Particle size -15 +5 µm HVOF Process energy 30 – 80 kW
  10. 10. Advantages of spraying fine powders - Higher residual compressive stress A summary of the advantages shows that the EU R&D NANO HVOF Project already is a further development of standard HVOF : - Higher residual compressive stress due to higher particle velocity - Improved wear properties, improved corrosion barrier due to a dense coating structure with submicron splatthickness - Reduced amount of heat to work piece,- Reduced amount of heat to work piece, because to melt a small particle less energy is needed.
  11. 11. ? Concerning the advantages of spraying with particles less than 15 µm, there is still one question left: Why is spraying with fine particles not common with HVOF technology yet?
  12. 12. Fine and crushed powder materials do not allow Near-net shape sprayed coating applications and ductile ID WC-CoCr coatings Challenges of spraying fine agglomerated, sintered and crushed powder materials • Crushed particle shape causes insufficient flow characteristics - an irregular pulsing powder flow does not allow Near-net shape Spraying • Crushed particles have a large surface SEM of a 5-15µm agglomerated, sintered and crushed WC-CoCr powder • Crushed particles have a large surface which is sensitive to be oxidized - Oxides reduce the ductility of the coating - With decreasing DE oxides will appear as dust Inclusions, especially in an ID coating structure.Internal cracks after ductility test
  13. 13. Fine agglomerated, sintered and crushed powder materials can not deliver good Seawater Resistance and lower the Wear Resistance Challenges of spraying fine agglomerated, sintered and crushed powder materials • agglomerated and sintered powders only provide a sintered Co, Cr metal matrix - an inhomogeneous phase distribution with free Co can not deliver a good Seawater Resistance • To provide metallurgical bonded Carbides in the matrix, agglomerated and sintered powders require high temperature andpowders require high temperature and stand-off in the spray process - High stand-off do not allow coating of small Inside Diameter Areas (ID must be > 14”) - Not metallurgical bonded carbides lower the Wear Resistance of the coating. SEM of a 5-15µm agglomerated, sintered and crushed WC-CoCr powder
  14. 14. Demand for WC-CoCr powder material with optimized characteristics The use of fine agglomerated, sintered and crushed powder materials is lowering performance characteristics and coating quality Problem Fine agglomerated, sintered and crushed powders: Solution Fine powder material with: do not allow Near-net shape spraying spheroid particle shape do not allow ductile Internal Diameter coatings dense, spheroid particle shape increase the amount of oxides in the coating dense, spheroid particle shape produce coatings with poor Seawater Resistance matrix providing a melted alloy do not allow coating of small Inside Diameter Areas metallurgical bonded carbidesdo not allow coating of small Inside Diameter Areas metallurgical bonded carbides have lower Wear Resistance, limited by process temperature metallurgical bonded carbides Thermico has coped with this challenge…
  15. 15. To achieve more performance characteristics and a higher coating quality further Research and Development of powder materials and System Technology was done by Thermico from 2006 up to 2010.Thermico from 2006 up to 2010.
  16. 16. Controlled Plasma Spherodization to achieve ultrafine and highly optimized nanoHVOF powder nanoHVOF Powder ® Feedstock Material WC-CoCr 86 10 4 Controlled Process nanoHVOF Powder WC-CoCr 86 10 4 ® ® Spherodized particle shape provides a matrix consisting of a 14 wt% CoCr28 melted alloy in which the submicron carbides are metallurgical bonded Feedstock material < 10 µm and a primary carbide size of 400 – 900 nm Plasma Spherodization
  17. 17. Quality Control and parameter adjustment to ensure a reliable powder production nanoHVOF Powder ® Bulk density by hall flowmeter funnel Element detection by EDX-AnalysisParticle shape by SEM Feedback of Powder Quality The Controlled Plasma Spherodization Process is based on a measurement and adjustment of: • Inert gas flow• Plasma gas composition • Plasma gas flow • Plasma Power • Powder feed rate •Powder gas flow Process Input
  18. 18. Controlled Plasma spherodization means to get the right quality of the metallurgical structure with only a very low amount of W2C phases nanoHVOF Powder ® X-Ray Diffraction of a WC-CoCr particle shows the structure after controlled Plasma Spherodization
  19. 19. nanoHVOF Powder Tailored nanoHVOF Powder cuts enable maximal Deposit Efficiency and an as-sprayed surface roughness less than 1.5 µm Ra ® ® Really smooth HVOF Ultra fine powders -5+2 µm or -10+5 µm produce ultra fine splats Ultra fine splats produce ultra fine surfaces Really smooth HVOF -5+2 µm or -10+5 µm ultra fine nanoHVOF Powder cuts® + Save on grinding + Save on finishing + Save powder + Reduce overall costs
  20. 20. Hard Inside and outside diameter coatings with Hardness > 1200 HV 0.3 (Standard deviation of ± 30 HV 0.3) More than smooth – nanoHVOF performance characteristics nanoHVOF Coating quality ® ® Hardness > 1200 HV 0.3 (Standard deviation of ± 30 HV 0.3) Ductile Performs well in tests such as a Guided Bend Test Vickers-indent with1Kg at the interface (Substrate / coating), without any formation of cracks
  21. 21. Dense Coating structure with virtually Zero Porosity, to survive more than 1000 hours in a Salt Fog Test by 50 µm coating thickness More than smooth – nanoHVOF performance characteristics nanoHVOF Coating quality ® ® Fog Test by 50 µm coating thickness Near-net Allows for coating thickness accuracy of ±15 µm as-sprayed Corrosion resistant Nanostructured Coating with homogeneous phase distribution providing a melted CoCr28 melted alloy matrix for high Seawater Resistance accuracy of ±15 µm as-sprayed
  22. 22. To achieve superior coating quality for the most demanding OD and ID Applications nanoHVOF is a System ® nanoHVOF Powder® nanoHVOF System Technology Ultra fine, spherodized and nano structured powder Powder feeder, torch and system technologies optimized for spraying ultra fine nanoHVOF powder ® ® nanoHVOF Application Know-How Thermico experience and training means successful coating developments for the most demanding applications ®
  23. 23. Feeding ultra fine powders with particle sizes less than 10 µm is a challenge nanoHVOF is a System Powder feeder ®
  24. 24. CPF-2 Powder feeder for standard, micro and nanoHVOF Powders® nanoHVOF is a System Powder feeder ®
  25. 25. Precise dosage of fluidized Powder by gravimetric feeding principle with controlled rotation of the feeding wheel nanoHVOF is a System Powder feeder ® Feeding wheel BalancerFeeding principal
  26. 26. 3rd Generation of the CPF Powder Feeder Software and visualization to control the feeding Process and get a constant powder flow nanoHVOF is a System Powder feeder ® In Control Customizable start and feeding parameter, trend data storage and on-line visualization
  27. 27. Torch technology for outside and inside diameter coatings nanoHVOF is a System OD and ID Torches ® CJS K5.2-N OD-Applications ID CoolFlow-N ID-Applications
  28. 28. Dual chamber, hydrogen stabilized kerosene combustion reduces thermal load to substrate and powder materials nanoHVOF is a System OD and ID Torches ® Principal of Thermico CJS K5.2-N HVOF torchPrincipal of Thermico CJS K5.2-N HVOF torch Increased volume of 2. combustion chamber Mach 1 – 2.5 Super sonic area • Low turbulence level for the supersonic jet • High pressure Area N2 , • Main part of combustion • Hydrogen stabilized Kerosene/O2-Combustion • Cold ignition point for powderN2 , 1. combustion chamber Optimized for spraying fine powders with high affinity to oxygen • Main part of combustion
  29. 29. nanoHVOF is a System OD and ID Torches To achieve a high quality coating structure with a very low amount of oxides it is recommended to choose a spray parameter with λ ≤ 1 ® Required Amount of Oxygen for 100% combustion of combustibles λ = Provided amount of Oxygen, due to process parameter A: Combustibles Hydrogen stabilized O2 / Kerosene combustion, due to vaporization of Kerosene jet by entering in the second combustion chamber A B B Required Amount of Oxygen for 100% combustion of combustibles Combustion chamber principle of CJS K5.2-N and ID CoolFlow-N B: Nitrogen + Oxygen If λ = 1, than nitrogen is used as an inert cooling gas which increases the jet velocity by its controllable mass flow. The C-CJS Nitrogen Technology allows for achieving a high amount of kinetic energy in the spray process without adding further thermal energy.
  30. 30. Control, visualization and analysis of the process nanoHVOF is a System System technology ® NANO HVOF State of the Art Soft- and Hardware for HVOF and Plasma
  31. 31. On-line Process monitoring and analysis nanoHVOF is a System System technology ® On-line spray-jet visualization via USB-CameraOn-line Spray-jet-geometry monitoring system. Observation of spray-spot and jet. Trend data storage of all mass flows
  32. 32. nanoHVOF Applications CJS K5.2-N ® Outside diameter coatings Turbine Blades Near-net, nano structuredNear-net, nano structured droplet erosion coatings Landing Gear Smooth surfaces and close control of coating thickness lead to reduced grinding and finishinggrinding and finishing costs on outside diameter surfaces
  33. 33. nanoHVOF Applications CJS K5.2-N ® Outside diameter coatings Gas Turbines Low oxide HVOF sprayedLow oxide HVOF sprayed metal coatings, for example, MCrAlY and T-800 Hard Chrome replacement Hydraulic Actuators, Rolls, Mud Rotors and other general applications
  34. 34. nanoHVOF Applications CJS K5.2-N ® CJS K5.2-N for cost-effective applications with brilliant results
  35. 35. nanoHVOF Applications ® Critical pumps in crude oil and FCC process are an example for a single application which demands for OD and ID Spraying pump case pump cover pump impeller
  36. 36. nanoHVOF Applications ID CoolFlow-N ® Inside diameter coatings Landing Gear Coating inside diameters forCoating inside diameters for hard chrome replacement even on temperature sensitive substrate materials without extra cooling Automotive Inside diameter Al-SiC-Cu-Mg coating
  37. 37. nanoHVOF Applications ID CoolFlow-N ® Pumps Non Line-of-Side spraying Inside diameter coatings Non Line-of-Side spraying improves erosion and corrosion protection inside casings, bushings and sleeves Pipes and Risers Inconel and Tungsten Carbide coatings of Pipes and Risers reduce maintenance costs
  38. 38. nanoHVOF Applications ID CoolFlow-N ® ID CoolFlow-N applications beginning from 4“ inside diameter 107.0°C Trough hole internal exhaustion
  39. 39. nanoHVOF Applications ID CoolFlow-N ® Pump case and Non-Line-of sight spraying Critical pumps in crude oil and fluid catalytic cracking FCC processes
  40. 40. nanoHVOF Applications ID CoolFlow-N ® Pump case and Non-Line-of sight spraying
  41. 41. nanoHVOF Application Facing sophisticating Applications ® Rotational Media Transfer Unit (RMTU) ID CoolFlow-N torch with Extension and RMTU
  42. 42. nanoHVOF Application Facing sophisticating Applications ® Rotational Media Transfer Unit (RMTU) RMTU equipped for spraying Control box
  43. 43. Thank you very much for your attention!Thank you very much for your attention!

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