Advancement in surface engineering processes by spraymet
- 1. ADVANCEMENTS IN SURFACE ENGINEERING PROCESSES P T BINDAGI TECHNICAL DIRECTOR Spraymet Surface Technologies Pvt Ltd Bangalore Plant : A 413, 9th Main, 2nd Stage, Peenya Indl area Bangalore 5600058 ,spraymet@gmail.com el : 080-28364565 , mobile : 9916903701 Pune Plant : T 180, T Block, MIDC , Bhosari, Pune Tel 020- 27110020 Mobile ; 8149046272 1 SPRAYMETS U R F A C E C O A T I N G
- 2. SURFACE ENGINEERING PROCESSES: 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 )
- 4. GAS NITRIDING PROCESS 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.
- 5. PLASMA NITRIDING 5 Schematic Representation of Plasma Nitriding
- 6. PLASMA NITRIDING PROCESS 6 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).
- 7. APPLICATIONS OF NITRIDING 7 Plasma Ion Nitriding on Gears Gas Nitride coating on Screws AND GEARS
- 9. 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
- 10. ISSUES WITH HARD CHROME PLATING – The process produces large amounts of hydrogen gas in the gas bubbles burst throwing hexavalent chrome solution into the air as fine mist. – Hexavalent chrome 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 limits for workers. – This results in increased costs and business risks..
- 11. ENP ( ELECTROLESS NICKEL PLATING) 11
- 12. 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.
- 14. APPLICATION OF ENP COATING 14 ENP Coated Bolts Wheel Rims ENP Coated
- 15. PVD ( PHYSICAL VAPOR DEPOSITION 15
- 16. PVD COATING TECHNIQUE 16 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
- 17. APPLICATIONS OF PVD COATING 17 PVD Coating on Drill Bits & Ornaments
- 18. CHEMICAL VAPOR DEPOSTION 18 Schematic of CVD Coating Process
- 19. 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.
- 20. APPLICATIONS OF CVD COATING 20 Typical CVD Coating Equipment CVD Coated Parts
- 21. CVD V/S PVD 21
- 22. 22 Cold spray NCMS HP/HVOF HVAF Axial plasma Wire spray Metco 2E Laser cladding Cold spray commercial guns Nano powders Composites Metal/carbide/ ceramic Powders Twin wires and MetalPowders wires
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- 24. xtausraxx Various surface Modification processes SPRAYMET SPRAYMETS U R F A C E C O A T I N G
- 25. Gun- Flsme/Plasma/HVOF Flame Temp 3000- 15000*C Particle velocity V ~ 800- 1200m/sec Spray dist 6-15 inches – No heat transfer to base Grit blasted surface D -- = 3.5 d SPRAYMETS U R F A C E C O A T I N G Heated particles propelled Concept and Schematic of THERMAL SPRAY Layer by layer coating builds up
- 26. COATING DEVELOPMENT 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 Energy INPUT MATL/POWDER SPRAY PROCESS / GUN COATING PROPERTIES Wear Resistance Corrosion Resistance Phase Composition Bond strength Hardness Porosity Deposition Efficiency SPRAYMETS U R F A C E C O A T I N G
- 27. PLASMA SPRAYING 27 • Most versatile process in terms of range of coatings •plasma temperature: up to 15000 ºC. • virtually all existing materials including ceramics. Flame spray 350- 500m/sec SPRAYMETS U R F A C E C O A T I N G
- 28. DETONATION GUN SPRAYING 28 • Flame temperature: 4000 ºC •Particle Velocity : 1000 m/Sec. •Bond Strength: 100 Mpa
- 29. HIGH-VELOCITY OXY FUEL SPRAYING (HVOF) 29 SPRAYMETS U R F A C E C O A T I N G
- 30. ADVANCEMENTS FROM HVOF TO HVAF HIGH VELOCITY AIR FUEL(HVAF) 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
- 31. 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
- 32. 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
- 33. EROSION RATE VS. AN ATTACK ANGLE: WC-10CO-4CR HVAF COATINGS PERFORM AS A DUCTILE MATERIAL 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 Volumeloss,mm3/min Dry erosion rate of hard coatings Angle 30 deg. Angle 90 deg.
- 34. UNIFORMITY OF HVAF COATING PROPERTIES: HARDNESS OF HVOF AND KERMETICO HVAF WC-10CO-4CR COATINGS (SCHLUMBERGER, UK) kermetico.com jrienecker@kermetico.com HVAF HVOF Relative standard deviation, % HVAF: 3.9 % HVOF: 15.7-17.8%
- 35. KERMETICO HVAF: 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. 36 Spray Particle Temperature Vs. Wc & W2C Phase CompositionB HVAF working zone (1600-1800 C )
- 37. 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
- 38. Suspension HVOF-spraying Petri Vuoristo HITSAUSTEKNIIKKAPÄIVÄ 19.04.2012
- 39. APPLICATIONS SPRAYED COATINGS IN AN AIRCRAFT ENGINE 39 Power and aero turbine areas where coatings are applied. Cold zone and Hot zone and abradables
- 40. SEVERE SERVICE APPLICATIONS 40 Plug Valve TC Coating Control Valve Stem-Stellite 6 Coating Ball Valve TC Coating Mud Rotor TC Coating & Super Polish
- 41. APPLICATIONS OF HVOF & HVAF IN COATING OF FRANCIS TURBINE HEAD COVER kermetico.com jrienecker@kermetico.com
- 42. WC-Co-Cr 1 mm thick Conveyor Screws
- 43. ROTOR SHAFT REPAIR – CHROME CARBIDE Repair of turbine casing Applications of TC Coating in Power Turbines
- 44. PUMP AND VALVE APPLICATIONS Pump and valve applications Cage carbide coated Knife Gate valve body carbide coated Sleeve ceramic coated& Impeller ceramic coated Ground Ceramic coated sleeves Hardfaced pump sleeve For Food industry 44
- 45. BRIDLE ROLL CARBIDE COATING SPRAYMETS U R F A C E C O A T I N G Application of HVOF Coating- Steel Mill CRM Roll
- 46. 46 Spray Particle Temperature Vs. Wc & W2C Phase CompositionB HVAF working zone (1600-1800 C )
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- 48. The gas dynamic cold spray coating is based on the projection of solid powder at high velocity. Compressed gas Powder feeder Substrate 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.
- 49. COLD SPRAYING 49 • Gas temperature: under the phase transition temperature ~ 800,1000C • sprayed materials: pure Al, Zn, Cu, Ni Alloys : NiCr, Cr- Carbide/NiCr SPRAYMETS U R F A C E C O A T I N G
- 50. Copper on copper Assadi et al., Bonding mechanism in cold gas spraying, Acta Materialia, 51, 4379-4394, 2003 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 Bonding mechanism Rebound zone Material jet Typical surface around the critical velocity A1050 powder on 2024- T3 substrate Q. Blochet, Influence of substrate surface roughness on cold-sprayed coating-substrate bond strength in aluminum- based systems, PhD Thesis, Mines ParisTech, 2015
- 51. 51 Portable
- 52. 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
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- 54. 54 SPRAYMETS U R F A C E C O A T I N G
- 55. 55 Hot Process ( Cladding ) Spray and fuse Plasma Transferred Arc ( PTA) cladding Laser Cladding
- 56. 56 SPRAYMET SPRAY AND FUSE PROCESS Tech sheet : NCB1C/S and F Bangalore / pune Self fluxing alloys # 45,50,60 ) 30.3.2013 : rev 3 25.10.2016 Clean the surface with solvents Shot blast with steel grits ( Do not use Aluminu, oxide grits) Preheat the job in rotation to ~ 200 deg ( flat jobs can be stationery with firm fixture) Spray the alloy ( # 45 , 55, 60 , ) approx 300 micorns to avoid surface oxidtion Increase the temp of job to ~ 650C with torch and when job is hot spray again to build up. Fuse total thickness ( 1.5 mm – 2mm) together with uniform orange color on job. ( 900-1050*C) Allow job to rotate for some time till orange color disappears. Else bend will come in job. Slow cool the job by keeping in rock wool or vermiculite till room temperature After spray brics are kept around job to contain heat for faster torch fusion Big jobs needs two or three torches for fusion. Long jobs can be gradually fused in rotation .
- 57. PLASMA TRANSFERED ARC SPRAYING (PTA) • Fe, Ni, Co, Cr based alloys, stainless steels, cermets •Dilution ~ 2 % SPRAYMETS U R F A C E C O A T I N G Schematic of PTA
- 58. APPLICATIONS 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.
- 59. EXAMPLES OF PTA CLADDING Rock Bit Journal Overlayed with Stellite 6 Crack Free Typical PTA depositon
- 60. LASER CLADDING 60 • virtually all metal alloys, cermets and ceramics. Dilution < 1 % SPRAYMETS U R F A C E C O A T I N G Schematic of Laser Cladding.
- 61. 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 : SPRAYMETS U R F A C E C O A T I N G
- 62. ADVANTAGES OF LASER CLADDING 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. 63 Laser Cladding Head Co Axial Laser Head
- 64. LASER CLADDING APPLICATIONS 64 Common Base Material Grades Common materials utilized in manufacture of oilfield MWD/LWD Collars. 17-4PH, INCONEL 718/925, P550, Duplex Stainless Steel and AISI 41XX. 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/LWD drill 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. APPLICATION OF LASER CLADDING 65 Before Laser Cladding Stabilizer Rollers After Laser Cladding Process on Stabilizer Rollers
- 66. Laser cladding process Dilution/distortion negligible Laser cladded stabilizer Cladding of Hydraulic Ram & Piston Guides Rotor Repair by Laser Cladding
- 67. ULTRA HIGH SPEED LASER CLADDING (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. SPRAYMETS U R F A C E C O A T I N G
- 68. 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
- 69. COMPARISON OF HARD CHROME PLATING TO HVOF Micro cracks Micro porosity max 1 % (No through passage) Hard chrome plate 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. Chrome Plating HVOF/HVAF Spray
- 70. Results form Komatsu paper 2016
- 71. 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
- 72. BOSCH REXROTH OEM CYLINDERS Endutorq 1000 laser cladded Endutorq 2000 HVOF coated
- 73. 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.
- 74. 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. But mechanical Bonding • COLD SPRAY is a emerging technology presently limited to SOFT materials • 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
- 75. THANK YOU 75 SPRAYMETS U R F A C E C O A T I N G