36877575 nano hvof-thermico-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

nanoHVOF - for the most demanding OD and ID Applications with

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OD and ID Applications withWC-CoCr 86 10 4

nanoHVOF powder – System Technology and Application Know-How

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Götz Matthäus – General Manager Thermico GmbH & Co. KG, GermanyMichael Molnar – President Thermico USA , Inc.

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

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6. Applications

Thermico

Research and DevelopmentAll scientific processes which lead to innovative p roducts are realized in our shop located in Dortmund - Germany

Performance profile

located in Dortmund - Germany

Spherodized Powder material, Coating and Technology development

System manufacturingA reliable Spare Part and component production to b uild up Turnkey Systems for HVOF and Plasma is done in our shop located in Dort mund - Germany.

ID and OD torches, Powder Feeder, Monitored and computer based Visualization and Controller Units

International Spray ShopInternational Spray ShopLocated in Dortmund – Germany and Greensboro, NC – US A* we have nanoHVOF coating Shops for the most demanding OD an d ID Applications

Aerospace, Landing Gear, Oil & Gas, Paper Rolls * under construction

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 conventionalagglomerated, sintered and crushed powders.

What are the advantages of spraying powders with particle

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sizes less than 15 µm?

Advantages of spraying fine powders

Diagram shows that particle velocity depends on particle size


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 mv2).


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 energy100 – 250 kW

Particle size-15 +5 µm

HVOF Process energy30 – 80 kW


- 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 stressdue to higher particle velocity

- Improved wear properties, improvedcorrosion barrier due to a dense coatingstructure with submicron splatthickness

- Reduced amount of heat to work piece,- Reduced amount of heat to work piece,because to melt a small particleless energy is needed.

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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?

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 insufficientflow 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 surfacewhich 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

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 onlyprovide 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 and powders require high temperature and stand-off in the spray process- High stand-off do not allow coating of smallInside Diameter Areas (ID must be > 14”)

- Not metallurgical bonded carbides lower theWear Resistance of the coating.

SEM of a 5-15µm agglomerated, sintered and crushed WC-CoCr powder

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

ProblemFine agglomerated, sintered and crushed powders:

SolutionFine 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…

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.

Controlled Plasma Spherodization to achieve ultrafine and highly optimized nanoHVOF powder

nanoHVOF Powder®

Feedstock MaterialWC-CoCr 86 10 4

Controlled Process nanoHVOF PowderWC-CoCr 86 10 4

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Spherodized particle shape provides a matrix consistingof a 14 wt% CoCr28 melted alloy in which thesubmicron carbides are metallurgical bonded

Feedstock material < 10 µmand a primary carbide size

of 400 – 900 nmPlasma Spherodization

Quality Control and parameter adjustment to ensure a reliable powder production

nanoHVOF Powder®

Bulk densityby hall flowmeter funnel

Element detection by EDX-AnalysisParticle shape by SEM

Feedback of Powder Quality

The Controlled Plasma Spherodization Process is based ona measurement and adjustment of:

• Inert gas flow• Plasma gas composition• Plasma gas flow

• Plasma Power • Powder feed rate•Powder gas flow

Process Input

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

nanoHVOF Powder

Tailored nanoHVOF Powder cuts enable maximal Deposit Efficiency and an as-sprayed surface roughness less than 1.5 µm Ra

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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

HardInside and outside diameter coatings withHardness > 1200 HV 0.3 (Standard deviation of ± 30 HV 0.3)

More than smooth – nanoHVOF performance characteristics

nanoHVOF Coating quality®

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Hardness > 1200 HV 0.3 (Standard deviation of ± 30 HV 0.3)

DuctilePerforms well intests such as a Guided Bend Test

Vickers-indent with1Kg at theinterface (Substrate / coating),without any formation of cracks

DenseCoating 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®

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Fog Test by 50 µm coating thickness

Near-netAllows for coating thicknessaccuracy of ±15 µm as-sprayed

Corrosion resistantNanostructured Coating with homogeneous phase distribution providing a melted CoCr28 melted alloy matrix for high Seawater Resistance

accuracy of ±15 µm as-sprayed

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 sprayingultra fine nanoHVOF powder

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nanoHVOF Application Know-HowThermico experience and training means successful coating developmentsfor the most demanding applications

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Feeding ultra fine powders with particle sizes less than 10 µm is a challenge

nanoHVOF is a SystemPowder feeder

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CPF-2 Powder feeder for standard, micro and nanoHVOF Powders ®


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Precise dosage of fluidized Powder by gravimetric feeding principle with controlled rotation of the feeding wheel


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Feeding wheel BalancerFeeding principal

3rd Generation of the CPF Powder Feeder Software and visualization to control the feeding Process and get a constant powder flow


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In ControlCustomizable start and feeding parameter, trend data storage and on-line visualization

Torch technology for outside and inside diameter coatings

nanoHVOF is a SystemOD and ID Torches

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CJS K5.2-NOD-Applications

ID CoolFlow-NID-Applications

Dual chamber, hydrogen stabilized kerosene combustion reduces thermal load to substrate and powder materials


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Principal of Thermico CJS K5.2-N HVOF torch Principal of Thermico CJS K5.2-N HVOF torch

Increased volume of2. combustion chamber

Mach 1 – 2.5Super sonic area

• Low turbulence level forthe supersonic jet

• High pressure Area

N2 ,

• Main part of combustion

• Hydrogen stabilizedKerosene/O2-Combustion

• Cold ignition point for powderN2 ,

1. combustion chamber

Optimized for spraying fine powders with high affinity to oxygen

• Main part of combustion


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

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Required Amount of Oxygen for 100% combustion of combustibles λ =

Provided amount of Oxygen, due to process parameter

A: CombustiblesHydrogen stabilized O2 / Kerosene combustion, due to vaporization of Kerosene jet by entering in the second combustion chamber

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B

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Required Amount of Oxygen for 100% combustion of combustibles

Combustion chamber principle of CJS K5.2-N and ID CoolFlow-N

B: Nitrogen + OxygenIf 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.

Control, visualization and analysis of the process

nanoHVOF is a SystemSystem technology

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NANO HVOF

State of the Art Soft- and Hardware for HVOF and Plasma

On-line Process monitoring and analysis

nanoHVOF is a SystemSystem technology

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On-line spray-jet visualization via USB-Camera On-line Spray-jet-geometry monitoring system.Observation of spray-spot and jet.

Trend data storage of all mass flows

nanoHVOF ApplicationsCJS K5.2-N

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Outside diameter coatings

Turbine BladesNear-net, nano structured Near-net, nano structured droplet erosion coatings

Landing GearSmooth surfaces and close control of coating thickness lead to reduced grinding and finishing grinding and finishing costs on outside diameter surfaces


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Outside diameter coatings

Gas TurbinesLow oxide HVOF sprayed Low oxide HVOF sprayed metal coatings, for example, MCrAlY and T-800

Hard Chrome replacementHydraulic Actuators, Rolls, Mud Rotors and other general applications


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CJS K5.2-N for cost-effective applications with brilliant results

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

nanoHVOF ApplicationsID CoolFlow-N

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Inside diameter coatings

Landing GearCoating inside diameters for Coating inside diameters for hard chrome replacement even on temperature sensitive substrate materials without extra cooling

AutomotiveInside diameter Al-SiC-Cu-Mg coating


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PumpsNon Line-of-Side spraying

Inside diameter coatings

Non Line-of-Side spraying improves erosion and corrosion protection inside casings, bushings and sleeves

Pipes and RisersInconel and Tungsten Carbide coatings of Pipes and Risers reduce maintenance costs


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ID CoolFlow-N applications beginning from 4“ inside diameter

107.0°C Trough hole internal exhaustion


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Pump case and Non-Line-of sight spraying

Critical pumps in crude oil and fluid catalytic cracking FCC processes


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Pump case and Non-Line-of sight spraying

nanoHVOF ApplicationFacing sophisticating Applications

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Rotational Media Transfer Unit (RMTU)

ID CoolFlow-N torch with Extension and RMTU

nanoHVOF ApplicationFacing sophisticating Applications

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Rotational Media Transfer Unit (RMTU)

RMTU equipped for spraying Control box

Thank you very much for your attention! Thank you very much for your attention!