TECHNISCH SEMINARIE METAALSECTOR Gent – 27 maart 2015
THERMISHE PROJECTIE: HIGH-TECH BESCHERMINGSLAGEN Claude Thomas / Sammy Lasseel
PIKOASUR • Opgestart in 2000 door : • Metrasur, Frankrijk, actief als thermische spuiter in de luchtvaartsector • Pikotechnic, Finland, actief als thermische spuiter in de papiersector
• Aankoop door Hannecard Groep op 1/10/2014 • Activiteiten : • 1. Produktie en Herstellen van spreidwalsen • 2. Voordraaien en Slijpen : zowel op werf als in eigen werkplaats • 3. Thermisch Spuiten : zowel op werf als in eigen werkplaats
ACTIVITEITEN
1. Productie en herstellen van spreidwalsen • Produktie en herstellen van alle merken spreidwalsen, zowel met rubber bekleed als verchroomd • 75 walsen / jaar
2. Voordraaien en Slijpen • Voordraaien en slijpen van zeer grote walsen zoals droogtrommels en perswalsen, zowel on-site als in eigen werkplaats • OOK herstellen van
astappen en zittingen : • oplassen • opspuiten • verbussen
3. Thermisch Spuiten Verbeteren slijtageweerstand Verbeteren corrosieweerstand Verbeteren chemische weerstand Opdikken (herstellen van originele afmetingen) • Controle van de frictiecoëfficiënt • • • •
Arc Jet
HVOF tov HP HVAF
3.1 Thermisch Spuiten : gereedschap
SOORTEN BEKLEDING
PIKOCAL • Bekleding met een wolfram
carbide
Verbeteren van de slijtageweesrtand - dikte : meerdere mm - hardheid : 1300 HV - ruwheid : Ra < 0,05 µm
PIKOCHROME •
Bekleding met een chroomcarbide Verbeteren van de corrosieweerstand zeer vochtige omstandigheden & indien voedingsgeschiktheid vereist is - dikte : meerdere mm, typisch 250 µm - hardheid : 1000HV - ruwheid : Ra < 0.05µm
CARBUFLON® • DUBBELE BEKLEDING :
Wolframcarbide + TEFLON Verbeteren van de slijtageweerstand + Aanbrengen van een anti-kleeflaag CARBUFLON® - hardheid : 1150HV - ruwheid : Ra < 1.5 µm - kan gerakeld worden - niet voedingsgeschikt
PIKOGRIP • Bekleding met een
wolframcarbide Contrôle van de grip (frictiecoëfficient) - dikte : 60 µm à 200 µm - hardheid : 1150 HV - ruwheid Ra : 3µm < Ra < 12µm (ifv korrel)
MACHINES IN EIGEN WERKPLAATS
Eigen werkplaats
• Productiehal : 1350 m2 • Burelen : 225 m²
Draaibanken : 1 CNC + 2 conventionele • Max. diameter : 1100 mm • Lengte tussen punten : 10 m • Max. gewicht : 15 ton
Spreidwalsen • 5 verschillende werkposten
Rolbrug • Capaciteit van 32 ton
Spuitcabine • Breedte : 5m • Lengte : 11m • Lineaire beweging tov roterende rol
Voorbeeld van HP HVAF in spuitcabine
• • • •
135 dB 1650°C 1900 m/sec 30 kg/hr
Dit voelt aan als :
+ + +
Om finaal te komen tot :
Inleiding Mr. Claude Thomas • Expert en consultant in thermisch spuiten : • installaties • toepassingen • poeders
• Lid van ”European Thermal Spray Association” • Lid van experten van de AFNOR ( Franse normalisatie ) • Docent aan verschillende ingenieursscholen en universiteiten
A mature technology , a new tool , result in the building of even more efficient coatings for further applications
• • • • •
Increase life times of wear parts, increasing machine productivity Reduce the assets following a maintenance Improve surface finish rolls or cylinders Improve product quality manufactured Reduce the number of intervention for the maintenance of production facilities • Reduce the cost of the replacement strategic part • Remedy through new technology recurring wear problem
Thermal Spraying Coating • Thermal spray principle • Synopsis • Adhesion • Cohesiveness • Porosity • Unmelt particle • Oxide • Micro hardness
Thermal Spray : Basic Principle Addition Material : wire or powder
Heat Source
Fused Particles
Acceleration Splashed onto the substrate surface
Coating Morphology Mechanical Bonding
Lamellar Structure Porosity
Surface Roughness
Oxide
Splat
Non fused particle
Adhésion , ASTM C633
Micro Hardness Definition Hardness measured with an instrument having a smaller indenter and applying a lower force than the standard instrument, permitting measurements on smaller specimens or thinner sheets that are not amenable to measurement by normal instruments. Usually the indentations are so small that they must be measured with a microscope.
Coating particularity • With Wire-Flame, Powder-Flame, ArcJet, Atmospheric Plasma Low Energy, Atmospheric Plasma High Energy, HVOF, coatings are in “tension”. • When the coating is in tension , the high temperature in the coating is transferred to the substrate and the expansion between coating and substrate can result to cracks. The coating then unhooks from the substrate due to the particle stickiness.
• With HP/HVOF, D-Gun, SD-Gun, HFPD, HVAF, coatings are in “compression”. • When the coating is in compression the high temperature in the coating goes to the substrate and the expansion between coating and substrate can make cracks but cannot unhook because the adhesion is very high and particle stickiness isn’t concerned.
It’s Elementary • Chemical Compositions of thermal spray powders are applications driven Carbides for abrasion resistance Ceramics (oxides) for high temperatures Alloys for corrosion + general wear
• Composition directly affects M.O.M. Atomizing vs. SD+S vs. Crushed vs. HOSP… Purity is very important: O2, Tramp Mat’ls
Apparently, Density is Important • In general, high density particles will feed well, melt slowly and travel slower • Low density particles won’t feed as well, but will melt easily and accelerate easily • AD is depending upon the nominal particle size and the breadth of the size distribution • AD is a key control variable in most manufacturing processes
Equipment
Speed vs Temperature Température des particules, °C 3500 3000
Plasma
2500
Arc -fil
2000
H.V.A.F
1500 1000 500 0 0
200
400
600
800
1000 1200 Vitesse des particules, m/s
HVAF ( High Velocity Air Propylen)
HP-HVAF Coatings aspect
Surface preparation with sand blasting
No surface preparation
HP-HVAF : WC and CrC coatings
WC-10Co 4Cr
Cr3C²-NiCr
HP/HVAF • Coating Characteristics • Adhesion • > à 70MPa • Coating in Compressive aspect
• Porosity • < 1% in the case of carbide
• Micro-hardness • 500 to 1500 HV0,3
• Oxide content • < à 2%
• Powder flow rate : • more than 500 gr/mn • More than 66 lbs/h
Achieving a High Quality Coating requires : • • • •
The use of High Quality Materials A thermal Spraying Tool adapted with High Perform Knowledge flawless powder metallurgy And finally , the most comprehensive definition regarding the functionality of the part and the surface directly involved in the final quality of the treated product and the most complete scan possible to the working environment of the part (temperature, corrosive environment, wear, rotation speed, etc.)
DIFFERENT WEAR
Steel Industry, Thermal Spraying Coatings applications • The Wear • • • •
Abrasive Corrosive High temperature Chemical reaction
• What is temperature definition • For Thermal Spraying Coating : • 0°C ≤ T°C ≤ 540°C = Cold • 550°C ≤T°C ≤ 980°C = Hot • T°C ≥ 1000°C = Very Hot
Part which is located and works in a
cold area • Different coatings as : • Mono-coating • Tungsten Carbide • Chrome Carbide • Molybdenum
• Duplex coating • Tungsten Carbide + Chemical Reactive Coating • Chrome Carbide + Chemical reactive Coating
Part which is located and works in a
hot area • Different coatings as : • Mono-coating • • • •
Chrome Carbide MCrAlY’s NiCoCrAlY’s CoNiCrAlY’s
• Duplex coating • Chrome Carbide + Chemical Reactive Coating • MCrAlY’s + Chemical Reactive Coating • CoNiCrAlY’s + Chemical Reactive Coating
Chemical Reactive Coating • What is it ? • Chemical reactive coating is a deposit, placed on the sprayed coating which confers significant characteristics such as: • Hydrophobic surface (non-wettability) • Porosity = 0 • Good resistance against corrosion at high and low temperature • Better surface roughness • Micro-hardness > 2000 HV 0,05
Special case : Immersed
rollers
• Zinc: • Sink Roll • Hard Coating + Chemical Reactive coating = Hydrophobic aspect
• Stabilizer Roll • Hard Coating + Chemical Reactive coating = Hydrophobic aspect
• Corrector Roll • Hard Coating + Chemical Reactive coating = Hydrophobic aspect
• Aluminium: • Aluminium Pot Rolls • Hard Coating + Chemical Reactive coating = Hydrophobic aspect
Last case : Continuous Casting Mold Plate • Special duplex coating which give high hardness and a best shield to protect the nickel deposit and cause random degradation of the copper plate. • Micro-hardness : ≥ up to 1500 HV 0,3 • Coating porosity : less than 0,5% • Oxide content : less than 1%
Steel industry application coatings • Process rolls • Deflector roll • WC-CoCr coating
• Block S roll • WC-12Co or WC-NiCr coating
• Accumulator roll • WC-12Co coating
• Guiding roll • WC-12Co coating
• Conductor roll • CrC-80/20 NiCr coating • WC-CoCr 86/10/4 coating
Steel industry application coatings • Cold rolling • WC-12Co • WC-17Co • WC-CrC-NiCr
• Sendzimir • WC-CoCr 86/10/4 • WC-NiCr
• Furnace roll • CrC-NiCr coating
BEDANKT VOOR UW AANDACHT