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Nano HVOFThermico
Nano HVOFThermico
®
nanoHVOF - for the most demanding
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.
Outline
4. nanoHVOF ® powder
5. nanoHVOF ® is a system
6. Applications
Thermico
Performance profile
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
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.
?
400 m/s
30µm
Ek (30µm) ½ m v2 1
------------------- = ------------ = ------------
Ek (5µm) ½ m v2 6,25
1000 m/s
5 µm
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.
2
Due to high particle velocity the kinetic energy increases exponentially (EK = ½ mv ).
Advantages of spraying fine powders
For melting a small particle less thermal energy is needed
Agglomerated, sintered
HVOF standard powder WC-CoCr 86 10 4
and crushed powder
Problem Solution
Fine agglomerated, sintered and crushed powders: 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 carbides
have lower Wear Resistance, limited by process temperature metallurgical bonded carbides
Process Input
The Controlled Plasma Spherodization Process is based on
a measurement and adjustment of:
• Plasma Power • Plasma gas composition • Powder feed rate • Inert gas flow
• Plasma gas flow •Powder gas flow
®
nanoHVOF Powder
Controlled Plasma spherodization means to get the right quality of the
metallurgical structure with only a very low amount of W2C phases
-5+2 µm or -10+5 µm
ultra fine nanoHVOF® Powder cuts
Hard
Inside and outside diameter coatings with
Hardness > 1200 HV 0.3 (Standard deviation of ± 30 HV 0.3)
Ductile
Performs well in
tests such as a Guided Bend Test
Dense
Coating structure with virtually Zero Porosity,
to survive more than 1000 hours in a Salt
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
®
nanoHVOF is a System
To achieve superior coating quality for the most demanding OD and ID
Applications
nanoHVOF® Powder
Ultra fine, spherodized and nano structured powder
In Control
Customizable start and feeding parameter, trend
data storage and on-line visualization
®
nanoHVOF is a System
OD and ID Torches
Torch technology for outside and inside diameter coatings
B
A
B
Combustion chamber principle of CJS K5.2-N and ID CoolFlow-N
A: Combustibles
Hydrogen stabilized O2 / Kerosene combustion, due to vaporization of Kerosene jet
by entering in the second combustion chamber
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.
®
nanoHVOF is a System
System technology
Control, visualization and analysis of the process
State of the Art Soft- and Hardware for HVOF and Plasma
NANO HVOF
®
nanoHVOF is a System
System technology
On-line Process monitoring and analysis
Turbine Blades
Near-net, nano structured
droplet erosion coatings
Landing Gear
Smooth surfaces and
close control of coating
thickness lead to reduced
grinding and finishing
costs on outside diameter
surfaces
®
nanoHVOF Applications
CJS K5.2-N
Outside diameter coatings
Gas Turbines
Low oxide HVOF sprayed
metal coatings, for example,
MCrAlY and T-800
Landing Gear
Coating inside diameters for
hard chrome replacement even
on temperature sensitive
substrate materials without
extra cooling
Automotive
Inside diameter Al-SiC-Cu-Mg
coating
®
nanoHVOF Applications
ID CoolFlow-N
Inside diameter coatings
Pumps
Non Line-of-Side spraying
improves erosion and
corrosion protection inside
casings, bushings and
sleeves