Professional Documents
Culture Documents
Motivation
Tribology and Wear
Surface properties and characterization
Pre-and post-treatment
Deposition methods - Overview
Painting
Electroplating and anodic oxidation
1
1.
Motivation
Motivation
Some Numbers
4.5 %
>50 Mrd
5%
of sales
are used for repair and maintenance (in wear intensive
industry 10-15%)
10 %
10 %
50 %
Motivation
Motivation
BALINITcoating
tools
31.800
15.700
maintanance
17.200
Coating
total
Source: Siemens AG
800
49.000
16.500
160.000
6,5 Mio
Motivation
Industrial Application
Motivation
Motivation
Hip implant
Engine block
EUROFLAMM
Synchronrings
Household devices
Motivation
Coated components
aerospace
engines
Medicine
Textile machines
rolls
Other industries
Consumer goods
On-site maintenance
2.
10
Tribological system
load
velocity
intermediary
metal
mineral
Liquid
gaseous
liquid
solid
gaseous
Counter body
metal
mineral
plasic
elastomere
Base body
enviroment
liqud
gas
dust
temperarture
11
Festkrper /
Festkrper
Festkrper //
Festkrper
Festkrper
Solid/liquid
Festkrper/
Festkrper/
Flssigkeit
Festkrper/
Flssigkeit
Flssigkeit
sliding
Mechanismus
Mechanism
sliding wear
adhesion
/ abrasion
Adhsion
Verschleiart
Verschleiart
Gleiten
Gleiten
Gleiten
rolling
Rollen
Rollen
Rollen
impact
Prallen
Prallen
Prallen
vibrations
Schwingen
Schwingen
Schwingen
Gleitverschlei
Gleitverschlei
Gleitverschlei
rolling wear
Wlzverschlei
Wlzverschlei
Wlzverschlei
impact wear
Stoverschlei
Stoverschlei
Stoverschlei
vibration wear
Schwingverschlei
Schwingverschlei
Schwingverschlei
Strmen
flowing
Strmen
Strmen
Prallen
Prallen
impact
Prallen
Kavitation
cavitation
Kavitation
Kavitation
Tropfenschlag
Tropfenschlag
droplet erosion
Tropfenschlag
Festkrper/
Strmen
Festkrper/
Gas
mit/FestSolid
gas with solid Strmen
flowing
Festkrper/
Strmen
Gas
mit
Feststoffpartikeln
Prallen
Gas
mit Festparticles
stoffpartikeln
Prallen
stoffpartikeln
impact
Prallen
Verschleiart
Wear
type
Mechanismus
Mechanismus
Abrasion
Adhsion
Adhsion
Abrasion
adhesion
/ fatigue
Abrasion
Adhsion
Ermdung
Adhsion
Adhsion
Ermdung
fatigue
/ adhesion
Ermdung
Ermdung
Ermdung
Ermdung
fatigue
Adhsion
Ermdung
Adhsion
Adhsion
Ermdung
Ermdung
Ermdung
fatigue
Ermdung
Ermdung
Ermdung
fatigue
Ermdung
Ermdung
Gleitstrahlverschlei
Abrasion
sliding jet wear
abrasion
Gleitstrahlverschlei
Abrasion
Gleitstrahlverschlei
Abrasion
Prallstrahlverschlei
Ermdung
impact
jet
wear
fatigue
Prallstrahlverschlei
Ermdung
Prallstrahlverschlei
Ermdung
VERSCHLP.CDR
VERSCHLP.CDR
VERSCHLP.CDR
Verschleipaarung
Wear combination Beanspruchung
loading
Verschleipaarung
Beanspruchung
Verschleipaarung
Beanspruchung
12
Wear depth
Adsorption
layer
Outher
unrelated
surface layer
Inner related
surface layer
Oxide-Reaction zone
Distubtion by
forming and
modified chemical
composition
Coating wear
Corrosion
wear
Adhesive wear
Abrasive wear
Base material
13
wear
Linear
Linearer
Verschleibetrag
Progress of wear
ion
as
r
Ab
sion
Adh
n
. Reaktio
Tribochem
g
ttun
err
z
n
he
rflc
Obe
Weg,
Zeit time
Distance,
14
Reduction of wear
Reduction of abrasion:
Reduction of adhesion
Reduction of fatigue:
15
Physical adsorption
Interaction of induced or permanent
dipoles (Van-der-Waals-forces)
Adsorption heat 4 40 kJ/mol
Process is reversible
Absorption:
Chemical Adsorption
Formation of a chemical bonding
Adsorption heat 40 400 kJ/mol
Process is not reversible
16
Cohesion:
17
= + cos
, :
:
:
Wetting:
< 90
No wetting:
> 90
Complete wetting: > +
18
3.
19
20
10
pressing
Compounds
21
optics
Heat
insulating
High
Temperature
protection
Bearring
Coating of
new parts
decoration
Repair
coatings
Oxidation
protection
Bioactivities
Wear
protection
Corrosion
protection
Elcetrical
properties
22
11
secondary
Chemical composition
elasticity
Phase composition
hardness
Residual stress
Surface roughness
corrosion resistance
wear resistance
adhesion is influenced by
Surface energy
adhesion mechanism:
Mechanical clamping
Adhesion
Diffusion
Chemical bonding
Electrostatical forces
24
12
coating thickness
coating adghesion strength
Hardness
Wear resitance at diferent loads
Friction coefficient
corrosion properties
Thermal properties
Mechanical properties (ductility,
elasitcity, stresses,
Electrical properties (conductiviy,
resistance,
Optical properties (color, brillance, )
Surface roughness
Metallographic investigations
Corrosion behaviour
Wear behaviour
Thermal behaviour
Mechanical behaviour
Optical behaviour
cupping test
measurement of residual stresses
creep behaviour
Metallographic evaluation
structure and microstructure
phase boundaries
pores and pore distribution
corrosion behaviour
salt-spray test, thermal test, current density potential test
Wear behaviour
Taber-Abraser-Test; pin on disc test; vibrational wear
.
26
13
Measurement examples
Measurement of coating thickness d
- Simple and cheap procedure
- Fast measurement
- Destructive method
parameters:
grinding time
ball diameter
Preparation of a calotte grinding
-
27
Measurement examples
Measurement of wear behaviour
- Destructive method
- Pin-On-dic method
- Determination of the friction and
the wear coefficient
Methode
Ball with defined load
Interaction with a coated surface
Friction between ball and surface
Measurement of Wear trace;
Determination friction coefficient :(FR = FN * R)
Parameter:
Normal force
Rotational speed
Speed
Trace diameterLaufspurdurchmesser
Friction length
rotation
Friction time
Principles of Coating Technology I
[N]
[s-1 ; m-1]
[m/s ; m/min]
[mm]
[m]
[min]
28
14
29
Scratch-Test
Diamond indenter will be moved with a defined
load along the coated surface
At critcal load: coating delamination or crack
formation
Determination and evaluation of the scratch
Measurement examples
Diamond
indenter
Depth
sensor
Acoustic
emission
sensor
30
15
Measurement examples
Measurement of roughness
4.
Pre-and post-treatment
32
16
Pre-treatment
cleaning
Surface activation
roughening
2.
Coating deposition
Determination of coating technology and parameters
Surface protection
3.
Post-treatment
Homogenization of the coating
Additional improvement of the properties
4.
Pre- Treatment
Cleaning
- removal of dirt
- removal of oils and greases
- removal of paints
Blasting
- roughening
- decontamination
- activation
Blasting materials
34
17
Post- Treatment
Objective:
reduction of porosity
Closing of cracks
35
Post- Treatment
Thermal Post-Treatment:
Thermo-mechanical
Mechanical
final expanding
hammering
shot peening
simultaneous spraying and peening
36
18
Thermal Post-Treatment
Fuly or partial remelting of the surface with and energy source (flame, laser beam, ) for
-
Coated
part
Bauteil
Bewegungsrichtung
Moving
direction of the probe
Thermal Post-Treatment
Heat treated Ti-coating with reaction zone
38
19
Thermal Post-Treatment
modification of the adhesive strength by different thermal post treatment processes
- Remelting without reaction zone: adhesive strength is reduced
- Remeling with reactive zone: increasing of adhesive strength
> 65
80
57
70
60
38,5
glue
coating
50
40
30
Probe
20
10
0
wie gespritzt
As sprayed
umgeschmolzen mit
remelted
fusion
Aufmischung
umgeschmolremelted
zen mit
Reaction
Reaktzone
ions-
zone
coating
substrate
39
Thermo-mechanical Post-Treatment
Hot isostatic pressing (HIP)
-
Material will be loaded with high temperature and high pressure in one process step
HIP will be used for compacting of poros structures (eg sintering of ceramics)
Processes during HIP
diffusion
creeping
Modification dring hip
Structural compacting, removal of pores
Phase formation within the coating
Grain growth wihin coating
40
20
Thermo-mechanical Post-Treatment
Hot isostatic pressing (HIP) - Example
Production of metal matrix composites (MMC)
-
Verbundwerkstoff
Faser
Spritzpistole
41
mechanical Post-Treatment
Shot peening
Objective of mechanical post-treatment
compacting
Reduction of surface roughness
Characteristics of shot peening
Ball shaped blasting material off metal, ceramic, glass
Process similar to sand blasting
Velocity of blasting material 15-150 m/s
Simultaneous shot peening
Compacting of the whole coating
Optimization of corrosion resistance
Induction of residual compressive stresses
42
21
5.
43
Deposition
from liquid or
pasty state
Deposition
from solids or
powders
Painting
Hot dipping
Powder
coating with
polymers or
metalls
Deposition by
welding
Deposition by
soldering
Deposition
from gaseous
or voporized
state
PVD / CVD
Deposition
from ionized
state by
electrolytical
or chemical
deposition
Galvanic
methods
Anodic
methods
44
22
Important methods
Deposition by welding
Fusion welding (autogenously, metal inert gas, tungsten inert gas plasma welding with wire or
powder, submerged , laser welding )
Pressure welding (roll cladding or explosive plating)
Deposition by brazing
fusion soldering (with gas, metal inert gas, plasma, oven)
Deposition from gaseous or voporized state
Physical Vapor Deposition
Chemical Vapor Deposition
Combination of PVD and CVD methods
Deposition from ionized state
Galvanic methods with and without an external current generator
anodic methods
45
Diffused element
C
C, N
N (H)
N, C (O, H)
O
N, O
S
N, S
N, C, S
B
V
Cr
Cr, V
Nb
Al
Si
Sn
Mn
Media
Gas, Paste, Pulver, Salzbad
Gas, Plasma, Salzbad
Gas, Plasma
Gas, Plasma, Pulver, Salzbad
Gas, Salzbad
Gas
Salzbad
Gas (Plasma)
Salzbad (Plasma)
Gas, Paste, Plasma, Pulver
Pulver, Salzbad
Gas, Pulver, Salzbad
Pulver
Pulver
Gas, Pulver, Salzbad
Pulver
galv. berzug
Pulver
temperature [C]
800 - 1050
600 - 930
350 - 550
350 - 600
150 - 550
~ 500
200
~ 600
570 - 580
800 - 1000
850 - 1100
900 - 1200
1000
1000 - 1100
~ 1200
930 - 1200
580
1000 - 1100
46
23
CVD / PVD
0,001 - 0,1 mm
chemical Ni
0,03 - 0,3 mm
galvanic Cr
0,01 - 0,5 mm
thermal spraying
0,05 - 3 mm
build up soldering
0,1 - 1 mm
build up welding
2 - 20 mm
roll cladding
2 - 12 mm
PVD
TiNcoating
Thermal spraying
APSAl2O3
50 m
6 mm
Built-up-welding
47
10
-4
10
-3
10
-2
-1
10
10
1
Coating thickness [mm]
10
100
48
24
CVD
Build-up welding
800
Thermal
Thermal spray
spraying
600
PVD
400
Chemical methods
200
II
0
0.1
10
100
1000
10000
49
50
25
Painting
Mechanical:
Brushing
Etching
Blasting
lubricating
51
Painting
Airless-nozzle Finespray-nozzle
Principles of Coating Technology I
Spritzlackieren
52
26
Painting
nozzle geometries
Compressed air nozzle
- Using compressed air
- High velocity differenz destroyed paint surface
Airless nozzle
- High pressure of the paint
- Expansion of the paint after the nozzle exit
- Priniple is used in sprays
Electrostatic nozzle
- Mechanical nebulization of the paint
- Electrostatic acceleration of the paint to the substrate
- Extremly low paint losses
53
Painting
Dipping
-
54
27
Painting
Paint particles
in aqueous solvent
Surface of the Component
Paint droplets
coagulated on the
surface
Surface of the Component
Good automatable
Complete painting of the components
(cavities, beadings,)
Low consumption of paint
55
Painting
56
28
Painting
57
Painting
58
29
Painting
Poder recycling
unit
Continous oven
Podwer spray
chamber
chain conveyor
give out
59
Painting
Good automation
Powder
cloud
Porous
Intermediate
layer
air
60
30
Painting
Processing time 7- 10 s
pipes
give out
Powder
deposition
Heating
cooling
Smoothing
61
Painting
unit
yes
no
yes
no
Powder type
PA
EP
yes
yes
no
yes
yes
320-360
yes
1
70
105-110
2,5 x 10-5
0,35
2,3
0
good
bad
yes
270-360
yes
1
80
70-150
8 x 10-5
0,15
0,98
0,2
moderate
moderate
yes
270-360
yes
1
95
186
12 x 10-5
0,29
2,4
0,8-1,5
moderate
moderate
PE
Pre treatment: blasting
Etching / phosphatizing
(without passivation)
Adhesion layer
Processing temperature
Post treatmend
Minimal sheet thickness
Shore hardnees
Melting tange
Thermal expansion
Heat conductivity
Spez. heat
Water absorption (24 Std. RT)
Chemical stability
Weather resistance
C
mm
C
K-1
W/Km
kJ/kgK
%
PVC
yes
200
yes
95
4 x 10-5
0,15
1,7
0,3-1,5
moderate
bad
EVAL
yes
yes
yes
180-360
no
0,5
85
105-108
13 x 10-5
0,28
1,9
0,2
good
good
62
31
7.
63
electroplating
Anode
Kathode
Metallionen
Ion exchange method (exchange of ion between anode and solved ions)
64
32
electroplating
Metals (steel, copper and copper alloys, zinc, aluminum and aluminum alloys
Plastics
ceramics
Electrical non conductive material must be pre-coated with a conductive coating (e.g. Au, Cu, Al)
Pre-tratment is nessecary
65
Complex ions
66
33
Brightener (organic materials for a more unifcorm and fain grained coating)
Defoaming agent
67
I t MG
zF
mth
Mg
current
ionic charge
time
Coating characterisitics
mth
a)
b)
c)
Grundwerkstoff
Beschichtung
68
34
Expensive equipment
Exampe of
bath electroplating
Steel
Copper and copper alloys (often adhesion layer for nickel coatings)
electrolytes
Bright nickel
(coating hardness 380 480 HV)
Exampe of
Hard nickel cylinder
Principles of Coating Technology I
70
35
Application
High hardness
High gloss
Used cylinder
Chrome plated
cylinder
High gloss chrome cylinder
71
Aluminum
Cast steel
Nickel
electrolytes
Cr3+ ions
Wetting agent
Hard chrome coating: higher CrO3 content
Bright chrome: lower CrO3 content
72
36
Coating properties
Process modifications
No pre-treatment necessary
Hot-dip galvanizing
Spray galvanization
73
Electroplating of plastics
Generation of conductive surfaces necessary by
Electro-paint
applications
Metallionen +
Reduktionsmittel
74
37
Electroplating methods
Fe
-
ee
2+
Cu
CuSO4
Dipping method
Inner shortcut
Fe2+
Stromfluss
Kontakt- material
Fe
Contact method
e-e
Fe2+ 3+
2Al
Cu2+ 2+
Cu
Cu2+ SO42-
75
Al
eeeeee
Deposition conditions
76
38
Chemical stability
Properties
Thin layer
During deposition inclusion of hydrogen into the substrate heat treatment necessary
78
39
79
40