Plasma spray ID coatings

HCAT Program Review

August 2001
Toronto

Keith Legg 847-6809420

Summary of technology development

approach
Praxair

Sulzer Metco

E
q
u
i
p
m Praxair 2700
e
n 30kW, 1.5 ID
t

NRC
All guns
F-100, 20 kW 4 ID

Characterize performance velocity

and temperature profiles

F-210, 12kW, 2.5ID

F-300, 9 kW, 1.6 ID

P Tribaloy 400
o
WC-Co small particles
w
d
e
r

Standard WC-Co powders

All powders

Nano-agglomerate WC-Co

Optimize spray conditions

WC-Co self-fluxing powder

Consider other materials

I
s
s
u
e
s

Best conditions for large parts landing gear

outer cylinders

Characterize coatings and coated

tubes

Do nanoparticles give better coaitngs?

Evaluate OSH issues

How small a diameter can we coat?

Powder and temperature control
Do small particles provide better
quality?

Keith Legg 847-680-9420

The story so far

All coatings made in 3 ID

tubes
3 guns used

Praxair 2700 (1.5 min)

SM F100, F210
perhaps look at new SM
F300 miniature gun

Evaluated large number

of WC materials to find
those with lowest porosity
Designed common
coupon coating rig

Measured particle T and V

for guns and powders so
can determine process
windows and transfer
processes
Begun to develop uniform
porosity measurement
procedure
In midst of optimization
preparatory to making
test coupons

Keith Legg 847-680-9420

Materials to be optimized

Tribaloy 400

Diamalloy 2003, or equivalent, fused and

crushed WC-Co

softer, lubricious, low porosity

lowest WC-Co porosity

evaluate standard and small particles

Diamalloy 2002, or similar, 75(WC-12Co)

NiCrFeSiBC self -fluxing blend

softer than WC-Co but low porosity

evaluate alloy modifications

Keith Legg 847-680-9420

Tribaloy development - Praxair, NRC

Velocity (C)

Operational range SG-2700 mini gun

215
195
175
155
135
T-800
115
95
75
55
2000
2200

T-400 fine

2005 NS

2400

2600

2800

3000

3200

3400

Small particles allow

higher T, probably also
higher V
But small particles (600
mesh, 20 m) too
difficult to feed reliably

Temperature (C)

trials continuing with

400 mesh, 38m
powder), which feeds
much more readily
smooth, low porosity
decent coatings at 1.5
standoff (approx 2 ID)
with 38m powder
Keith Legg 847-680-9420

T 400 microstructure

Porosity 6%

measurement depends on met

prep

best porosity method appears to be

vacuum infiltration

Hardness ~350 - 400 HV

softer than carbides

lubricious - can be used against
itself (piston + ID)
becoming used in some actuators

Almen can = 0 (no residual

stress)

very important for fatigue

most plasma spray coatings are
tensile
Keith Legg 847-680-9420

Diamalloy 2003
Fused WC-12Co

Porosity 4%

Microhardness 780 HV300

Cross section, 200X

close to requirements,
may need sealing
lower than standard OD
coatings, but certainly
adequate

Likely to be more brittle

than WC-17Co

may not matter too much

in IDs

Keith Legg 847-680-9420

Diamalloy 2002
WC-12Co self-fluxing with NiCrFeSiB

Porosity <1%
Microhardness 670 HV300

Expected to be more
lubricious and less brittle
than WC-Co

Cross section, 200X

lower than WC-12Co but

acceptable

may be ideal combination

of wear resistance, lubricity,
porosity, toughness
blend - can adjust blend for
optimum combination of
wear and lubricity

May be good for ODs too

Keith Legg 847-680-9420

Sample holder - 3ID

Coat coupons
for all tests
under ID
conditions

metallography
adhesion
wear
corrosion
fatigue

Keith Legg 847-680-9420

To be done

Standard coupon jig being

made for NRC, Sulzer
Metco, Praxair

Optimize coating
parameters

to ensure samples
produced under
equivalent conditions

spray coupons for testing

(fatigue, corrosion, etc)

Perfect methods for

temperature and particle
control

Porosity measurements to
be normalized and all
final measurements to be
made at NRC
S-M may evaluate new F300 miniature gun
Determine minimum
sprayable ID

determines range of
applications

Keith Legg 847-680-9420