Technisch SEMINARIE STAALSECTOR

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