Thermal Spray Center Finland: research and coating equipment

Thermal Spray Center Finland
§ Strategic collaboration platform between Tampere
University of Technology, Department of Materials
Science, and VTT Technical Research Centre of
Finland Ltd.
§ Aim is to be at the leading edge of this research field
thus creating a perfect platform for international highimpact research and remarkable national industrial
influence.
§ Modern and well-equipped thermal spray research
laboratory with supporting materials research
laboratories of TUT and VTT.
Thermal spray equipment
at Thermal Spray Center
Finland in 2015
3.2.2015
36
Thermal spray equipment of TUT
Traditional thermal spray technologies
Arc and flame spray equipment
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Sulzer Metco 6RC (arc spray)
Sulzer Metco 6P-II (powder flame spray)
Castolin DS 8000 (powder flame spray)
Sulzer Metco 12E (wire flame spray)
Saint Gobain MasterJet
(wire, rod, flexicord flame spray)
TeroDyn polymer flame spray
Detonation equipment
•
PERUN P D-gun
(Paton Electric Welding Institute)
Arc
Flame
Spray
method
Process
temperature (°C)
Particle
velocity (m/s)
Plasma
12000
200 - 400
Arc
4000
100
Flame
3000
40
Detonation
4000
900
HVOF
3000
800
Cold
25-1000
550-1200
Thermal spray equipment of TUT
Advanced thermal spray technologies
Plasma spray equipment
• Sulzer Metco F4
• Saint Gobain ProPlasma
• Suspension plasma spray process
HVOF and HVAF spray equipment
• Sulzer Metco DJ Standard (propane),
DJ-1000 (propane), DJ-2600 (hydrogen)
and DJ-2700 (propane, ethene)
• GTV Top Gun (hydrogen, ethene)
• S-HVOF (suspension)
• UniqueCoat M3TM (HVAF)
Cold spray equipment
• CGT Kinetiks 3000
• Laser-assisted cold spray (CGT Kinetiks 3000)
• DYMET 403K (low-pressure cold spray)
Plasma
HVOF
LPCS
HVAF spraying
HVAF spray equipment at TUT
•
Uniquecoat Technologies LLC M3 spray gun
(UltraCoat Supersonic spray system)
Cold spraying
High-pressure cold spraying
• Process gas N2 or He (40 bar)
• Pure metals and metal alloys
• TUT: CGT Kinetiks 3000
Low-pressure cold spraying
• Process gas compressed air (9 bar)
• Metal-ceramic powder mixtures
• TUT: DYMET 403K
• Coating is formed by powder particle impacts on
substrate surface with high kinetic energy (high
velocity) à Particles impact, deform
and adhere to the sprayed surface,
forming the coating
• High plastic deformation
• No melting, no oxidation
M. Grujicic et al., Applied Surface Science, 2003, 219, p. 211-227
Thermal spray equipment of VTT
Advanced thermal spray technologies
HVOF and HVAF spray equipment
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Sulzer Metco DJ Hybrid DJ-2600 (hydrogen)
Miller HV-2000 TopGun (hydrogen, ethene)
Kermetico HVAF propane/air system
Thermico HP-HVOF liquid fuel torch
Arc spray equipment
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Sulzer Metco SmartArc
Supplementary equipment
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Powder manufacturing method: spray drying
Grit-blasting cabin
On-line monitoring systems: SprayWatch and HiWatch (Oseir)
FANUC robot, ABB robot, x-y manipulator
Thermal spray research
at TUT
3.2.2015
43
Surface Engineering – research expertise
Processing of advanced coatings by thermal spray, laser and
thin film processes
Materials science of coatings and thin films - microstructure and
engineering properties
Application-related properties and performance of advanced
surfaces and coatings
Industrial applications of coatings and surface treatments
Surface Engineering – research strategies
•
Development of coating solutions to demanding engineering
applications à paper industry, energy, SOFC, wear, …
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Coating manufacturing processes – process, parameters,
developments à cold spray, HVAF, suspension spraying, laser
hybride technologies, …
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Materials science of engineering and functional coatings
à wear, corrosion, friction, heat, tailored properties, …
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Performance of coatings (wear, corrosion, high temperature,
friction, optical, electrical properties, etc.)
Surface Engineering
Examples of on-going and recent research activities or projects
• Multifunctional thin coatings and multifunctional thick coatings and hybrids
(FIMECC/HYBRIDS)
• New cost/effective superHYDROphobic coatings with enhanced BOND
strength and wear resistance for application in large wind turbine blades –
HYDROBOND (EU FP7)
• COaxially Laser Assisted cold spray – COLA (EU FP7 SME)
• Thin films and thin coatings for green energy applications for solar thermal
absorbers and SOFC applications
• Development of high-rate laser cladding process - Novel innovations in
production solutions – Trilaser (FIMECC/Innovations and network)
• Processing/structure/properties/performance relationships of coatings by
thermal spraying, laser and thin film processes
European Thermal Spray Association - ETSA
Established in December 2009 in Lille, France
Board of delegates established (France, Italy, England, Sweden, Finland,
Norway, Germany, Switzerland, Czech, Spain)
National representative of Finland: prof. Petri Vuoristo
Internet website: under construction
Main activities: conferences, workhops, seminars, summer schools, expert
network, interaction academia/industry, networking with other TS
organisations (ASM/TSS, GTS, China, Japan etc.)
National organisations; e.g. ETSA Finland
Thermal spraying
research at VTT
3.2.2015
48
49
03/02/2015
Thermal Spray coating development at VTT
Modeling
Surface design,
modeling,
specification
Raw material
selection
Phase stability –
thermodynamics
Spray drying,
atomization
Component
performance,
lifetime, wear,
corrosion
User
requirement
Performance
Performance
testing
Modeling
Microstructure,
Surface and
material
roperties
Characterization
Product,
component
Price
Material
tailoring
Powder
optimizations
and
production
TS-process
optimisation and
control
Process Mapping
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50
Why modelling assisted material design is important just now
§ Novel manufacturing methods are
maturing
§ Almost everything that can be
designed can be manufactured
§ Freedom in design
§ Freedom in materials
§ Also restrictions in materials
FROM DESIGN FOR MANUFACTURING TO
MANUFACTURING FOR DESIGN
03/02/2015
51
Material digitalization – multiscale material
modelling and computational simulations
§ VTT is world leader on microstructural
material modelling with regard to wear
failure and tribological material
optimisation
§ New product:
03/02/2015
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52
03/02/2015
Multiscale modelling for material design
MODELLING ASSISSTED ROUTE
Raw materials
Process
Constructional
design
P
Structure
S
Life time control
of component
Properties Performance
P
P
E.G controlled wear
Maintenance
strategy
03/02/2015
53
Case study:
Thermal spray coatings – WC-CoCr thermal spray metal
matrix composite, image based analysis
SEM image
detail
Simulated
material test –
indentation
stress and
strain
distribution
Segmentation
for phases
and defects
local
material
distribution
Meshing or
use of discrete
methods
stress contours
strain contours
03/02/2015
54
E.g. Digital Design of materials
wear behaviour
SYSTEMS
COMPONENT
Deeper
understanding of
microstructural
behaviour
Design charts
Multiscale
modelling shows
relevant
mechanism
Design tool for
systems
Design tool e.g. for
wear performance
prediction
Data mining brings
statistical accuracy
03/02/2015
55
Modeling assisted design and tailoring of a wear resistant solution
isosurfaces of WC-CoCr coating equivalent stress during indentation
contact region – wear resistance
within coating – fracture
and cohesion
coating to substrate interface – adhesion
Thermal Spray Center
Finland (TSCF)
www.tut.fi/thermalspray