US20210317558A1 - Method for coating a component and coated component - Google Patents

Method for coating a component and coated component Download PDF

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Publication number
US20210317558A1
US20210317558A1 US17/267,729 US201917267729A US2021317558A1 US 20210317558 A1 US20210317558 A1 US 20210317558A1 US 201917267729 A US201917267729 A US 201917267729A US 2021317558 A1 US2021317558 A1 US 2021317558A1
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United States
Prior art keywords
crater
laser
coated
component
depth
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Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US17/267,729
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English (en)
Inventor
Tobias Kalfhaus
Caren S. Gatzen
Daniel E. Mack
Robert Edward Vaßen
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Forschungszentrum Juelich GmbH
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Forschungszentrum Juelich GmbH
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Publication of US20210317558A1 publication Critical patent/US20210317558A1/en
Assigned to Forschungszentrum Jülich GmbH reassignment Forschungszentrum Jülich GmbH ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: VASSEN, ROBERT, KALFHAUS, Tobias, Gatzen, Caren S., MACK, DANIEL E.
Abandoned legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/129—Flame spraying

Definitions

  • German Publication No. 10 2018 215 389 filed Sep. 11, 2018, the entire disclosures of each of which is expressly incorporated by reference herein.
  • the present disclosure relates to a method for coating a component.
  • the present disclosure further relates to a component coated in accordance with the method.
  • Some components may be coated by cold spraying.
  • a surface of the component may be roughened by sandblasting in order to improve the adhesion between a substrate consisting of steel and the coating material to be applied.
  • Tilted structural elements may be provided on a surface in order to be able to coat regions of a component that are difficult to access satisfactorily by cold spraying.
  • cold spraying In cold spraying (cold gas spraying), a surface of a component is coated by depositing a coating material in powder form.
  • a heated gas such as nitrogen or helium is accelerated to very high velocities, for example by expansion in a de Laval nozzle, in the direction of the surface to be coated.
  • the velocities are above the speed of sound and amount to 500 to 1000 m/s, for example.
  • the powdered coating material is injected into the accelerated gas jet. This causes the powdered coating material to impact the surface to be coated at such a high velocity that the particles of the powder plastically deform on impact and as a result adhere to the surface to be coated.
  • thermal coating processes such as plasma spraying, arc spraying, flame spraying, the particles of the powder are not melted.
  • the roughness of a surface to be coated may influence an adiabatic shear instability upon impact.
  • One aspect of the present disclosure includes a method for coating a component, in which a surface to be coated of the component is roughened by a laser and the roughened surface is coated by a thermal spraying process with high energy, such as cold spraying.
  • roughening is done in a crater-shaped manner.
  • the component can be coated with metals, polymers, ceramics, composite materials and nanocrystalline powder by cold spraying. In order to achieve sufficient adiabatic shear instabilities on impact and thus good adhesion, sufficiently smooth surfaces may be used.
  • FIG. 1 shows two sectional views of a surface generated according to the present disclosure
  • FIG. 2 is a top view of surface to be coated of a component
  • FIG. 3 is a transverse section of a component coated according to the present disclosure.
  • a surface to be coated of a component is ground and/or polished, i.e. smoothed, before it is roughened by means of a laser.
  • ground and/or polished surface areas may remain even after processing by a laser in order to favorably influence adiabatic shear instabilities and thereby achieve further improved adhesion properties.
  • Grinding may be performed with a grinding machine and polishing can be performed with a polishing machine.
  • Polishing may be performed using a polishing paste or a suspension, each with polishing grains included therein.
  • the surface to be coated of the component is exposed by laser at predetermined locations in such a way that crater-shaped depressions are produced at the exposed locations and other areas of the surface to be coated remain in the previous state even after the production of crater-shaped depressions, i.e. in particular in a ground and/or polished and thus smoothed state.
  • the ratio between crater-shaped depressions and areas not roughened by laser can be optimized in order to achieve particularly good adhesion properties.
  • the surface to be coated of the component is repeatedly exposed by laser in pulses at the predetermined locations in such a way that crater-shaped depressions are formed at the exposed locations, in particular to achieve crater depths of at least 10 ⁇ m or 20 ⁇ m, or to achieve crater depths of at least 30 ⁇ m, in order to further improve the adhesion properties. It has been found that too great depths again worsen adhesion properties. Therefore, the depth of a crater-shaped depression may be limited to 60 ⁇ m, or to 50 ⁇ m, in some embodiments.
  • the diameter of the crater-shaped depression at the upper edge corresponds approximately to the depth of the crater-shaped depression.
  • a crater-shaped depression at the upper edge has a diameter of about 40 ⁇ m, for example, then a depth of about 40 ⁇ m is included. In some embodiments, the depth does not deviate more than 20% from the diameter. Thus, if the diameter is 40 ⁇ m, the depth should be at least 32 ⁇ m and no more than 48 ⁇ m to further improve adhesion properties.
  • the crater-shaped depressions have a diameter of 30 ⁇ m to 50 ⁇ m at the upper edge and a depth of 30 ⁇ m to 50 ⁇ m.
  • Time intervals are provided between the individual light pulses in such a way that material melted by laser light can first solidify again before the predetermined location is again exposed. Crater-shaped depressions can thus be optimized in a further improved manner. The adhesion between the component and the coating can thus be further improved.
  • Each predetermined location is exposed by the light of the laser at least 3 times, at least 5 times, and/or not more than 25 times, and/or not more than 15 times, in order to produce crater-shaped depressions in an optimized manner, in order to thus achieve particularly good adhesion properties.
  • the crater-shaped depressions have circular diameters. By this embodiment it is achieved that areas of the surface to be coated remain between crater-shaped depressions that have not been exposed by the laser and therefore have not been roughened.
  • the upper edge of the crater-shaped depressions protrudes in a bead-like manner with respect to areas of the surface to be coated that have not been exposed to the light of the laser. In some embodiments, the upper edge protrudes by at least 5 ⁇ m, or by at least 10 ⁇ m, and/or by not more than 20 ⁇ m with respect to areas of the surface to be coated that have not been exposed to the light of the laser.
  • the component is located in a gas atmosphere of noble gas, such as argon or of nitrogen, during its processing.
  • the component is then in a space through which, for example, a noble gas or nitrogen is passed, or which is gas-tight and into which noble gas or nitrogen has previously been introduced.
  • a protective gas jacket is created which surrounds the laser beam during exposure.
  • a protective gas jacket can be created by means of nozzles arranged around the light of the laser in such a way that the light beam of the laser impinging on the component is enveloped by the gas emerging from the nozzles. The adhesion between the component and the coating can be further improved in this way.
  • the coating material corresponds to the material of the surface to be coated. If the material of a component has been damaged by external influences, such damage can be repaired in a particularly stable and reliable manner by a coating according to the present disclosure with the same material.
  • beads of crater-shaped depressions adjoin each other and/or overlap or intersect.
  • the diameter of each crater-shaped depression then corresponds approximately to the distance between two centers of two adjacent crater-shaped depressions.
  • the predetermined locations and thus the crater-shaped depressions are arranged according to a repeating pattern and thus in a planned manner.
  • This can be, for example, a checkerboard pattern.
  • the predetermined locations and thus the crater-shaped depressions are arranged one behind the other and side by side along a straight line, respectively.
  • the craters are therefore not randomly distributed.
  • the gas is heated to temperatures of 500° C. to 1200° C. during cold spraying to thus improve adhesion properties.
  • the component to be coated may not be heated beyond this. In this way, thermally induced physical and/or chemical changes to the surface to be coated are avoided.
  • Nitrogen can be used as the gas.
  • the laser beam impinges on the surface of the component at a right angle to create crater-shaped depressions.
  • FIG. 1 shows two sectional views of the surface to be coated generated according to the present disclosure, according to the aforementioned first part of the substrates, which were determined using a laser microscope. Shown is on the one hand a sectional view of exposed locations in xz direction and on the other hand in yz direction. The two sectional views illustrate that a crater-shaped depression with a diameter of about 0.4 ⁇ m was created at an exposed location. The depth was just under 0.4 ⁇ m.
  • the centers of the essentially circular crater-shaped depressions were regularly spaced 40 ⁇ m apart on the polished surface of the component according to a checkerboard pattern.
  • FIG. 2 shows an image of the laser microscope on the surface of a component to be coated, i.e. a substrate.
  • This image shows a top view of the distribution of the crater-shaped depressions 1 according to a checkerboard pattern created by multiple exposures.
  • the edges of the craters have on the edge side a solidification pattern 3 due to the individual exposure, which protrude upwards, i.e. in the z-direction, by up to approx. 15 ⁇ m relative to the unexposed, polished areas.
  • the bead-like solidification patterns 3 form upper edges of the crater-shaped depressions 1 .
  • Upper edges 3 of the craters overlap or at least adjoin each other.
  • the depth of the crater-shaped depressions 1 in relation to the polished base surface is about 20 ⁇ m. A total depth of about 35 ⁇ m has thus been created.
  • Three substrates each consisting of the IN738 alloy were coated with IN738 powder having an average diameter of 7.89 ⁇ m in the commercially available equipment “CGT-Oerlikon Metco Kinetics 8000” using a water-cooled D-24 De-Laval nozzle, wherein the first three substrates comprised surfaces to be coated treated according to the present disclosure, the second three substrates comprised surfaces to be coated treated by sandblasting, and the third three substrates comprised polished surfaces to be coated.
  • a pressure of 40 bar nitrogen, a gas temperature of 950° C. and a coating distance of 60 mm were selected as coating parameters.
  • the layer thicknesses produced in this way were approx. 400 ⁇ m.
  • coated substrates were glued between two cylinders for adhesion peel tests, so that the substrate was glued to one of the cylinders and the produced coating to the other cylinder.
  • the coating detached from the substrate.
  • one cylinder always detached from the coated substrate. It was thus found that in the case of the surfaces to be coated treated according to the present disclosure, a significantly better adhesion between the coating and the substrate was achieved.
  • FIG. 3 shows a transverse section of a component 4 coated according to the present disclosure with a layer 5 on the substrate 6 in the region of a crater-shaped depression 1 after the adhesion peel tests have been performed.
  • FIG. 3 illustrates that the crater-shaped depressions 1 have been completely filled by the cold spraying and that the adhesion peel tests performed could not change this. No cracks have formed either.
  • the present disclosure is not limited to the exemplary embodiment.
  • Good adhesion properties can also be achieved in this way, especially in comparison with surface preparation that comprises only sandblasting for subsequent coating.
  • another thermal coating process can be used instead of cold spraying, in which the coating material is brought to a high velocity in order to coat.
  • HVAF High Velocity Air-Fuel
  • HVAF High Velocity Air-Fuel
  • the mentioned alternatives relating to sandblasting, shot peening or HVAF are less preferable.
  • the task of the present disclosure can also be solved by a method for coating a component, in which a surface to be coated of the component is roughened by a laser and the roughened surface is coated by a thermal spraying process with high kinetic energy such as cold spraying or HVAF.
  • the maximum achievable layer thickness could be tripled by the present disclosure.
  • the inventors have found that a combination of the two measures “roughening by laser” and “coating by cold spraying” lead to a stable adhesion between the component and the coating layer. It has been found that roughening by means of a laser does not adversely modify the material of the surface of the component physically or chemically in such a way as to reduce adhesion between component and layer. Roughening by means of a laser is therefore advantageous over roughening by sandblasting. It has also been found that cold spraying does not adversely modify the physical and chemical properties of the surface either, so that a very good adhesion between the component and the coating can be achieved by a combination of the two measures.
  • the substrate surface to be coated was ablated at a frequency of 35 kHz and a pulse length of 120 ns.
  • Crater-shaped depressions with a diameter of 40 ⁇ m were thus created on the surface to be coated.
  • Craters were made one behind the other and side by side, i.e., checkerboard-like, with a spacing of 40 ⁇ m.
  • Each individual location where a crater was to be created was exposed to the light of the laser a total of 12 times. However, a single location was not exposed immediately again, following an exposure.
  • each of the locations was exposed for a first time and then, in the same order, for a second time and so on, until all locations had been exposed twelve times in this way.
  • Each individual location was therefore allowed to cool down and solidify again after an exposure before being exposed again. Unwanted oxidation of the surface could thus be avoided in an improved manner.
  • the surfaces to be coated of substrates consisting of the alloy IN738 were also roughened by sandblasting. These surfaces to be coated had also been previously ground and polished.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Laser Beam Processing (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
US17/267,729 2018-09-11 2019-08-19 Method for coating a component and coated component Abandoned US20210317558A1 (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
DE102018215389.2 2018-09-11
DE102018215389.2A DE102018215389A1 (de) 2018-09-11 2018-09-11 Verfahren für ein Beschichten eines Bauteils und beschichtetes Bauteil
PCT/EP2019/072137 WO2020052917A1 (fr) 2018-09-11 2019-08-19 Procédé de revêtement d'un élément structural et élément structural revêtu

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US20210317558A1 true US20210317558A1 (en) 2021-10-14

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US17/267,729 Abandoned US20210317558A1 (en) 2018-09-11 2019-08-19 Method for coating a component and coated component

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US (1) US20210317558A1 (fr)
EP (1) EP3850120A1 (fr)
DE (1) DE102018215389A1 (fr)
WO (1) WO2020052917A1 (fr)

Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0757904B2 (ja) * 1989-01-23 1995-06-21 住友金属工業株式会社 熱処理炉用ロールおよびその製造法

Family Cites Families (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1854903B1 (fr) * 2006-05-08 2013-10-02 Ford-Werke GmbH Procédé de fabrication de revêtements résistant à l'usure sur un corps de base métallique
DE102007023418B4 (de) * 2007-05-18 2010-09-09 Daimler Ag Verfahren zum Aufrauen von Oberflächen für die spätere Aufbringung von Spritzschichten, entspechend aufgeraute Bauteile sowie beschichtete Metallbauteile
DE102011106564A1 (de) * 2011-07-05 2013-01-10 Mahle International Gmbh Verfahren zur Herstellung einer Zylinderlauffläche sowie Zylinderlaufbuchse
US20130209745A1 (en) * 2012-02-10 2013-08-15 National Research Council Of Canada Method of coating of a substrate with a thermal spray coating material and coated substrate formed thereby
DE102012217685A1 (de) * 2012-09-28 2014-04-03 Siemens Aktiengesellschaft Verfahren zum Beschichten durch thermisches Spritzen mit geneigtem Partikelstrahl
DE102015207602A1 (de) 2015-04-24 2016-10-27 Gfe Metalle Und Materialien Gmbh Verfahren zur Herstellung einer Rohrkathode zum Einsatz in PVD-ARC-Beschichtungsanlagen
DE102016200951A1 (de) * 2016-01-25 2017-07-27 Volkswagen Aktiengesellschaft Verfahren zum Erzeugen einer verschleiß- und/oder korrosionsfesten Beschichtung auf einer Reibfläche eines Bremskörpers sowie nach dem Verfahren herstellbarer Bremskörper

Patent Citations (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0757904B2 (ja) * 1989-01-23 1995-06-21 住友金属工業株式会社 熱処理炉用ロールおよびその製造法

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DE102018215389A1 (de) 2020-03-12
WO2020052917A1 (fr) 2020-03-19
EP3850120A1 (fr) 2021-07-21

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