WO1995012473A1 - Production de depots par pulverisation - Google Patents

Production de depots par pulverisation Download PDF

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Publication number
WO1995012473A1
WO1995012473A1 PCT/GB1994/002386 GB9402386W WO9512473A1 WO 1995012473 A1 WO1995012473 A1 WO 1995012473A1 GB 9402386 W GB9402386 W GB 9402386W WO 9512473 A1 WO9512473 A1 WO 9512473A1
Authority
WO
WIPO (PCT)
Prior art keywords
spray
producing
material composition
sprays
sprayed
Prior art date
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.)
Ceased
Application number
PCT/GB1994/002386
Other languages
English (en)
Inventor
Richard Michael Jordan
Alfred Richard Eric Singer
Gordon Idris Davies
Allen Dennis Roche
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.)
Sprayforming Developments Ltd
Original Assignee
Sprayforming Developments Ltd
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Sprayforming Developments Ltd filed Critical Sprayforming Developments Ltd
Publication of WO1995012473A1 publication Critical patent/WO1995012473A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23P—METAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/24—Making specific metal objects by operations not covered by a single other subclass or a group in this subclass dies
    • 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

Definitions

  • the present invention relates to the production of sprayed deposits, and in particular to techniques for producing sprayed deposits using sprays of one or more metallic compositions.
  • EP-A-0270265 discloses the production of spray formed metal articles by building up a laminated structure comprising alternately deposited discrete layers of two or more metals.
  • EP- A-0270265 specifically teaches that where overlapping sprays are utilised, it is necessary to operate the two sprays alternatively in order to achieve the desired laminated structure.
  • EP-A- 0270265 also teaches that, in building up one of the layers comprising the laminated structure two or more sprays may be operated simultaneously to form a "composite" layer of the laminated structure. From the teaching of EP-A-0270265, such a composite layer would comprise constant proportions of the constituent materials throughout.
  • a method of producing a sprayed deposit comprising directing sprays of different material compositions A and B respectively to form a layer formed by coincident deposition of both material composition A and material composition B, characterised in that deposition is controlled such that a gradient of the relative proportion of material composition A to material composition B is produced across the layer.
  • a controllable gradient of the relative proportion of material composition A to material composition B across the deposited layer provides a graded composition such that the physical properties of the deposited layer may alter gradually across the depth of the layer.
  • a metal product may be produced comprising a layer of two or more metals in which the boundary between two metals comprises a gradually graded composition from the composition of the first metal to the composition of the second metal. This inhibits possible delamination that might otherwise occur at a boundary between two different compositions.
  • Prior art methods for achieving different properties within or at the surface of materials comprise surface coating or plating using an homogenous layer, laminating, diffusion techniques (e.g. nitriding or case hardening) and ion implantation techniques. All these prior art methods of treatment are applied after the first stage of manufacture and suffer from technical disadvantages such as limited penetration below the surface, delamination with time, or unacceptable cost.
  • the gradient variation of composition of the deposited layer provides an intrinsic change of composition where there is no definite boundary between one composition and another. This allows gradual change of composition (and therefore properties) between different parts of the product being manufactured and also enables immiscible, insoluble, or otherwise incompatible materials to be combined in a composition.
  • the sprays of material compositions A and B may comprise, for example, liquid droplets, partially solidified droplets or fine solid particulate material. Desirably at least one of the sprays comprises a spray of metallic material which may be produced by any convenient means such as arc spray, oxyfuel spray, gas atomisation of a melt, plasma spray or other techniques. In certain embodiments both spray compositions A and B may be of metallic material; in other embodiments, one of spray composition material A or B may be a metal, with the other spray composition material being non-metallic.
  • a further spray having yet a further composition may be deposited coincident with deposition of material compositions A and B.
  • the relative proportion of material composition C to the remainder of the material comprising the layer may be constant, or may be controlled to produce a gradient across the deposited layer.
  • Fourth and further sprays of still further material compositions may be used in a similar manner where required.
  • the spray of material composition A and the spray of material composition B are arranged to overlap. They are preferably operated simultaneously to produce the layer of the deposit.
  • deposition is controllable such that the gradient of the relative proportion of material composition A to material composition B is controlled.
  • An approximately linear gradient may, for example, be relatively steep or relatively shallow giving, respectively, a relatively large or relatively small change in the relative proportions of material composition A and B per unit depth of deposited layer.
  • the sprays may be controllably scanned, rapidly, in a conventional manner to deposit over a wider area or contour the deposit.
  • the deposit may be moved relative to the sprays which may therefore be stationary.
  • the sprays depositing materials A and B can either be generated by identical spray processes or by different spray processes which may include atomisation of a melt, metallic arc, plasma spray or other thermal spray processes.
  • the deposited layer may be formed on a substrate or collector, which can either remain a part of the spray formed product, or alternatively be subsequently removed.
  • a substrate or collector which can either remain a part of the spray formed product, or alternatively be subsequently removed.
  • an atomised spray (or sprays) of molten metal composition is directed at a cool or cold substrate or collector (usually of different chemical composition to the material of the spray) such that the molten particles splat and solidify to form a coherent solid deposit on cooling.
  • the sprays of material composition A and B may be controlled to be coincident over substantially the same area to form the deposited layer. It is preferred that the sprays are operated simultaneously, and are controllable to produce the required gradient within the deposited layer by varying over time the respective proportions of material compositions A and B being sprayed.
  • the rate of change in the relative proportion of material compositions A to B being sprayed is preferably controllable, so as to determine the gradient of the proportion of material composition A to B in the spray deposited layer.
  • the sprays of material composition A and B may not be wholly coincident over the same area but may merely overlap and be operated simultaneously to form a coincident region.
  • the gradient of the relative proportion of material composition A to composition B may be produced by moving the layer deposit (or substrate on which the layer deposit is formed) through the overlapping stationary sprays.
  • the degree of overlap and fanning of the sprays may be controlled to vary the gradient of the proportion of material composition A to B in the spray deposited layer.
  • Figure 1 is a schematic of a sprayed deposit being produced according to a preferred method according to the invention.
  • FIG. 2 is a schematic view of sprayed deposit being produced according to an alternative method according to the invention.
  • an aluminium pattern of a round memorial coin (1) is attached to a 4-axis manipulator arm (2) operating inside a spray chamber (not shown) .
  • the manipulator has x and y directions of motion and also rotation and tilting.
  • a plasma gun (3) operating on N 2 + 10% H 2 into which is fed tungsten carbide powder at position (4) is directed towards the position where the pattern will be when it is introduced into the spray by the manipulator arm (2) .
  • An arc spray gun (5) fed with two low carbon steel wires (6) and operating with N 2 is pointed such that the two spray footprints are coincident on the pattern.
  • the gun positions and distances can be checked beforehand on a trial flat plate substrate to ensure coincidence.
  • the plasma spray is started producing a spray (7) and the pattern rapidly introduced by the manipulator arm (2) .
  • the manipulator is operated rapidly in a manner to obtain uniform coverage of the working surface of the pattern (1) .
  • the arc spray gun is operated producing a spray (8) which coincides with the area of impingement of the plasma spray (7) on the pattern (1) .
  • the current in the arc gun, and the wire feed rate, are gradually increased and therefore the feed of low carbon steel is increased and the power to the plasma gun is decreased together with the feed of tungsten carbide powder so as to give gradient or a gradation of composition across the deposit from 100% tungsten carbide at the working face of the replicated spray formed die (9) to 100% low carbon steel for the backing material of the die (10) .
  • the composition within the graded layer of the deposit very quickly increases to 90% low carbon steel and then gradually increases to 100% low carbon steel.
  • a very ductile and high integrity bond is formed through the graded transition layer. hen sufficient backing low carbon steel has been sprayed the process is stopped, the pattern (1) with the die (10) attached is allowed to cool and the aluminium pattern is then removed by dissolving in NaOH solution.
  • a hard tungsten carbide faced die can be produced from an easily machined aluminium pattern.
  • the advantages are speed of replication, low usage of expensive tungsten carbide powder, cheapness of the backing material, ease of machining of the backing to fit any required bolster and excellent bonding of the die steel face to low carbon steel backing because of the graded composition.
  • a laminated Cu/Ni-steel strip is produced by the use of two overlapping sprays.
  • Two arc guns are directed vertically downwards towards a grit blasted flat steel substrate (11) at a temperature of 150°C travelling as indicated at a speed of 500mm/min.
  • the first arc gun (12) is fed with twin wires of low carbon steel working at 1000 amps.
  • the second arc gun (13) is fed with twin wires of 80/20 Cu/Ni also at a current of approximately 1000 amps.
  • the two arc guns are spaced longitudinally in relation to the direction of travel of the substrate and at a distance apart of 70mm, such that the sprays overlap.
  • the spray from the arc guns is deflected by scanning jets of nitrogen (not shown) in a direction normal to the plane of the paper so that the two sprays are scanned rapidly at a speed of 20Hz across the strip (14) produced by deposition.
  • the scanning action is used to ensure that the deposit is uniform in thickness across its width.
  • the scanning procedure used is the subject of known technology.
  • a laminated strip (14) is produced continuously having dimensions approximately 75mm width and 6mm thickness.
  • Low carbon steel is deposited at position (15) followed by a graded composition having a gradient of linearly varying proportion (low carbon steel to Cu/Ni) from position (16) to (17) and pure Cu/Ni at position (18) .
  • the mingling of the two overlapping sprays between positions (16) and (17) ensures that a graded mixture of steel and Cu/Ni is deposited and the extent of grading can be altered by adjusting the spacing of the two guns or the degree of fanning of the sprays.
  • the laminated strip was composed of approximately 50% steel and 50% Cu/Ni with a graded composition zone 1mm in width the centre of which is indicated by the dotted line.
  • All such laminates can be rolled subsequent to deposition to give greater accuracy of gauge, smaller thickness, higher density or hot or cold working. Such subsequent rolling may be carried out hot or cold, in-line or off-line.
  • spray deposition can be carried out using a wide range of atomising and deposition procedures any one of which may be used in combination with one or more of the full range of procedures.
  • the range of procedures includes the use of atomising from a melt, twin wire fed arc guns, single wire fed arc guns using a non-consumable electrode, plasma guns using either direct or transferred arc fed with either powder or wire or oxyfuel guns using either powder or wire.
  • the deposition may be carried out substantially at atmospheric pressure or alternatively at reduced pressure which in the case of plasma is often advantageous because it gives a longer plasma flame, in addition to reducing oxidation and porosity.
  • cored wire containing powder In all cases where wire can be used as a feed the use of cored wire containing powder is permissible.
  • cored wires can have a casing of metal or in certain instances a casing of polymer.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

On pulvérise des jets de deux compositions différentes A et B afin de former une couche composée des deux compositions simultanément déposées. Le dépôt est régulé de façon que les rapports appropriés entre les deux compositions varient sur toute la couche déposée pour former un gradient. La possibilité d'obtenir un gradient réglable des rapports entre les deux compositions sur la couche déposée permet de modifier graduellement les caractéristiques physiques de la couche de dépôt sur sa profondeur. Ce procédé de dépôt par pluvérisation convient à la production d'une machine-outil, d'un moule ou d'une matrice.
PCT/GB1994/002386 1993-11-02 1994-10-31 Production de depots par pulverisation Ceased WO1995012473A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB939322565A GB9322565D0 (en) 1993-11-02 1993-11-02 Improvements in graded composites
GB9322565.4 1993-11-02

Publications (1)

Publication Number Publication Date
WO1995012473A1 true WO1995012473A1 (fr) 1995-05-11

Family

ID=10744499

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/GB1994/002386 Ceased WO1995012473A1 (fr) 1993-11-02 1994-10-31 Production de depots par pulverisation

Country Status (2)

Country Link
GB (1) GB9322565D0 (fr)
WO (1) WO1995012473A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1101832A1 (fr) * 1999-11-19 2001-05-23 Basf Aktiengesellschaft Procédé de production combinatoire d'une bibliothèque de matériaux
WO2007026043A1 (fr) * 2005-08-29 2007-03-08 Valtion Teknillinen Tutkimuskeskus Procédé destiné à la fabrication de composants métalliques et composant métallique
WO2008052516A2 (fr) 2006-11-01 2008-05-08 Zollern Bhw Gleitlager Gmbh & Co. Kg Procédé de fabrication de deux couches mutuellement reliées, et élément fonctionnel pouvant être fabriqué selon le procédé
DE102004040460B4 (de) * 2004-07-16 2008-07-10 Daimler Ag Thermisches Spritzverfahren und thermisch gespritzte Werkstoffschicht sowie beschichtetes Pleuellager

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1002383A (en) * 1963-05-15 1965-08-25 Tetra Pak Ab A method of bonding ceramic and metal materials by flame spraying
GB1083003A (en) * 1964-10-23 1967-09-13 Glacier Co Ltd Hot metal spraying of bearing materials
GB1531222A (en) * 1975-12-10 1978-11-08 Vandervell Products Ltd High strength bearing materials
WO1986006106A1 (fr) * 1985-04-17 1986-10-23 Plasmainvent Ag Couche de protection
US4740395A (en) * 1986-02-13 1988-04-26 Yoshiki Tsunekawa Method of manufacturing composite material by combined melt-spraying
GB2239462A (en) * 1989-12-26 1991-07-03 Gen Electric Microlaminated structure formed using two plasma guns
GB2247635A (en) * 1990-08-02 1992-03-11 Nat Res Dev A method of producing tools and dies

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1002383A (en) * 1963-05-15 1965-08-25 Tetra Pak Ab A method of bonding ceramic and metal materials by flame spraying
GB1083003A (en) * 1964-10-23 1967-09-13 Glacier Co Ltd Hot metal spraying of bearing materials
GB1531222A (en) * 1975-12-10 1978-11-08 Vandervell Products Ltd High strength bearing materials
WO1986006106A1 (fr) * 1985-04-17 1986-10-23 Plasmainvent Ag Couche de protection
US4740395A (en) * 1986-02-13 1988-04-26 Yoshiki Tsunekawa Method of manufacturing composite material by combined melt-spraying
GB2239462A (en) * 1989-12-26 1991-07-03 Gen Electric Microlaminated structure formed using two plasma guns
GB2247635A (en) * 1990-08-02 1992-03-11 Nat Res Dev A method of producing tools and dies

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP1101832A1 (fr) * 1999-11-19 2001-05-23 Basf Aktiengesellschaft Procédé de production combinatoire d'une bibliothèque de matériaux
DE102004040460B4 (de) * 2004-07-16 2008-07-10 Daimler Ag Thermisches Spritzverfahren und thermisch gespritzte Werkstoffschicht sowie beschichtetes Pleuellager
WO2007026043A1 (fr) * 2005-08-29 2007-03-08 Valtion Teknillinen Tutkimuskeskus Procédé destiné à la fabrication de composants métalliques et composant métallique
WO2008052516A2 (fr) 2006-11-01 2008-05-08 Zollern Bhw Gleitlager Gmbh & Co. Kg Procédé de fabrication de deux couches mutuellement reliées, et élément fonctionnel pouvant être fabriqué selon le procédé
WO2008052516A3 (fr) * 2006-11-01 2008-06-26 Zollern Bhw Gleitlager Gmbh & Procédé de fabrication de deux couches mutuellement reliées, et élément fonctionnel pouvant être fabriqué selon le procédé
US8573283B2 (en) 2006-11-01 2013-11-05 Zollern Bhw Gleitlager Gmbh & Co., Kg Method for producing two bonded-together layers and functional component that can be produced by the method

Also Published As

Publication number Publication date
GB9322565D0 (en) 1993-12-22

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