Thermal Spraying of Aluminium Cylinder Bores by the Ford PTWA Spray Process

2006 ◽  
Author(s):  
C. Verpoort ◽  
W. Blume ◽  
R. Ehrenpreis ◽  
M. Silk ◽  
W. Polich ◽  
...  
Keyword(s):  
Thermal Spray ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Thermal Spray Process ◽  
Spray Process ◽  
Nano Material ◽  
Future Demands ◽  
Engine Blocks ◽  
Cylinder Bore

One of the main drivers in the automotive industry is the reduction in fuel consumptions and emissions. In order to achieve these goals, the weight of the engine block as well as the friction in the cylinder bore has to be optimized. This paper describes the FORD PTWA (Plasma Transferred Wire Arc) thermal spray process that protects the aluminum cylinder bore surface against wear by a thermal spray coating. The PTWA technology was originally developed for the application in gasoline V8 engines and it will be shown in this paper how this process can be modified to apply nano-material to produce high-wear resistant, low-friction coatings for highly loaded engine blocks for future demands. A large German BMBF “Nanomobile” Research Program was started in 2005 with 13 partners (DaimlerChrysler, Opel, Porsche, Ford, Gehring, Federal Mogul, GTV Thermal Spray Systems, DURUM, RWTH University and other institutes) in order to develop next generation nano-material coatings for cylinder bores.

Thermal Spray Alternatives for Electroplated Chromium

1996 ◽  
Author(s):  
G. Irons ◽  
W. Kratochvil ◽  
M. Schroeder ◽  
C. Brock
Keyword(s):  
Thermal Spray ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Ceramic Materials ◽  
Thermal Spray Coating ◽  
Waste Products ◽  
Spray Process ◽  
Arc Spray ◽  
Chromium Plating ◽  
Thermal Spray Processes

Abstract Many thermal spray coatings provide excellent wear and corrosion resistance, while providing die same surface finish offered by chromium plating. In the past, the choice between thermal spraying or plating was usually based on part size, area to be coated, cost and familiarity with one or the other method. Today, the thermal spray processes are showing greater popularity due to: ♦ New thermal spray processes and coatings with better properties ♦ Increased chromium plating costs due to stricter regulations on the process and the disposal of its waste products ♦ The closing of chromium plating facilities Thermal spraying offers an opportunity to select a coating from a wide variety of processes and materials that will meet the specific requirements of each application. While this may cause some difficulty in selecting the optimum coating, the selected thermal spray coating often has superior propolies and/or lower cost compared to chromium plating. The highest quality coatings are sprayed by the HVOF process, many with carbide containing materials. Dense plasma grayed ceramic materials offer good wear resistance plus elevated temperature capability. The most economical replacements for chromium plate are applied by the two-wire arc spray process. This paper examines the properties and costs of eight different dismal sprayed coatings and compares them with electroplated chromium.

Thermal Spray for Corrosion Control: A Competitive Edge for Commercial Shipbuilding

1995 ◽  
Vol 11 (01) ◽  
pp. 53-55
Author(s):  
Frank S. Rogers
Keyword(s):  
Thermal Spray ◽  
Marine Environment ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Cost Effective ◽  
Thermal Spray Coating ◽  
Coating System ◽  
Protection Mechanism ◽  
Arc Spray ◽  
Spray System

Thermal spraying of steel with aluminum to protect it from corrosion is a technology that has been proven to work in the marine environment. The thermal spray coating system includes a paint sealer that is applied over the thermally sprayed aluminum; this extends the service life of the coating, and provides color to the end product. The thermal spray system protects steel both through the principle of isolation (as in painting) and galvanization (as in galvanizing). With this dual protection mechanism, steel is protected from corrosion even when the coating is damaged. The thermal sprayed aluminum coating system has proven to be the most cost-effective corrosion protection system for the marine environment. Until recently, however, the initial cost of application has limited its use for general application. Today a new arc spray technology has reduced the application cost of thermal spraying aluminum to below that of painting. Commercial shipbuilders could use this technology to enhance their market position in the marine industry.

International and National Thermal Spray Standards Program with Comment on Those for the Corrosion Protection of Steel and Reinforced Concrete

1996 ◽  
Author(s):  
R.A. Sulit
Keyword(s):  
Reinforced Concrete ◽  
Corrosion Protection ◽  
Thermal Spray ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Test Methods ◽  
Current Status ◽  
Work Program ◽  
Society Committee

Abstract A review of selected national and international thermal spraying guides and specifications for the preservation of steel and reinforced concrete using thermal spray coating of aluminum, zinc and their alloys is presented. The work program and current status of the US national organizations contributing to and developing test methods and process standards are summarized along with those of ISOATC 107/SC 5. The Secretariat of the ISO/TC 107/SC 5, Thermal Spraying was transferred from AFNOR, France, to ANSI, US, in June 1995. ANSI, in turn, designated AWS to be its delegate in thermal spray matters. The work program of the newly formed SSPC/NACE/AWS Tri-Society Committee on thermal spray coatings for the corrosion protection of steel is summarized.

The Comparison Study on Abrasive and Erosive Resistance Properties of Thermal Spray Coatings

2020 ◽  
Vol 901 ◽  
pp. 49-54
Author(s):  
Jirasak Tharajak ◽  
Noppakun Sanpo
Keyword(s):  
Thermal Spray ◽  
Thermal Spraying ◽  
Spray Coating ◽  
Solid Material ◽  
Thermal Spray Coating ◽  
Comparison Study ◽  
Spray Coatings ◽  
Wide Range ◽  
Resistance To Wear ◽  
Sprayed Coating

Thermal spraying is a technology which improves and restores the surface of a solid material. The process can be used to apply coatings to a wide range of materials and components, in order to provide resistance to wear, erosion, cavitation, corrosion, abrasion or heat. In this paper, the study of abrasive and erosive properties of Cr3C2/20%NiCr and FeCrB + Al thermal sprayed coating samples were focused. It was revealed that both received thermal spray coating samples show outstanding abrasive and erosive resistance properties.

Laser-Induced Surface Texturing of Metal or Organic Substrates for Structural Adhesive Bonding

2016 ◽  
Vol 879 ◽  
pp. 390-395
Author(s):  
Sophie Costil ◽  
Robin Kromer ◽  
Sébastien Gojon ◽  
Emilie Aubignat ◽  
Christophe Verdy ◽  
...  
Keyword(s):  
Laser Beam ◽  
Thermal Spray ◽  
Adhesive Bonding ◽  
Surface Texturing ◽  
Thermal Spraying ◽  
Cold Spraying ◽  
Adhesive Bond ◽  
Organic Substrates ◽  
Thermal Spray Process ◽  
Spray Process

Laser-matter interaction is commonly described regarding three main factors: laser beam, materials and environment. Conversion of absorbed energy via collision process into heat is the most important effect that occurs during laser interaction. Short-pulsed laser beam induces fast transition from the overheated liquid to a mixture of vapor and drops which allows the ablation of micrometric layers. Specific patterns can then be achieved using scanning and automation technology also called laser texturing. New materials with specific properties such as endurance life and/or lower environmental impact attract emerging technologies such as thermal spraying. However, adhesive bond strengths have to be high enough to play a key role in surface properties. A clean surface to enhance mechanical interlocking is a key element. Mechanical and physico-chemical bond strength for thick coatings elaborated by thermal spray process can then be developed using laser. The aim of the present paper is to show the potential of such emerging treatments through new results using various thermal spray processes (thermal spraying as well as cold spraying). Metal or organic materials were investigated implementing various powders.

Advanced Ceramic Tribological Layers by Thermal Spray Routes

2010 ◽  
Vol 66 ◽  
pp. 106-119 ◽  
Author(s):  
Rainer Gadow ◽  
Andreas Killinger ◽  
Andreas Rempp ◽  
Andrei Manzat
Keyword(s):  
Thermal Spray ◽  
High Performance ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Industrial Applications ◽  
General Interest ◽  
Special Focus ◽  
Functional Coatings ◽  
Spray Process ◽  
Combined Coatings

Protective and functional coatings featuring outstanding tribological performance are of general interest for all kinds of industrial applications i.e for high performance automotive and mechanical applications. Thermal spray coating technologies play a key role in fabricating hard layers based on ceramic, metal - ceramic and further multiphase materials. Additional functionality can be achieved by combining these coatings with polymer based top coats with low friction coefficient or anti adhesive behaviour. Combined coatings feature also designed thermophysical and electrophysical properties. Several case studies will be discussed, ranging from automotive applications to paper and printing industry. Thermally sprayed coatings were applied using APS, HVOF and the newly developed HVSFS processes (High Velocity Suspension Spraying) with a special focus on nanoceramic feedstocks. In some applications polymer top coats with dispersed solid phases are applied to enhance functional properties. Special aspects in manufacturing engineering are addressed with particular importance not only of the influence of spray process parameters on coating properties but also of spray torch kinematic and robot trajectories on hardness, residual stress distributions, dimensional tolerances and porosity distributions will be discussed.

scholarly journals Thermal Spray Techniques for Developing a Carbide Coating

2019 ◽  
Vol 8 (12S) ◽  
pp. 692-700
Keyword(s):  
Thermal Spray ◽  
Product Life Cycle ◽  
Spray Coating ◽  
Thermal Spray Coating ◽  
Manufacturing Cost ◽  
Flame Spray ◽  
Coating Materials ◽  
Surface Protection ◽  
Spray Process ◽  
Coating Methods

In the industries, different components of different materials are being used in a different service environment, in the view of this requirement day by day specific surface properties are demanding by industries to enhance the product life cycle. A range of surface protection techniques are accessible for various apps with a common goal of protecting a part or object that is subjected to a chemical environment. This process leads to decreases manufacturing cost as no need to fabricate a new part. Commercially Coating materials include strong and rigid metal alloys, ceramics and polymers, composites material are available for durable protection. There are different methods of thermal spray such as flame spray, D-gun spray, high-velocity oxy-fuel Spray, Plasma Spray, and cold spray process have been introduced and investigated. Even though each method has distinct values and procedures that limit their applications. However, there are many things to understand that are used to overcome the lack of thermal spray coating methods by combining process parameters. In this article, we have discussed the various coating materials have been used commercially, and further categorized and compared various thermal spray processes.

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