EP1358943B1 - Method and apparatus for electric arc spraying - Google Patents
Method and apparatus for electric arc spraying Download PDFInfo
- Publication number
- EP1358943B1 EP1358943B1 EP03405214A EP03405214A EP1358943B1 EP 1358943 B1 EP1358943 B1 EP 1358943B1 EP 03405214 A EP03405214 A EP 03405214A EP 03405214 A EP03405214 A EP 03405214A EP 1358943 B1 EP1358943 B1 EP 1358943B1
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- European Patent Office
- Prior art keywords
- particles
- fluid
- melt
- spray
- accordance
- 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.)
- Expired - Lifetime
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- 238000000034 method Methods 0.000 title claims description 52
- 238000005507 spraying Methods 0.000 title claims description 43
- 238000010891 electric arc Methods 0.000 title description 2
- 239000002245 particle Substances 0.000 claims description 89
- 239000007921 spray Substances 0.000 claims description 79
- 239000012530 fluid Substances 0.000 claims description 71
- 239000000155 melt Substances 0.000 claims description 70
- 239000007789 gas Substances 0.000 claims description 36
- 239000000463 material Substances 0.000 claims description 27
- 238000003860 storage Methods 0.000 claims description 18
- 238000002844 melting Methods 0.000 claims description 17
- 230000008018 melting Effects 0.000 claims description 17
- 230000008569 process Effects 0.000 claims description 17
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 10
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 8
- 239000001301 oxygen Substances 0.000 claims description 8
- 229910052760 oxygen Inorganic materials 0.000 claims description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 7
- 239000000203 mixture Substances 0.000 claims description 7
- 229910052757 nitrogen Inorganic materials 0.000 claims description 5
- 229910052756 noble gas Inorganic materials 0.000 claims description 5
- 229910052786 argon Inorganic materials 0.000 claims description 4
- 239000001307 helium Substances 0.000 claims description 4
- 229910052734 helium Inorganic materials 0.000 claims description 4
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims description 4
- 229910052751 metal Inorganic materials 0.000 claims description 4
- 239000002184 metal Substances 0.000 claims description 4
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 4
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 claims description 3
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 claims description 3
- 150000004767 nitrides Chemical class 0.000 claims description 3
- 229910003468 tantalcarbide Inorganic materials 0.000 claims description 3
- INZDTEICWPZYJM-UHFFFAOYSA-N 1-(chloromethyl)-4-[4-(chloromethyl)phenyl]benzene Chemical compound C1=CC(CCl)=CC=C1C1=CC=C(CCl)C=C1 INZDTEICWPZYJM-UHFFFAOYSA-N 0.000 claims description 2
- 230000008859 change Effects 0.000 claims description 2
- UNASZPQZIFZUSI-UHFFFAOYSA-N methylidyneniobium Chemical compound [Nb]#C UNASZPQZIFZUSI-UHFFFAOYSA-N 0.000 claims description 2
- 229910003470 tongbaite Inorganic materials 0.000 claims description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims 2
- 229910034327 TiC Inorganic materials 0.000 claims 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims 1
- 229910001567 cementite Inorganic materials 0.000 claims 1
- 229910010293 ceramic material Inorganic materials 0.000 claims 1
- 229910052593 corundum Inorganic materials 0.000 claims 1
- 229910003460 diamond Inorganic materials 0.000 claims 1
- 239000010432 diamond Substances 0.000 claims 1
- 229910001845 yogo sapphire Inorganic materials 0.000 claims 1
- 239000002344 surface layer Substances 0.000 description 32
- 239000010410 layer Substances 0.000 description 12
- 238000002347 injection Methods 0.000 description 9
- 239000007924 injection Substances 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 7
- 229910052582 BN Inorganic materials 0.000 description 6
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 6
- 239000007787 solid Substances 0.000 description 6
- 239000000919 ceramic Substances 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- 239000011156 metal matrix composite Substances 0.000 description 4
- 239000002347 wear-protection layer Substances 0.000 description 4
- 239000012080 ambient air Substances 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 2
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- 230000008901 benefit Effects 0.000 description 2
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- 238000001035 drying Methods 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000008240 homogeneous mixture Substances 0.000 description 2
- 239000000314 lubricant Substances 0.000 description 2
- 238000010309 melting process Methods 0.000 description 2
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-UHFFFAOYSA-N 0.000 description 2
- 230000001681 protective effect Effects 0.000 description 2
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 239000003570 air Substances 0.000 description 1
- 238000000889 atomisation Methods 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- UFGZSIPAQKLCGR-UHFFFAOYSA-N chromium carbide Chemical compound [Cr]#C[Cr]C#[Cr] UFGZSIPAQKLCGR-UHFFFAOYSA-N 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 238000010285 flame spraying Methods 0.000 description 1
- 230000004907 flux Effects 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- KSOKAHYVTMZFBJ-UHFFFAOYSA-N iron;methane Chemical compound C.[Fe].[Fe].[Fe] KSOKAHYVTMZFBJ-UHFFFAOYSA-N 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 230000008646 thermal stress Effects 0.000 description 1
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 1
- 229910001928 zirconium oxide Inorganic materials 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
- B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
- B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
- B05B7/224—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material having originally the shape of a wire, rod or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
- B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
- B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
- B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
- B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
- B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
- B05B7/226—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material being originally a particulate material
-
- 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
- C23C4/131—Wire arc spraying
Definitions
- the invention relates to a method for arc spraying, and a device for arc spraying according to the preamble of the independent claim of the respective category.
- a method and such a device is known from JP-A-63 121 648 known.
- Arc spraying is a common technology for the production of surface layers on workpieces that are to be protected, for example against mechanical wear, corrosion or chemical or thermal stresses.
- arc spraying a wire or tubular spray medium in the form of two spray wires is melted in an electric arc and atomized by a sputtering gas, for example by nitrogen, a noble gas or simply by air under a predetermined pressure on a material surface with a spray gun.
- a sputtering gas for example by nitrogen, a noble gas or simply by air under a predetermined pressure on a material surface with a spray gun.
- the arc between the two ends of the spray wires is initiated by applying an electrical voltage and contact ignition.
- flame spraying a process in which the heat energy is applied to melt the spray wire by a fuel gas-oxygen flame, while the arc energy released in the arc electrical energy provides the necessary heat energy to melt the spray wires.
- the spray wire from a wire supply must be continuously tracked by a wire feed.
- stationary spray guns which are often used in automated operation for processing large series application, or even relatively small handguns that allow a more flexible use.
- the device for wire feed can be installed either in the spray gun itself or be accomplished by a lying outside the spray gun wire feed unit.
- the properties of the sprayed layers by various parameters such as the wire diameter, the material of the spray wire, the speed of the wire feed, the electrical voltage for generating or the electric current to maintain the arc, the choice of atomizing gas and its working pressure or the spray distance, directly influence.
- the arc spraying is characterized by a high degree of flexibility.
- the spray drop size or the kinetic energy of the spray droplets can be set automatically in a simple manner, even during a running coating process, depending on the requirements become.
- the spraying process can take place even under ordinary ambient atmosphere, in a vacuum chamber or under a protective gas.
- a disadvantage of the known methods for arc spraying is the fact that very specific requirements have to be made of the wire materials which are used as material for the production of the sprayed wires.
- the spray wires must have sufficient ductility, ie, a sufficiently high ductility and / or ductility and a sufficiently high electrical conductivity. If electrically poor or non-conductive or relatively hard, so less ductile components, such as ceramics, are introduced into a layer to be sprayed with, so-called cored wires must be used.
- Cored wires are understood to be injection-molded wires in which additional components, usually in the form of discrete particles, which do not melt in the arc, or are merely fused into the base material of the spray wire, are incorporated into the sprayed-on surface layer.
- the particles are greatly limited in their volume and can be changed in part already by the melting process of the spray wire in its structure, which often leads to unwanted modifications in the layer.
- the volume fraction of the particles in the melt can be virtually uncontrolled changed, as this is fixed by the distribution of the particles in the flux-cored wire.
- the size, shape and type of particles can only be changed by replacing the filler wire and thus during the injection itself.
- electrically non-conductive particles in the spray wire can disturb the stability of the arc and thus the quality of the sprayed surface layer sustainably negative influence.
- the production of cored wires compared to ordinary spray wires is correspondingly complicated and expensive.
- the object of the invention is therefore to propose a method for arc spraying by means of a spray gun, which makes it possible to introduce in the melt produced from the base material of the spray wires additional solid particles, in particular electrically poor or non-conductive and / or less ductile particles controlled in that the stability of the arc is not impaired and the use of flux cored wires can be dispensed with. Furthermore, it is an object of the invention to propose a corresponding device for arc spraying with a spray gun.
- a method for arc spraying by means of a spray gun which spray gun comprises two electrically conductive spray wires and at least one first feeder for supplying a fluid, wherein the spray wires an electrical voltage is applied, the spray wires are tracked by a wire guide, by the electrical Voltage an arc is ignited, the spray wires are transferred in a melting area in a melt and the melt is applied by the fluid to the surface of a body.
- the melt is supplied by the fluid particles from a reservoir.
- a device with a spray gun known per se for carrying out the method according to the invention for arc spraying, in a preferred embodiment a device with a spray gun known per se is used.
- the arc spraying apparatus comprises a spray gun, a wire guide for feeding two spray wires, a gas supply providing a fluid, preferably a gaseous fluid at an adjustable working pressure, an energy source adapted to supply the spray wires with electrical energy, and a freely programmable drive unit for setting various process parameters.
- the spray wires are supplied from a storage device of a wire guide comprising a wire feed and a guide device.
- the wire feed which may be housed either in the spray gun itself or in an external device, conveys the spray wires from the storage device via the guide device into a melting region such that an arc is ignited between the two spray wires in the melting region and stably maintained for a predeterminable period of time can be.
- the guide device is preferably designed such that it can be connected as an electrically conductive device to the energy source and is electrically conductively in contact with the spray wire, so that the necessary electrical energy for the generation of the arc can be supplied to the spray wire via the guide means.
- the guide device against the spray wires also be electrically isolated, wherein the electrical energy is then supplied to the spray wires in another way. Since during arc spraying in the melting area the material of the spray wire is continuously transferred into a melt, the spray wire must be maintained to maintain the Arc are continuously tracked through the wire guide in the melting area.
- the gas supply is via a first supply device, which may be configured for example in the form of a pressure line, in such connection with the melting region, that the melt produced by the arc in the melting region of the material of the spray wire is acted upon by the fluid with an adjustable working pressure and so is applied to the surface of a workpiece to be coated, wherein the fluid may preferably comprise a gas, in particular a noble gas such as helium or argon, or an inert gas such as nitrogen or oxygen or ambient air.
- a gas in particular a noble gas such as helium or argon, or an inert gas such as nitrogen or oxygen or ambient air.
- the inventive apparatus for arc spraying has in comparison to the prior art additionally to a reservoir, which is in an embodiment of the device by suitable means in communication with the first feeder, so that the solid particles are fed to the fluid.
- the melt is thereby acted upon by the fluid flow, which comprises the fluid and the supplied solid particles, via the first supply with an adjustable working pressure, that the particles fed to the melt and together with the melt formed from the spray wires on the surface of a to be coated Body to be applied.
- the particles can be supplied from different reservoirs of the melt, so that the number and type of the fluid supplied in the form of particles materials can be controlled during the injection process.
- the storage container and the gas supply are formed by a common container.
- the Particles supplied by means of a second feed device through the fluid of the melt comprises in the same way and function, the components already described, in particular the first feeder, which, however, if necessary only serves to pressurize the melt produced by the arc in the melting region of the material of the spray wire by the fluid with an adjustable working pressure and so apply the melt to the surface of a workpiece to be coated.
- this device for arc spraying in addition to the first feeder on a second feeder, which second feeder means of a fluid particles are fed from a reservoir, wherein two or more reservoirs may be present.
- the storage containers are connected to a gas supply, which provides fluid under a prescribable working pressure for the transport of the particles.
- the same gas supply can be connected both to the first supply device and to the storage container.
- there may also be two or more gas supplies so that, for example, the first feeder on the one hand and the hopper on the other hand can be supplied with fluid from different gas supplies. If there are several gas supplies, it goes without saying that different fluids can also be used simultaneously during an injection process.
- the melt is acted upon by the first feeder from a gas supply with a first gas, for example oxygen, with working pressure, while the particles from another gas supply with a second gas, for example, by a noble gas applied with a different working pressure , are fed to the melt via the second feed device.
- a gas supply with a first gas for example oxygen
- a second gas for example, by a noble gas applied with a different working pressure
- the melt is supplied by the fluid, the particles by means of the second supply from the reservoir that the particles are mixed in the melt with the melt and applied together with the melt on the surface of the body by the fluid and thus an integral part of the surface layer become.
- the second feed device preferably comprises a nozzle device which is suitable for introducing the particles into the melt acted upon by the fluid at working pressure.
- a device according to the invention for arc spraying may well also comprise further feed devices in addition to the first and the second feed device.
- the apparatus for arc spraying preferably comprises a freely programmable control unit, which permits various process parameters such as the working pressure of the fluid and / or the supplied quantity or type of particles and / or the wire feed and / or further process parameters to set a predefinable scheme individually.
- the particles supplied to the fluid from the reservoir can, in a preferred embodiment, be a ceramic and / or a carbide and / or a boride and / or a nitride, in particular hexagonal boron nitride (hBN) or cubic boron nitride (cBN) and / or a metal and / or or a metal alloy.
- the size of the particles is between 1 .mu.m and 200 .mu.m and is preferably selected between 5 .mu.m and 80 .mu.m.
- volume fraction of the particles which are supplied to the fluid from the reservoir can be set variable or fixed, so that the volume fraction of the particles in the sprayed by the inventive method layer is between 0.1% and 40% of the total volume of the applied surface layer.
- the volume fraction of the particles in the sprayed surface layer is preferably between 1% and 20%.
- the device according to the invention can have a plurality of storage containers with different types of particles, wherein the particles, which can be composed of different materials and / or of different sizes, are supplied to the fluid from the various storage containers and the composition of the particle flow by the drive unit to a predefinable Scheme can be changed continuously.
- This makes it possible to constantly adapt both the structure and the composition of the surface layer to be sprayed during a spraying process, whereby workpieces with highly structured surfaces in all surface areas can always be optimally coated.
- a particular advantage of the method according to the invention for arc spraying is that the particles are introduced into the melt together with the fluid and are not introduced into the coating process by using a filler wire. As a result, the particles are much less restricted in volume and have no negative effects on the stability of the arc and the melting process.
- the particles introduced into the melt can already be completely or partly enclosed by the molten phase during their way to the surface of the body to be coated, for example within small droplets which, during atomization, of the Melt formed, or only on the surface of the coating body from the molten phase, before or during the solidification in the layer formation, to be enclosed.
- the particles comprise, for example, oxidic ceramics or carbides and are substantially not melted in the injection process, but are incorporated in a matrix-like manner into the sprayed surface layer in a carrier layer which is largely composed of the material of the spray wire.
- the resulting surface layer can, depending on the nature of the incorporated particles, have very different properties.
- a significantly improved wear resistance of the sprayed surfaces can be achieved.
- wear protection layers for brake discs produced that can be used, inter alia, in vehicles whose brake discs are constantly heavily loaded by frequent braking.
- wear protection layers can be sprayed onto the brake disks of such vehicles for the first time, which even outlasts the service life of the corresponding vehicle.
- the economic advantages that result from the use of such wear protection layers are obvious.
- the method according to the invention is of course not limited to the production of wear protection layers for brake discs, but can also be successfully used, for example, for coating smooth or creping cylinders (so-called drying cylinders) for the production of papers in the paper industry or in many other fields.
- Next Protective layers on surfaces of workpieces can even be sprayed free-standing bodies of MMC (Metal Matrix Composite).
- the particles can be substantially dry lubricants, such as hexagonal boron nitride (hBN) or other materials, thereby providing increased lubricity and / or improved abrasive properties of the surface.
- substantially dry lubricants such as hexagonal boron nitride (hBN) or other materials
- the particles are also melted in the arc, so that a more or less homogeneous mixture of melt and molten particles is formed, which then leads to correspondingly more homogeneous structures in the surface layer.
- the particles that are supplied to the fluid from the reservoir may include materials such as metals or metal alloys.
- the properties of the sprayed surface layer can also be influenced by the fluid itself, which is used in the injection process to apply melt to the working pressure and / or to feed the particles.
- the fluid may comprise an increased content of oxygen, so that the materials comprising the melt and / or the particles already to a certain extent during the injection process oxidize, whereby the chemical and physical properties of the sprayed surface can be positively influenced.
- the inventive device for arc spraying with a spray gun comprises a wire guide for tracking two electrically conductive spray wires and at least a first supply means for supplying a fluid to which spray wires an electrical voltage can be applied, so that an arc is ignited and thereby the spray wires in a melting region in a melt can be transferred, wherein the melt can be applied by the fluid to the surface of a body.
- means are provided on the device according to the invention to supply the melt with particles through the fluid from a storage container.
- Different types of particles can either be supplied to the fluid separately from a plurality of different storage containers, or mixtures of different types of particles are available in one or more storage containers and can be supplied to the fluid from the storage containers.
- Fig. 1 shows a schematic representation of an embodiment of an apparatus for arc spraying with spray gun 1, first feeder 3, reservoir 12 and drive unit 14 for arc spraying according to an inventive method.
- the spray gun 1 comprises in a known manner two electrically conductive spray wires 2, which are connected to the supply of electrical energy to a power source 16, so that between the spray wires 2 in a melting region 7 ignited an arc 6 and can be stably maintained stable over a predetermined period ,
- the spray wires 2 are fed from a storage device, not shown, a wire guide 5.
- the wire guide 5 comprises a wire feed 13, which is suitable for feeding the spray wire 2 through a guide device 17 to the melting region 7.
- the guide device 17 is preferably designed such that it is connectable to the energy source 16 as an electrically conductive device and is electrically conductively in contact with the spray wire 2, so that via the guide device 17 necessary for the generation of the arc 6 electrical energy to the spray wire. 2 can be supplied. Since during the arc spraying in the melting region 7 material of the spray wire 2 is continuously transferred into a melt 8, the spray wire 2 must be continuously fed to maintain the arc 6 through the wire guide 5 in the melting region 7.
- the melt 8 formed from the material of the spray wire 2 in the arc 6 is applied to a surface 9 of a body 10 by a fluid 4 via a first feed device 3 from a gas reservoir 19.
- a fluid 4 preferably a gas, in particular oxygen, nitrogen, argon, Helium, ambient air or another gas
- the melt 8 is acted upon with a predetermined working pressure, whereby the melt 8 is thrown onto the surface 9 of the body 10, the melt 8 condenses on the surface 9 of the body 10 in a solid state and so forms a surface layer 18 with predetermined properties on the surface 9 of the body 10.
- An apparatus for arc spraying further comprises means 15, with which the fluid 4 particles 11 can be fed from a reservoir 12, wherein, as in Fig. 1 shown by way of example, two or more reservoir 12 may be present.
- the melt 8 is supplied by the fluid 4, the particles 11 from the reservoir 12 such that the particles 11 are mixed in the melting region 7 with the melt 8 and applied together with the melt 8 on the surface 9 of the body 10 by the fluid 4 and thus become an integral part of the surface layer 18.
- the particles 11 preferably comprise a ceramic, in particular aluminum oxide (Al 2 O 3 ), chromium oxide (Cr 2 O 3 ), titanium oxide (TiO 2 ), zirconium oxide (ZrO 2 ), and / or a carbide, in particular tungsten carbide (WC), chromium carbide (Cr 3 C 2 ), titanium carbide (TiC), tantalum carbide (TaC), iron carbide (Fe 3 C), niobium carbide, vanadium carbide and / or a boride and / or a nitride, such as hexagonal boron nitride (hBN) or cubic boron nitride (cBN) , and / or a metal and / or a metal alloy.
- a ceramic in particular aluminum oxide (Al 2 O 3 ), chromium oxide (Cr 2 O 3 ), titanium oxide (TiO 2 ), zirconium oxide (ZrO 2 ), and / or
- the particles 11 are preferably not melted substantially, but incorporated into the surface 18 in a matrix-like structure. However, it is also conceivable that the particles 11 are likewise melted and mixed with the melt 8, for example with formation of an alloy, so as to form a substantially homogeneous surface layer 18.
- a device for arc spraying has a freely programmable Drive unit 14, with which the working pressure with which the fluid 4, the melt 8 is applied, and / or the supplied amount and / or type of particles 11 and / or the wire feed 13 and / or the injection wires 2 supplied electrical energy and / or another process parameter can be set individually.
- the gas supply 19 and / or the wire guide 5 and / or the reservoir 12 and / or the power source 16 and / or other components of the device via control lines 20 to the drive unit 14 are connected.
- the control unit 14 may comprise sensor lines 21, by means of which the control unit 14 can transmit various operating parameters, such as actual working pressure, gas pressure in the process chamber, ambient pressure, temperature, electrical operating parameters of the energy source or other parameters.
- Fig. 2 schematically shows an embodiment of an apparatus for arc spraying according to a novel method with spray gun 1, a first feeder 3, reservoir 12 and drive unit 14.
- the particles 11 are supplied by means of a second feed device 31 of the melt 8 through the fluid 4
- the spray gun 1 comprises in the same way and function the already described known components of a spray gun 1 for arc spraying.
- the first feeder 3 may optionally serve only the supply of fluid 4 for acting on the melt 8 with working pressure.
- the in Fig. 2 apparatus shown also an energy source 16, the representation has been omitted here for reasons of clarity.
- the melt 8 formed from the material of the spray wire 2 in the arc 6 is applied to a surface 9 of a body 10 by a fluid 4 via a feed device 3 from a gas reservoir 19 analogously to the previously described embodiment.
- the fluid 4 which is preferably a gas, in particular nitrogen, oxygen, argon, helium, ambient air or another gas
- the melt 8 is acted upon by a predeterminable working pressure, whereby the melt 8 is thrown onto the surface 9 of the body 10, the melt 8 condenses on the surface 9 of the body 10 into a solid state and thus forms a surface layer 18 with predefinable properties on the surface 9 of the body 10.
- FIG. 2 shown embodiment of a device according to the invention for arc spraying further comprises means 15, with which from a reservoir 12 of a second feeder 31 by means of a fluid 4 particles 11 can be fed, wherein as in Fig. 2 shown by way of example, two or more reservoir 12 may be present.
- the storage containers 12 are connected to a gas reservoir 19, which provides fluid 4 under a prescribable working pressure for conveying the particles 11.
- the same gas supply 19 can be connected both to the first supply device 3 and to the storage container 12 and / or the second supply device 31.
- two or more gas supplies 19 may be present, so that, for example, the first supply device 3 and the storage containers 12 and / or the second supply device 31 are supplied with fluid 4 from different gas supplies 19.
- different fluids 4 can also be used simultaneously during an injection process.
- the melt 8 is acted upon by the first feeder 3 from a gas reservoir 19 by oxygen at working pressure, while the particles 11 from another gas supply 19, For example, acted upon by a noble gas with a different working pressure, are fed via the second feed 31 of the melt 8.
- other fluids 4 as the gases exemplified here come into question.
- each reservoir 12 may be fed from one or more gas supplies 19 that may provide the same or different fluids 4.
- the melt 8 are supplied by the fluid 4, the particles 11 by means of the second feeder 31 from the reservoir 12 that the particles 11 are mixed in the melting region 7 with the melt 8 and together with the melt 8 on the surface 9 of the body 10th applied by the fluid 4 and thus become an integral part of the surface layer 18.
- the second feed device 31 comprises a nozzle device 32 which is suitable for introducing the particles 11 into the melt 8 subjected to working pressure by the fluid 4.
- Fig. 3 shows a schematic representation of an example of a surface layer 18 which has been applied to the surface 9 of a body 10 by arc spraying according to an inventive method.
- particles 11 were supplied to the working fluid pressure fluid 4 from the reservoir 12, and the melt 8 formed in the arc 6 was thrown onto the surface 9 of the body 10 by the particle flow formed by fluid 4 and particles 11.
- the particles 11 used in this embodiment were substantially not melted, but incorporated in a carrier layer 22, which as far as possible comprises the (from the molten by the arc 6) material of the spray wire 2, matrix-like.
- the resulting surface layer 18 may, for example, each in the nature of the incorporated particles 11 compared to surface layers 18, which were prepared by known methods for arc spraying, have a significantly improved wear resistance.
- surface layers 18 for brake disks can thus be produced by the method according to the invention, which can be used inter alia in vehicles whose brake disks are constantly heavily loaded by frequent braking processes. This applies, inter alia, to trucks, trams, buses and other vehicles, especially in local traffic, which often and at short intervals have to decelerate relatively large masses.
- the inventive method is of course not limited to the production of surface layers 18 for brake discs, but can be used successfully for example for the coating of smooth or creping cylinders (so-called drying cylinders) for the production of papers in the paper industry or in many other areas.
- smooth or creping cylinders smooth or creping cylinders
- drying cylinders for the production of papers in the paper industry or in many other areas.
- MMC Metal Matrix Composite
- the particles 11 may comprise substantially dry lubricants, such as hexagonal boron nitride or others, thereby providing enhanced lubricity and / or improved abrasive properties of the surface layer 18.
- substantially dry lubricants such as hexagonal boron nitride or others
- the particles 11 are also melted in the arc 6, so that a more or less homogeneous mixture of melt 8 and molten particles 11 is formed, which then leads to correspondingly more homogeneous structures in the surface layer 18.
- the supply of the particles 11 to the melt 8 from different reservoirs 12 and the amount and / or type of particles 11 supplied for each reservoir 12 can be adjusted individually, it is possible in a single operation to produce surface layers 18 whose properties the surface layer 18 may vary from place to place and / or across the thickness of the surface layer 18, ie It is also possible to generate predefinable concentration profiles of particles 11 in the surface layer 18. Thus, it is possible, for example, to produce surface layers 18 whose abrasive properties and / or their wear resistance vary from place to place or change in a predeterminable manner with increasing layer removal.
- the inventive method for arc spraying by means of a spray gun makes it possible to introduce in the melt produced from the material of the spray wires additionally solid particles controlled by a pressurized fluid with working pressure, so that can be dispensed with the use of expensive cored wires. Characterized in that the particles are supplied from different reservoirs through the fluid of the melt according to a predeterminable scheme, if necessary, different types of particles of different size and chemical composition can be introduced simultaneously into the layer to be sprayed. This makes it possible to produce surface layers with significantly improved properties and a greater variety of possible structures and compositions by arc spraying.
Description
Die Erfindung betrifft ein Verfahren zum Lichtbogenspritzen, sowie eine Vorrichtung zum Lichtbogenspritzen gemäss dem Oberbegriff des unabhängigen Anspruchs der jeweiligen Kategorie. Ein derartiges Verfahren und eine derartige Vorrichtung ist aus der
Lichtbogenspritzen, häufig in der Fachliteratur auch genauer als Lichtbogendrahtspritzen bezeichnet, ist eine gängige Technologie zur Herstellung von Oberflächenschichten auf Werkstücken, die beispielsweise gegen mechanischen Verschleiss, Korrosion oder gegen chemische oder thermische Beanspruchungen geschützt werden sollen.Arc spraying, often referred to in the literature as arc wire spraying, is a common technology for the production of surface layers on workpieces that are to be protected, for example against mechanical wear, corrosion or chemical or thermal stresses.
Beim Lichtbogenspritzen wird mit einer Spritzpistole ein draht- oder röhrenförmiges Spritzmedium in Form zweier Spritzdrähte in einem elektrischen Lichtbogen aufgeschmolzen und durch ein Zerstäubungsgas, z.B. durch Stickstoff, ein Edelgas oder einfach durch Luft unter einem vorgebbaren Druck auf eine Werkstoffoberfläche zerstäubt. Dabei wird der Lichtbogen zwischen den beiden Enden der Spritzdrähte durch Anlegen einer elektrischen Spannung und Kontaktzündung initiiert. Das ist der Unterschied zum sogenannten "Flammspritzen", ein Verfahren bei dem die Wärmeenergie zum Aufschmelzen des Spritzdrahtes durch eine Brenngas-Sauerstoff-Flamme aufgebracht wird, während beim Lichtbogenspritzen die im Lichtbogen freigesetzte elektrische Energie die notwendige Wärmeenergie zum Aufschmelzen der Spritzdrähte liefert.When arc spraying a wire or tubular spray medium in the form of two spray wires is melted in an electric arc and atomized by a sputtering gas, for example by nitrogen, a noble gas or simply by air under a predetermined pressure on a material surface with a spray gun. The arc between the two ends of the spray wires is initiated by applying an electrical voltage and contact ignition. This is the difference to the so-called "flame spraying", a process in which the heat energy is applied to melt the spray wire by a fuel gas-oxygen flame, while the arc energy released in the arc electrical energy provides the necessary heat energy to melt the spray wires.
Da das Material der Spritzdrähte im Bereich des Lichtbogen in die Schmelze überführt und auf die Oberfläche des Werkstücks gespritzt wird, muss der Spritzdraht aus einem Drahtvorrat kontinuierlich durch einen Drahtvorschub nachgeführt werden. Je nach Anforderung sind stationäre Spritzpistolen bekannt, die häufig im automatisierten Betrieb zur Bearbeitung grosser Serien Anwendung finden, oder aber auch relativ kleine Handpistolen, die einen flexibleren Einsatz gestatten. Die Einrichtung zum Drahtvorschub kann dabei sowohl in der Spritzpistole selbst installiert sein oder aber durch eine ausserhalb der Spritzpistole liegende Drahtvorschubeinheit bewerkstelligt werden.Since the material of the spray wires in the arc is transferred to the melt and sprayed onto the surface of the workpiece, the spray wire from a wire supply must be continuously tracked by a wire feed. Depending on the requirement stationary spray guns are known, which are often used in automated operation for processing large series application, or even relatively small handguns that allow a more flexible use. The device for wire feed can be installed either in the spray gun itself or be accomplished by a lying outside the spray gun wire feed unit.
Dabei lassen sich die Eigenschaften der gespritzten Schichten durch verschiedene Parameter, wie beispielsweise den Drahtdurchmesser, das Material des Spritzdrahtes, die Geschwindigkeit des Drahtvorschubs, die elektrische Spannung zur Erzeugung bzw. den elektrischen Strom zur Aufrechterhaltung des Lichtbogens, die Wahl des Zerstäubungsgases sowie dessen Arbeitsdruck oder den Spritzabstand, unmittelbar beeinflussen. Das heisst, in aller Regel wird eine Änderung eines oder mehrerer dieser (oder auch anderer hier nicht genannter) Parameter zu Schichten mit unterschiedlichen Eigenschaften und Qualität führen. Da die zuvor genannten Parameter durch Wahl der Materialien oder durch elektronische Steuer- und /oder Regeleinrichtungen im allgemeinen leicht beeinflussbar sind, zeichnet sich das Lichtbogenspritzen durch eine hohe Flexibilität aus. Beispielsweise kann unter anderem die Spritztropfengrösse oder die kinetische Energie der Spritztropfen auf einfache Weise, auch während eines laufenden Beschichtungsvorgang, je nach Anforderungen automatisch eingestellt werden. Darüber hinaus kann der Spritzvorgang selbst unter gewöhnlicher Umgebungsatmosphäre, in einer Vakuumkammer oder unter einem Schutzgas stattfinden. Dadurch kann eine breite Auswahl verschiedenster Werkstücke mit unterschiedlichsten Anforderungen an Eigenschaften und Qualität mit dem Verfahren des Lichtbogenspritzens mit schützenden Oberflächen versehen werden.In this case, the properties of the sprayed layers by various parameters, such as the wire diameter, the material of the spray wire, the speed of the wire feed, the electrical voltage for generating or the electric current to maintain the arc, the choice of atomizing gas and its working pressure or the spray distance, directly influence. This means that as a rule, changing one or more of these (or other parameters not mentioned here) will lead to layers with different properties and quality. Since the aforementioned parameters are easily influenced by choice of materials or by electronic control and / or regulating devices in general, the arc spraying is characterized by a high degree of flexibility. For example, the spray drop size or the kinetic energy of the spray droplets can be set automatically in a simple manner, even during a running coating process, depending on the requirements become. In addition, the spraying process can take place even under ordinary ambient atmosphere, in a vacuum chamber or under a protective gas. Thus, a wide range of different workpieces with different requirements for properties and quality can be provided with the method of arc spraying with protective surfaces.
Ein Nachteil der bekannten Verfahren zum Lichtbogenspritzens ist darin zu sehen, dass an die Drahtwerkstoffe, die als Material für die Herstellung der Spritzdrähte in Frage kommen, ganz spezifische Anforderungen zu stellen sind. So müssen die Spritzdrähte eine ausreichende Duktilität, also eine genügend hohe Verformbarkeit und / oder Dehnbarkeit und eine genügend hohe elektrische Leitfähigkeit aufweisen. Sollen elektrisch schlecht oder nicht leitende oder relativ harte, also wenig duktile Komponenten, wie beispielsweise Keramiken, in eine zu spritzende Schicht mit eingebracht werden, muss auf sogenannte Fülldrähte zurückgegriffen werden. Unter Fülldrähten versteht man Spritzdrähte, bei welchen in das Basismaterial des Spritzdrahtes zusätzliche Komponenten, meist in Form von diskreten Partikeln eingelagert sind, die im Lichtbogen nicht schmelzen, bzw. nur anschmelzen und in die aufgespritzte Oberflächenschicht mit eingebaut werden. Dabei sind die Partikel in ihrem Volumen stark beschränkt und können zum Teil bereits durch den Schmelzvorgang des Spritzdrahtes in ihrer Struktur verändert werden, was häufig zu nicht gewünschten Modifikationen in der Schicht führt. Auch kann der Volumenanteil der Partikel in der Schmelze praktisch nicht kontrolliert verändert werden, da dieser durch die Verteilung der Partikel im Fülldraht fest vorgegeben ist. Auch die Grösse, Form und Art der Teilchen kann nur durch Austausch des Fülldrahtes und damit während des Spritzvorgangs selbst nicht verändert werden. Zudem können elektrisch nicht leitende Partikel im Spritzdraht die Stabilität des Lichtbogens stören und damit die Qualität der gespritzten Oberflächenschicht nachhaltig negativ beeinflussen. Darüber hinaus ist die Herstellung von Fülldrähten im Vergleich zu gewöhnlichen Spritzdrähten entsprechend aufwendig und teuer.A disadvantage of the known methods for arc spraying is the fact that very specific requirements have to be made of the wire materials which are used as material for the production of the sprayed wires. Thus, the spray wires must have sufficient ductility, ie, a sufficiently high ductility and / or ductility and a sufficiently high electrical conductivity. If electrically poor or non-conductive or relatively hard, so less ductile components, such as ceramics, are introduced into a layer to be sprayed with, so-called cored wires must be used. Cored wires are understood to be injection-molded wires in which additional components, usually in the form of discrete particles, which do not melt in the arc, or are merely fused into the base material of the spray wire, are incorporated into the sprayed-on surface layer. The particles are greatly limited in their volume and can be changed in part already by the melting process of the spray wire in its structure, which often leads to unwanted modifications in the layer. Also, the volume fraction of the particles in the melt can be virtually uncontrolled changed, as this is fixed by the distribution of the particles in the flux-cored wire. The size, shape and type of particles can only be changed by replacing the filler wire and thus during the injection itself. In addition, electrically non-conductive particles in the spray wire can disturb the stability of the arc and thus the quality of the sprayed surface layer sustainably negative influence. In addition, the production of cored wires compared to ordinary spray wires is correspondingly complicated and expensive.
Die Aufgabe der Erfindung ist es daher, ein Verfahren zum Lichtbogenspritzen mittels einer Spritzpistole vorzuschlagen, das es gestattet, in die aus dem Basismaterial der Spritzdrähte erzeugten Schmelze zusätzliche feste Partikel, insbesondere elektrisch schlecht oder nicht leitende und / oder wenig duktile Partikel, derart kontrolliert einzubringen, dass die Stabilität des Lichtbogens nicht beeinträchtigt wird und auf die Verwendung von Fülldrähten verzichtet werden kann. Ferner ist es eine Aufgabe der Erfindung, eine entsprechende Vorrichtung zum Lichtbogenspritzen mit einer Spritzpistole vorzuschlagen.The object of the invention is therefore to propose a method for arc spraying by means of a spray gun, which makes it possible to introduce in the melt produced from the base material of the spray wires additional solid particles, in particular electrically poor or non-conductive and / or less ductile particles controlled in that the stability of the arc is not impaired and the use of flux cored wires can be dispensed with. Furthermore, it is an object of the invention to propose a corresponding device for arc spraying with a spray gun.
Die diese Aufgaben in verfahrenstechnischer und apparativer Hinsicht lösenden Gegenstände der Erfindung sind durch die Merkmale des unabhängigen Anspruchs der jeweiligen Kategorie gekennzeichnet.The objects of the invention which solve these objects in terms of process and apparatus are characterized by the features of the independent claim of the respective category.
Die jeweiligen abhängigen Ansprüche beziehen sich auf besonders vorteilhafte Ausführungsformen der Erfindung.The respective dependent claims relate to particularly advantageous embodiments of the invention.
Erfindungsgemäss wird somit ein Verfahren zum Lichtbogenspritzen mittels einer Spritzpistole vorgeschlagen, welche Spritzpistole zwei elektrisch leitende Spritzdrähte und mindestens eine erste Zuführeinrichtung zur Zuführung eines Fluids umfasst, wobei an die Spritzdrähte eine elektrische Spannung angelegt wird, die Spritzdrähte mittels einer Drahtführung nachgeführt werden, durch die elektrische Spannung ein Lichtbogen gezündet wird, die Spritzdrähte in einem Schmelzbereich in eine Schmelze überführt werden und die Schmelze durch das Fluid auf die Oberfläche eines Körpers aufgebracht wird. Dabei werden der Schmelze durch das Fluid Partikel aus einem Vorratsbehälter zugeführt. Durch Anwendung des erfindungsgemässen Verfahrens können zusätzlich Partikel in die Schmelze und damit in die zu erzeugende Oberflächenschicht eingebracht werden, wobei auf die Verwendung von Fülldrähten verzichtet werden kann.According to the invention, a method is proposed for arc spraying by means of a spray gun, which spray gun comprises two electrically conductive spray wires and at least one first feeder for supplying a fluid, wherein the spray wires an electrical voltage is applied, the spray wires are tracked by a wire guide, by the electrical Voltage an arc is ignited, the spray wires are transferred in a melting area in a melt and the melt is applied by the fluid to the surface of a body. In this case, the melt is supplied by the fluid particles from a reservoir. By applying the method according to the invention, particles can additionally be introduced into the melt and thus into the melt Surface layer can be introduced, which can be dispensed with the use of cored wires.
Zur Durchführung des erfindungsgemässen Verfahrens zum Lichtbogenspritzen kommt in einem bevorzugten Ausführungsbeispiel eine Vorrichtung mit einer an sich bekannten Spritzpistole zum Einsatz. Die Vorrichtung zum Lichtbogenspritzen umfasst eine Spritzpistole, eine Drahtführung zur Zuführung zweier Spritzdrähte, einen Gasvorrat, der ein Fluid, bevorzugt ein gasförmiges Fluid unter einem einstellbaren Arbeitsdruck zur Verfügung stellt, eine Energiequelle, die dazu geeignet ist, die Spritzdrähte mit elektrischer Energie zu versorgen, sowie eine frei programmierbare Ansteuereinheit zur Einstellung verschiedener Prozessparameter. Die Spritzdrähte werden aus einer Vorratseinrichtung einer Drahtführung zugeführt, die einen Drahtvorschub und eine Führungseinrichtung umfasst. Der Drahtvorschub, der entweder in der Spritzpistole selbst oder in einer externen Einrichtung untergebracht sein kann, befördert die Spritzdrähte aus der Vorratseinrichtung über die Führungseinrichtung derart in einen Schmelzbereich, dass zwischen den beiden Spritzdrähten im Schmelzbereich ein Lichtbogen gezündet und über einen vorgebbaren Zeitraum stabil aufrecht erhalten werden kann. Die Führungseinrichtung ist bevorzugt so ausgelegt, dass sie als elektrisch leitende Einrichtung mit der Energiequelle verbindbar ist und mit dem Spritzdraht elektrisch leitend in Kontakt steht, so dass über die Führungseinrichtung die für die Erzeugung des Lichtbogens notwendige elektrische Energie dem Spritzdraht zugeführt werden kann. Selbstverständlich kann die Führungseinrichtung gegen die Spritzdrähte auch elektrisch isoliert werden, wobei die elektrische Energie dann den Spritzdrähten auf andere Weise zugeführt wird. Da beim Lichtbogenspritzen im Schmelzbereich kontinuierlich das Material des Spritzdrahtes in eine Schmelze überführt wird, muss der Spritzdraht zur Aufrechterhaltung des Lichtbogens durch die Drahtführung kontinuierlich in den Schmelzbereich nachgeführt werden.For carrying out the method according to the invention for arc spraying, in a preferred embodiment a device with a spray gun known per se is used. The arc spraying apparatus comprises a spray gun, a wire guide for feeding two spray wires, a gas supply providing a fluid, preferably a gaseous fluid at an adjustable working pressure, an energy source adapted to supply the spray wires with electrical energy, and a freely programmable drive unit for setting various process parameters. The spray wires are supplied from a storage device of a wire guide comprising a wire feed and a guide device. The wire feed, which may be housed either in the spray gun itself or in an external device, conveys the spray wires from the storage device via the guide device into a melting region such that an arc is ignited between the two spray wires in the melting region and stably maintained for a predeterminable period of time can be. The guide device is preferably designed such that it can be connected as an electrically conductive device to the energy source and is electrically conductively in contact with the spray wire, so that the necessary electrical energy for the generation of the arc can be supplied to the spray wire via the guide means. Of course, the guide device against the spray wires also be electrically isolated, wherein the electrical energy is then supplied to the spray wires in another way. Since during arc spraying in the melting area the material of the spray wire is continuously transferred into a melt, the spray wire must be maintained to maintain the Arc are continuously tracked through the wire guide in the melting area.
Der Gasvorrat steht über eine erste Zuführeinrichtung, die zum Beispiel in Form einer Druckleitung ausgestaltet sein kann, derart mit dem Schmelzbereich in Verbindung, dass die durch den Lichtbogen im Schmelzbereich aus dem Material des Spritzdrahtes erzeugte Schmelze durch das Fluid mit einem einstellbaren Arbeitsdruck beaufschlagt und so auf die Oberfläche eines zu beschichtenden Werkstücks aufgebracht wird, wobei das Fluid vorzugsweise ein Gas, insbesondere ein Edelgas wie Helium oder Argon, oder ein Inertgas wie Stickstoff oder auch Sauerstoff oder Umgebungsluft umfassen kann.The gas supply is via a first supply device, which may be configured for example in the form of a pressure line, in such connection with the melting region, that the melt produced by the arc in the melting region of the material of the spray wire is acted upon by the fluid with an adjustable working pressure and so is applied to the surface of a workpiece to be coated, wherein the fluid may preferably comprise a gas, in particular a noble gas such as helium or argon, or an inert gas such as nitrogen or oxygen or ambient air.
Die erfindungsgemässe Vorrichtung zum Lichtbogenspritzen weist im Vergleich zum Stand der Technik zusätzlich einen Vorratsbehälter auf, der in einem Ausführungsbeispiel der Vorrichtung durch geeignete Mittel mit der ersten Zuführeinrichtung in Verbindung steht, so das dem Fluid feste Partikel zuführbar sind. Die Schmelze wird dabei durch den Fluidstrom, der das Fluid und die zugeführten festen Partikel umfasst, über die erste Zuführeinrichtung so mit einem einstellbaren Arbeitsdruck beaufschlagt, dass die Partikel der Schmelze zugeführt und gemeinsam mit der aus den Spritzdrähten gebildeten Schmelze auf die Oberfläche eines zu beschichtenden Körpers aufgebracht werden. Dabei ist es möglich, dass die Partikel aus verschiedenen Vorratsbehältern der Schmelze zugeführt werden können, so dass die Zahl und die Art der dem Fluid in Form von Partikeln zugeführten Materialien während des Spritzvorgangs kontrolliert eingestellt werden kann. Ferner ist es möglich, dass der Vorratsbehälter und der Gasvorrat durch einen gemeinsamen Behälter gebildet werden.The inventive apparatus for arc spraying has in comparison to the prior art additionally to a reservoir, which is in an embodiment of the device by suitable means in communication with the first feeder, so that the solid particles are fed to the fluid. The melt is thereby acted upon by the fluid flow, which comprises the fluid and the supplied solid particles, via the first supply with an adjustable working pressure, that the particles fed to the melt and together with the melt formed from the spray wires on the surface of a to be coated Body to be applied. It is possible that the particles can be supplied from different reservoirs of the melt, so that the number and type of the fluid supplied in the form of particles materials can be controlled during the injection process. Furthermore, it is possible that the storage container and the gas supply are formed by a common container.
In einem Ausführungsbeispiel der erfindungsgemässen Vorrichtung zum Lichtbogenspritzen nach einem erfindungsgemässen Verfahren werden die Partikel mittels einer zweiten Zuführeinrichtung durch das Fluid der Schmelze zugeführt . Dabei umfasst die Vorrichtung in gleicher Weise und Funktion, die bereits beschriebenen Komponenten, insbesondere auch die erste Zuführeinrichtung, die gegebenenfalls jedoch nur dazu dient, die durch den Lichtbogen im Schmelzbereich aus dem Material des Spritzdrahtes erzeugte Schmelze durch das Fluid mit einem einstellbaren Arbeitsdruck zu beaufschlagen und so die Schmelze auf die Oberfläche eines zu beschichtenden Werkstücks aufzubringen.In one embodiment of the inventive device for arc spraying according to a method according to the invention, the Particles supplied by means of a second feed device through the fluid of the melt. The device comprises in the same way and function, the components already described, in particular the first feeder, which, however, if necessary only serves to pressurize the melt produced by the arc in the melting region of the material of the spray wire by the fluid with an adjustable working pressure and so apply the melt to the surface of a workpiece to be coated.
Somit weist diese Vorrichtung zum Lichtbogenspritzen zusätzlich zur ersten Zuführeinrichtung eine zweite Zuführeinrichtung auf, welcher zweiten Zuführeinrichtung mittels eines Fluids Partikel aus einem Vorratsbehälter zuführbar sind, wobei auch zwei oder mehr Vorratsbehälter vorhanden sein können. Die Vorratsbehälter sind mit einem Gasvorrat verbunden, der unter einem vorgebbaren Arbeitsdruck Fluid zur Beförderung der Partikel zur Verfügung stellt. Dabei kann derselbe Gasvorrat sowohl mit der ersten Zuführeinrichtung, als auch mit dem Vorratsbehälter in Verbindung stehen. Es können jedoch auch zwei oder mehr Gasvorräte vorhanden sein, so dass beispielsweise die erste Zuführeinrichtung einerseits und die Vorratsbehälter andererseits aus verschiedenen Gasvorräten mit Fluid versorgt werden können. Sind mehrere Gasvorräte vorhanden, so können selbstverständlich auch verschiedene Fluide bei einem Spritzvorgang gleichzeitig zum Einsatz kommen. So ist es beispielsweise möglich, dass die Schmelze durch die erste Zuführeinrichtung aus einem Gasvorrat mit einem ersten Gas, z.B. Sauerstoff, mit Arbeitsdruck beaufschlagt wird, während die Partikel aus einem anderen Gasvorrat mit einem zweiten Gas, beispielsweise durch ein Edelgas mit einem anderen Arbeitsdruck beaufschlagt, über die zweite Zuführeinrichtung der Schmelze zugeführt werden. Selbstverständlich können je nach Erfordernis auch andere Fluide, als die hier beispielhaft angeführten Gase, in Frage kommen. Wenn mehrere Vorratsbehälter vorhanden sind, die gleiche oder verschiedene Partikel bereitstellen, kann selbstverständlich jeder Vorratsbehälter aus einem oder mehreren Gasvorräten gespeist werden, die gleiche oder verschiedene Fluide bereitstellen können.Thus, this device for arc spraying in addition to the first feeder on a second feeder, which second feeder means of a fluid particles are fed from a reservoir, wherein two or more reservoirs may be present. The storage containers are connected to a gas supply, which provides fluid under a prescribable working pressure for the transport of the particles. In this case, the same gas supply can be connected both to the first supply device and to the storage container. However, there may also be two or more gas supplies so that, for example, the first feeder on the one hand and the hopper on the other hand can be supplied with fluid from different gas supplies. If there are several gas supplies, it goes without saying that different fluids can also be used simultaneously during an injection process. So it is for example possible that the melt is acted upon by the first feeder from a gas supply with a first gas, for example oxygen, with working pressure, while the particles from another gas supply with a second gas, for example, by a noble gas applied with a different working pressure , are fed to the melt via the second feed device. Of course, depending on the requirements, other fluids, as the gases exemplified here, come into question. Of course, if there are multiple reservoirs providing the same or different particles, then everyone can Reservoir can be fed from one or more gas stocks that can provide the same or different fluids.
Dabei werden der Schmelze durch das Fluid die Partikel mittels der zweiten Zuführeinrichtung derart aus dem Vorratsbehälter zugeführt, dass die Partikel im Schmelzbereich mit der Schmelze vermischt werden und gemeinsam mit der Schmelze auf die Oberfläche des Körpers durch das Fluid aufgebracht und damit zum integralen Bestandteil der Oberflächenschicht werden. Bevorzugt umfasst die zweite Zuführeinrichtung eine Düseneinrichtung, die dazu geeignet ist, die Partikel in die durch das Fluid mit Arbeitsdruck beaufschlagte Schmelze einzubringen.In this case, the melt is supplied by the fluid, the particles by means of the second supply from the reservoir that the particles are mixed in the melt with the melt and applied together with the melt on the surface of the body by the fluid and thus an integral part of the surface layer become. The second feed device preferably comprises a nozzle device which is suitable for introducing the particles into the melt acted upon by the fluid at working pressure.
Selbstverständlich ist es auch möglich, dass Partikel gleichzeitig über die erste Zuführeinrichtung und über die zweite Zuführeinrichtung der Schmelze zugeführt werden, wobei eine erfindungsgemässe Vorrichtung zum Lichtbogenspritzen darüber hinaus neben der ersten und der zweiten Zuführeinrichtung durchaus auch weitere Zuführeinrichtungen umfassen kann.Of course, it is also possible for particles to be simultaneously fed via the first feed device and via the second feed device to the melt, wherein a device according to the invention for arc spraying may well also comprise further feed devices in addition to the first and the second feed device.
Dabei umfasst die erfindungsgemässe Vorrichtung zum Lichtbogenspritzen wie bereits erwähnt, bevorzugt eine frei programmierbare Ansteuereinheit, die es erlaubt, verschiedene Prozessparameter wie beispielsweise den Arbeitsdruck des Fluids und / oder die zugeführte Menge oder Art von Partikeln und / oder den Drahtvorschub und / oder weitere Prozessparameter nach einem vorgebbaren Schema einzeln einzustellen.As already mentioned, the apparatus for arc spraying according to the invention preferably comprises a freely programmable control unit, which permits various process parameters such as the working pressure of the fluid and / or the supplied quantity or type of particles and / or the wire feed and / or further process parameters to set a predefinable scheme individually.
Die dem Fluid aus dem Vorratsbehälter zugeführten Partikel können in einem bevorzugten Ausführungsbeispiel eine Keramik und / oder ein Karbid und / oder ein Borid und / oder ein Nitrid, insbesondere hexagonales Bornitrid (hBN) oder kubisches Bornitrid (cBN) und / oder ein Metall und / oder eine Metallegierung umfassen. Die Grösse der Partikel liegt zwischen 1 µm und 200 µm und wird vorzugsweise zwischen 5 µm und 80 µm gewählt. Der Volumenanteil der Partikel, die dem Fluid aus dem Vorratsbehälter zugeführt werden, kann variabel oder fest eingestellt werden, so dass der Volumenanteil der Partikel in der durch das erfindungsgemässe Verfahren gespritzen Schicht zwischen 0.1 % und 40 % des Gesamtvolumens der aufgebrachten Oberflächenschicht beträgt. Bevorzugt liegt der Volumenateil der Partikel in der gespritzten Oberflächenschicht zwischen 1 % und 20 %.The particles supplied to the fluid from the reservoir can, in a preferred embodiment, be a ceramic and / or a carbide and / or a boride and / or a nitride, in particular hexagonal boron nitride (hBN) or cubic boron nitride (cBN) and / or a metal and / or or a metal alloy. The size of the particles is between 1 .mu.m and 200 .mu.m and is preferably selected between 5 .mu.m and 80 .mu.m. Of the Volume fraction of the particles which are supplied to the fluid from the reservoir, can be set variable or fixed, so that the volume fraction of the particles in the sprayed by the inventive method layer is between 0.1% and 40% of the total volume of the applied surface layer. The volume fraction of the particles in the sprayed surface layer is preferably between 1% and 20%.
Die erfindungsgemässe Vorrichtung kann dabei mehrere Vorratsbehälter mit verschiedenen Sorten von Partikeln aufweisen, wobei die Partikel, die aus unterschiedlichen Materialien aufgebaut und / oder von unterschiedlicher Grösse sein können, dem Fluid aus den verschiedenen Vorratsbehältern zugeführt und die Zusammensetzung des Partikelstroms durch die Ansteuereinheit nach einem vorgebbaren Schema kontinuierlich verändert werden kann. Dadurch ist es möglich, sowohl die Struktur, als auch die Zusammensetzung der zu spritzenden Oberflächenschicht auch während eines Spritzvorgangs ständig anzupassen, wodurch auch Werkstücke mit stark strukturierten Oberflächen in allen Oberflächenbereichen immer optimal beschichtet werden können.The device according to the invention can have a plurality of storage containers with different types of particles, wherein the particles, which can be composed of different materials and / or of different sizes, are supplied to the fluid from the various storage containers and the composition of the particle flow by the drive unit to a predefinable Scheme can be changed continuously. This makes it possible to constantly adapt both the structure and the composition of the surface layer to be sprayed during a spraying process, whereby workpieces with highly structured surfaces in all surface areas can always be optimally coated.
Ein besonderer Vorteil des erfindungsgemässen Verfahrens zum Lichtbogenspritzen besteht darin, dass die Partikel mit dem Fluid in die Schmelze eingeführt werden und nicht durch Verwendung eines Fülldrahtes in den Beschichtungsprozess eingebracht werden. Dadurch sind die Partikel weit weniger in ihrem Volumen eingeschränkt und haben keine negative Auswirkungen auf die Stabilität des Lichtbogens und des Schmelzprozesses. Je nach eingesetzten Materialien und / oder den beim Lichtbogenspritzen gewählten Parametern können die in die Schmelze eingebrachten Partikel bereits während ihrem Weg zur Oberfläche des zu beschichtenden Körpers entweder von der schmelzflüssigen Phase ganz oder teilweise umschlossen sein, beispielsweise innerhalb kleiner Tröpfchen, die sich beim Zerstäuben der Schmelze gebildet haben, oder erst auf der Oberfläche des zu beschichtenden Körpers von der schmelzflüssigen Phase, vor oder während dem Erstarren bei der Schichtbildung, umschlossen werden.A particular advantage of the method according to the invention for arc spraying is that the particles are introduced into the melt together with the fluid and are not introduced into the coating process by using a filler wire. As a result, the particles are much less restricted in volume and have no negative effects on the stability of the arc and the melting process. Depending on the materials used and / or the parameters selected during the arc spraying, the particles introduced into the melt can already be completely or partly enclosed by the molten phase during their way to the surface of the body to be coated, for example within small droplets which, during atomization, of the Melt formed, or only on the surface of the coating body from the molten phase, before or during the solidification in the layer formation, to be enclosed.
In einer besonderen Ausführungsvariante des erfindungsgemässen Verfahrens umfassen die Partikel beispielsweise oxidische Keramiken oder Karbide und werden im Spritzprozess im wesentlichen nicht aufgeschmolzen, sondern in eine Trägerschicht, die weitestgehend aus dem Material des Spritzdrahtes aufgebaut ist, matrixartig in die gespritzte Oberflächenschicht eingebaut. Die so entstandene Oberflächenschicht kann, je nach Art der eingebauten Partikel, ganz unterschiedliche Eigenschaften aufweisen. Im Vergleich zu Oberflächenschichten, die mit bekannten Verfahren zum Lichtbogenspritzen hergestellt wurden, kann beispielsweise durch Verwendung harter keramischer Partikel eine deutlich verbesserte Verschleissfestigkeit der gespritzten Oberflächen erreicht werden. Beispielsweise sind durch das erfindungsgemässe Verfahren Verschleissschutzschichten für Bremsscheiben herstellbar, die unter anderem in Fahrzeugen zum Einsatz kommen können, deren Bremsscheiben durch häufige Bremsvorgänge ständig stark belastet sind. Dies trifft beispielsweise auf Lastkraftwagen, Strassenbahnen, Autobusse und andere Fahrzeuge, insbesondere im Nahverkehr zu, die häufig und in kurzen Intervallen relativ grosse Massen abbremsen müssen. Durch die Verwendung des erfindungsgemässen Verfahren können auf die Bremsscheiben solcher Fahrzeuge erstmals Verschleisschutzschichten aufgespritzt werden, die sogar die Lebensdauer des entsprechenden Fahrzeugs überdauert. Die wirtschaftlichen Vorteile, die sich durch Einsatz solcher Verschleissschutzschichten ergeben liegen auf der Hand. Dabei ist das erfindungsgemässe Verfahren selbstverständlich nicht auf die Herstellung von Verschleisschutzschichten für Bremsscheiben beschränkt, sondern kann zum Beispiel auch zur Beschichtung von Glatt- oder Kreppzylindern (sogenannten Trockenzylindern) für die Herstellung von Papieren in der Papierindustrie oder in vielen anderen Bereichen erfolgreich eingesetzt werden. Neben Schutzschichten auf Oberflächen von Werkstücken können sogar freistehende Körper aus MMC (Metal Matrix Composite) gespritzt werden.In a particular embodiment of the method according to the invention, the particles comprise, for example, oxidic ceramics or carbides and are substantially not melted in the injection process, but are incorporated in a matrix-like manner into the sprayed surface layer in a carrier layer which is largely composed of the material of the spray wire. The resulting surface layer can, depending on the nature of the incorporated particles, have very different properties. In comparison with surface layers which have been produced by means of known methods for arc spraying, for example by using hard ceramic particles, a significantly improved wear resistance of the sprayed surfaces can be achieved. For example, by the inventive method wear protection layers for brake discs produced that can be used, inter alia, in vehicles whose brake discs are constantly heavily loaded by frequent braking. This applies, for example, to trucks, trams, buses and other vehicles, especially in local traffic, which must slow down frequently and at relatively short intervals relatively large masses. By using the method according to the invention, wear protection layers can be sprayed onto the brake disks of such vehicles for the first time, which even outlasts the service life of the corresponding vehicle. The economic advantages that result from the use of such wear protection layers are obvious. Of course, the method according to the invention is of course not limited to the production of wear protection layers for brake discs, but can also be successfully used, for example, for coating smooth or creping cylinders (so-called drying cylinders) for the production of papers in the paper industry or in many other fields. Next Protective layers on surfaces of workpieces can even be sprayed free-standing bodies of MMC (Metal Matrix Composite).
Ferner ist es möglich, dass die Partikel im wesentlichen Trockenschmierstoffe sind, wie beispielsweise hexagonales Bornitrid (hBN) oder andere Materialien, wodurch eine erhöhte Schmierfähigkeit und / oder verbesserte abrasive Eigenschaften der Oberfläche erreicht werden. So können beispielsweise bewegliche Komponenten in Turbinen aller Art, die hohen Temperaturen und /oder starken mechanischen Belastungen ausgesetzt sind und gewisse dichtende Funktionen haben, mit solchen Schichten durch Anwendung des erfindungsgemässen Verfahrens ausgestattet werden.Further, it is possible for the particles to be substantially dry lubricants, such as hexagonal boron nitride (hBN) or other materials, thereby providing increased lubricity and / or improved abrasive properties of the surface. Thus, for example, moving components in turbines of all types, which are exposed to high temperatures and / or heavy mechanical loads and have certain sealing functions, can be equipped with such layers by applying the method according to the invention.
Darüber hinaus ist es sogar möglich, dass die Partikel ebenfalls im Lichtbogen aufgeschmolzen werden, so dass eine mehr oder weniger homogene Mischung von Schmelze und geschmolzenen Partikeln gebildet wird, was dann zu entsprechend homogeneren Strukturen in der Oberflächenschicht führt. Beispielsweise können die Partikel, die dem Fluid aus dem Vorratsbehälter zugeführt werden, Materialien wie Metalle oder Metallegierungen umfassen. Durch Zuführung solcher Partikel in die aus dem Material des Spritzdrahtes gebildeten Schmelze, kann in der Schmelze zum Beispiel eine Legierung gebildet werden, die eine vom Material des Spritzdahtes abweichende Zusammensetzung bzw. vom Material des Spritzdrahtes abweichende Eigenschaften aufweist.In addition, it is even possible that the particles are also melted in the arc, so that a more or less homogeneous mixture of melt and molten particles is formed, which then leads to correspondingly more homogeneous structures in the surface layer. For example, the particles that are supplied to the fluid from the reservoir may include materials such as metals or metal alloys. By feeding such particles into the melt formed from the material of the spray wire, it is possible, for example, to form an alloy in the melt which has a composition deviating from the material of the sprayed wire or deviating from the material of the sprayed wire.
Die Eigenschaften der gespritzten Oberflächenschicht können darüberhinaus auch durch das Fluid selbst beeinflusst werden, das im Spritzprozess zur Beaufschlagung der Schmelze mit Arbeitsdruck und / oder zur Zuführung der Partikel verwendet wird. Beispielsweise kann das Fluid einen erhöhten Gehalt an Sauerstoff umfassen, so dass die die Schmelze umfassenden Materialien und / oder die Partikel bereits beim Spritzvorgang zu einem gewissen Grad oxidieren, wodurch die chemischen und physikalischen Eigenschaften der gespritzten Oberfläche positiv beeinflusst werden können.In addition, the properties of the sprayed surface layer can also be influenced by the fluid itself, which is used in the injection process to apply melt to the working pressure and / or to feed the particles. For example, the fluid may comprise an increased content of oxygen, so that the materials comprising the melt and / or the particles already to a certain extent during the injection process oxidize, whereby the chemical and physical properties of the sprayed surface can be positively influenced.
Die erfindungsgemässe Vorrichtung zum Lichtbogenspritzen mit einer Spritzpistole umfasst eine Drahtführung zum Nachführen zweier elektrisch leitender Spritzdrähte und mindestens eine erste Zuführeinrichtung zur Zuführung eines Fluids, an welche Spritzdrähte eine elektrische Spannung anlegbar ist, so dass ein Lichtbogen zündbar ist und dadurch die Spritzdrähte in einem Schmelzbereich in eine Schmelze überführbar sind, wobei die Schmelze durch das Fluid auf die Oberfläche eines Körpers aufbringbar ist. Dabei sind an der erfindungsgemässen Vorrichtung Mittel vorgesehen, um der Schmelze durch das Fluid Partikel aus einem Vorratsbehälter zuzuführen.The inventive device for arc spraying with a spray gun comprises a wire guide for tracking two electrically conductive spray wires and at least a first supply means for supplying a fluid to which spray wires an electrical voltage can be applied, so that an arc is ignited and thereby the spray wires in a melting region in a melt can be transferred, wherein the melt can be applied by the fluid to the surface of a body. In this case, means are provided on the device according to the invention to supply the melt with particles through the fluid from a storage container.
Dadurch, dass Mittel vorgesehen sind, um der Schmelze Partikel durch das Fluid zuzuführen, kann auf die Verwendung von Fülldrähten als Spritzdrähte verzichtet werden. Unterschiedliche Sorten von Partikel sind dem Fluid entweder aus mehreren verschiedenen Vorratsbehältern getrennt zuführbar oder in einem oder mehreren Vorratsbehältern sind Mischungen von verschiedenen Sorten von Partikeln verfügbar und dem Fluid aus den Vorratsbehältern zuführbar.Characterized in that means are provided to supply the melt particles through the fluid, can be dispensed with the use of cored wires as injection wires. Different types of particles can either be supplied to the fluid separately from a plurality of different storage containers, or mixtures of different types of particles are available in one or more storage containers and can be supplied to the fluid from the storage containers.
Im folgenden wird die Erfindung wird an Hand der Zeichnung näher erläutert. Es zeigen in schematischer Darstellung:
- Fig. 1
- die wesentlichen Teile eines Ausführungsbeispiels einer Vorrichtung zum Lichtbogenspritzen;
- Fig. 2
- wie
Fig. 1 für ein Ausführungsbeispiel einer Vorrichtung zum Lichtbogenspritzen gemäß der Erfindung; - Fig. 3
- ein Beispiel einer Schicht auf einer Oberfläche eines Körpers, aufgebracht durch Lichtbogenspritzen nach einem erfindungsgemässen Verfahren.
- Fig. 1
- the essential parts of an embodiment of an apparatus for arc spraying;
- Fig. 2
- as
Fig. 1 for an embodiment of an apparatus for arc spraying according to the invention; - Fig. 3
- an example of a layer on a surface of a body, applied by arc spraying according to a method according to the invention.
Die aus dem Material des Spritzdrahtes 2 im Lichtbogen 6 gebildete Schmelze 8 wird durch ein Fluid 4 über eine erste Zuführeinrichtung 3 aus einem Gasvorrat 19 auf eine Oberfläche 9 eines Körpers 10 aufgebracht. Durch das Fluid 4, das bevorzugt ein Gas, insbesondere Sauerstoff, Stickstoff, Argon, Helium, Umgebungsluft oder ein anderes Gas ist, wird die Schmelze 8 mit einem vorgebbaren Arbeitsdruck beaufschlagt, wodurch die Schmelze 8 auf die Oberfläche 9 des Körpers 10 geschleudert wird, die Schmelze 8 auf der Oberfläche 9 des Körpers 10 in einen festen Zustand kondensiert und so eine Oberflächenschicht 18 mit vorgebbaren Eigenschaften auf der Oberfläche 9 des Körpers 10 bildet.The melt 8 formed from the material of the
Eine Vorrichtung zum Lichtbogenspritzen weist weiter Mittel 15 auf, mit welchen dem Fluid 4 Partikel 11 aus einem Vorratsbehälter 12 zuführbar sind, wobei wie in
Zur Steuerung und / oder Regelung weist eine Vorrichtung zum Lichtbogenspritzen eine frei programmierbare Ansteuereinheit 14 auf, mit welcher der Arbeitsdruck, mit dem das Fluid 4 die Schmelze 8 beaufschlagt, und / oder die zugeführte Menge und /oder Art von Partikeln 11 und / oder der Drahtvorschub 13 und / oder die den Spritzdrähten 2 zugeführte elektrische Energie und / oder ein weiterer Prozessparameter einzeln eingestellt werden können. Dazu sind zum Beispiel der Gasvorrat 19 und / oder die Drahtführung 5 und / oder der Vorratsbehälter 12 und / oder die Energiequelle 16 und / oder weitere Komponenten der Vorrichtung über Ansteuerleitungen 20 mit der Ansteuereinheit 14 verbunden. Desweiteren kann die Ansteuereinheit 14 Sensorleitungen 21 umfassen, durch die der Ansteuereinheit 14 von nicht dargestellten Sensoren verschiedene Betriebsparameter, wie beispielsweise aktueller Arbeitsdruck, Gasdruck in der Prozesskammer, Umgebungsdruck, Temperatur, elektrische Betriebsparameter der Energiequelle oder andere Parameter, übermittelbar sind.For control and / or regulation, a device for arc spraying has a freely
Die aus dem Material des Spritzdrahtes 2 im Lichtbogen 6 gebildete Schmelze 8 wird analog zu dem zuvor beschriebenen Ausführungsbeispiel auch hier durch ein Fluid 4 über eine Zuführeinrichtung 3 aus einem Gasvorrat 19 auf eine Oberfläche 9 eines Körpers 10 aufgebracht. Durch das Fluid 4, das bevorzugt ein Gas, insbesondere Stickstoff, Sauerstoff, Argon, Helium, Umgebungsluft oder ein anderes Gas ist, wird die Schmelze 8 mit einem vorgebbaren Arbeitsdruck beaufschlagt, wodurch die Schmelze 8 auf die Oberfläche 9 des Körpers 10 geschleudert wird, die Schmelze 8 auf der Oberfläche 9 des Körpers 10 in einen festen Zustand kondensiert und so eine Oberflächenschicht 18 mit vorgebbaren Eigenschaften auf der Oberfläche 9 des Körpers 10 bildet.The melt 8 formed from the material of the
Das in
Dabei werden der Schmelze 8 durch das Fluid 4 die Partikel 11 mittels der zweiten Zuführeinrichtung 31 derart aus dem Vorratsbehälter 12 zugeführt, dass die Partikel 11 im Schmelzbereich 7 mit der Schmelze 8 vermischt werden und gemeinsam mit der Schmelze 8 auf die Oberfläche 9 des Körpers 10 durch das Fluid 4 aufgebracht und damit zum integralen Bestandteil der Oberflächenschicht 18 werden. Bevorzugt umfasst die zweite Zuführeinrichtung 31 eine Düseneinrichtung 32, die dazu geeignet ist, die Partikel 11 in die durch das Fluid 4 mit Arbeitsdruck beaufschlagte Schmelze 8 einzubringen.In this case, the melt 8 are supplied by the
Beispielsweise sind so durch das erfindungsgemässe Verfahren Oberflächenschichten 18 für Bremsscheiben herstellbar, die unter anderem in Fahrzeugen zum Einsatz kommen können, deren Bremsscheiben durch häufige Bremsvorgänge ständig stark belastet sind. Dies trifft unter anderem auf Lastkraftwagen, Strassenbahnen, Autobusse und andere Fahrzeuge, insbesondere im Nahverkehr zu, die häufig und in kurzen Intervallen relativ grosse Massen abbremsen müssen. Dabei ist das erfindungsgemässe Verfahren selbstverständlich nicht auf die Herstellung von Oberflächenschichten 18 für Bremsscheiben beschränkt, sondern kann zum Beispiel auch zur Beschichtung von Glatt- oder Kreppzylindern (sogenannten Trockenzylindern) für die Herstellung von Papieren in der Papierindustrie oder in vielen anderen Bereichen erfolgreich eingesetzt werden. Neben Oberflächenschichten 18 auf Oberflächen 9 von Werkstücken können sogar freistehende Körper, beispielsweise aus MMC (Metal Matrix Composite) gespritzt werden.For example, surface layers 18 for brake disks can thus be produced by the method according to the invention, which can be used inter alia in vehicles whose brake disks are constantly heavily loaded by frequent braking processes. This applies, inter alia, to trucks, trams, buses and other vehicles, especially in local traffic, which often and at short intervals have to decelerate relatively large masses. Of course, the inventive method is of course not limited to the production of surface layers 18 for brake discs, but can be used successfully for example for the coating of smooth or creping cylinders (so-called drying cylinders) for the production of papers in the paper industry or in many other areas. In addition to surface layers 18 on
Ferner ist es möglich, dass die Partikel 11 im wesentlichen Trockenschmierstoffe, wie beispielsweise hexagonales Bornitrid oder andere umfassen, wodurch eine erhöhte Schmierfähigkeit und / oder verbesserte abrasive Eigenschaften der Oberflächenschicht 18 erreicht werden. Selbstverständlich ist es auch möglich, dass die Partikel 11 ebenfalls im Lichtbogen 6 aufgeschmolzen werden, so dass eine mehr oder weniger homogene Mischung von Schmelze 8 und geschmolzenen Partikeln 11 gebildet wird, was dann zu entsprechend homogeneren Strukturen in der Oberflächenschicht 18 führt.Further, it is possible for the
Dadurch, dass die Zufuhr der Partikel 11 zur Schmelze 8 aus verschiedenen Vorratsbehältern 12 erfolgen und die Menge und / oder Art von zugeführten Partikeln 11 für jeden Vorratsbehälter 12 einzeln eingestellt werden kann, ist es möglich in einem Arbeitsgang auch Oberflächenschichten 18 herzustellen, deren Eigenschaften über die Oberflächenschicht 18 von Ort zu Ort und / oder über die Dicke der Oberflächenschicht 18 variieren, d.h. es können auch vorgebbare Konzentrationsprofile von Partikeln 11 in der Oberflächenschicht 18 erzeugt werden. So ist es zum Beispiel möglich, Oberflächenschichten 18 herzustellen, deren abrasive Eigenschaften und / oder deren Verschleissfestigkeit von Ort zu Ort variieren oder sich mit wachsendem Schichtabtrag in vorgebbarer Weise verändern.Because the supply of the
Das erfindungsgemässe Verfahren zum Lichtbogenspritzen mittels einer Spritzpistole gestattet es, in die aus dem Material der Spritzdrähte erzeugte Schmelze zusätzlich feste Partikel kontrolliert durch ein mit Arbeitsdruck beaufschlagtes Fluid einzubringen, so dass auf die Verwendung von teuren Fülldrähten verzichtet werden kann. Dadurch, dass die Partikel aus verschiedenen Vorratsbehältern durch das Fluid der Schmelze nach einem vorgebbaren Schema zugeführt werden, können bei Bedarf gleichzeitig verschiedene Partikelsorten unterschiedlicher Grösse und chemischer Zusammensetzung in die zu spritzende Schicht eingebracht werden. Dadurch wird es möglich, durch Lichtbogenspritzen Oberflächenschichten mit deutlich verbesserten Eigenschaften und einer grösseren Vielfalt möglicher Strukturen und Zusammensetzung herzustellen.The inventive method for arc spraying by means of a spray gun makes it possible to introduce in the melt produced from the material of the spray wires additionally solid particles controlled by a pressurized fluid with working pressure, so that can be dispensed with the use of expensive cored wires. Characterized in that the particles are supplied from different reservoirs through the fluid of the melt according to a predeterminable scheme, if necessary, different types of particles of different size and chemical composition can be introduced simultaneously into the layer to be sprayed. This makes it possible to produce surface layers with significantly improved properties and a greater variety of possible structures and compositions by arc spraying.
Claims (10)
- A method of arc spraying by means of a spray gun (1) which consists essentially of two electrically conductive spray wires (2) and at least one first supply device (3) for supplying a fluid (4), with an electrical voltage being applied to the spray wires (2), the spray wires (2) being fed by means of a wire guide (5), an arc (6) being ignited by the electrical voltage, the spray wires (2) being converted into a melt (8) in a melting region (7) and the melt (8) being applied by the fluid (4) to the surface (9) of a body (10), whereby particles (11) from a storage container (12) are supplied to the melt (8) by the fluid (4) characterised in that the particles (11) are supplied to the melt (8) by the fluid (4) by means of a second supply device (31).
- A method in accordance with claim 1, in which the fluid (4) acts upon the melt (8) with an adjustable working pressure.
- A method in accordance with any one of the preceding claims, in which the fluid (4) includes a gas, in particular a noble gas such as helium or argon, or nitrogen or oxygen.
- A method in accordance with any one of the preceding claims, in which the particles (11) include a ceramic material, in particular Al2O3, Cr2O3, TiO2, ZrO2 and/or a carbide, in particular WC, Cr3C2, TiC, TaC, Fe3C, diamond niobium carbide, vanadium carbide and/or a boride and/or a nitride, in particular cBN or hBN, and/or a metal and/or a metal alloy.
- A method in accordance with any one of the preceding claims, in which the size of the particles (11) is selected to be between 1 µm and 200 µm, preferably between 5 µm and 80 µm.
- A method in accordance with any one of the preceding claims, in which the wire guide (5) includes a controllable or regulatable wire feed (13).
- A method in accordance with any one of the preceding claims, in which the working pressure of the fluid (4) and/or the supplied amount and/or kind of particles (11) and/or the wire feed (13) and/or any desired further process parameter can be set individually by means of a freely programmable control unit (14).
- A method in accordance with any one of the preceding claims, in which particles (11) of different materials and/or particles of different size are supplied to the fluid (4) from different storage containers (12) to change the composition of the particle flow.
- An apparatus for arc spraying comprising a spray gun (1) which essentially consists of a wire guide (5) for feeding two electrically conductive spray wires (2) and at least one first supply device (3) for supplying a fluid (4), with an electrical voltage being able to be applied to said spray wires (2) such that an arc (6) can be ignited and thereby the spray wires (2) can be converted into a melt (8) in a melting region (7), with the melt (8) being able to be applied to the surface (9) of a body (10) by the fluid (4), whereby means (15) are provided in order to supply particles (11) from a storage container (12) to the melt (8) by the fluid (4) characterised in that a second supply device (31) which is suitable to supply particles (11) to the melt (8) is included.
- A wear part, in particular a brake disc for a vehicle, or smooth or Yankee or crepe cylinders for paper making, which was coated in accordance with a method in accordance with any one of claims 1 to 8 or using an apparatus in accordance with claim 9.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP03405214A EP1358943B1 (en) | 2002-04-29 | 2003-03-31 | Method and apparatus for electric arc spraying |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP02405350 | 2002-04-29 | ||
EP02405350 | 2002-04-29 | ||
EP03405214A EP1358943B1 (en) | 2002-04-29 | 2003-03-31 | Method and apparatus for electric arc spraying |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1358943A1 EP1358943A1 (en) | 2003-11-05 |
EP1358943B1 true EP1358943B1 (en) | 2008-07-30 |
Family
ID=29217239
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP03405214A Expired - Lifetime EP1358943B1 (en) | 2002-04-29 | 2003-03-31 | Method and apparatus for electric arc spraying |
Country Status (1)
Country | Link |
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EP (1) | EP1358943B1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102012112488A1 (en) * | 2012-12-18 | 2014-06-18 | Gebr. Heller Maschinenfabrik Gmbh | Twin wire arc spray coating method for component e.g. cylinder bore of internal combustion engine, involves detecting and supplying process variables influencing coating process to process controller that controls variables |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE10334704A1 (en) * | 2003-07-30 | 2005-02-24 | Daimlerchrysler Ag | Self-supporting, three-dimensional components deposited by a thermal spraying process |
DE102009026655B3 (en) * | 2009-06-03 | 2011-06-30 | Linde Aktiengesellschaft, 80331 | Method of making a metal matrix composite, metal matrix composite and its use |
US20120180747A1 (en) * | 2011-01-18 | 2012-07-19 | David Domanchuk | Thermal spray coating with a dispersion of solid lubricant particles |
EP2524973A1 (en) * | 2011-05-18 | 2012-11-21 | Sulzer Metco AG | Arc spraying method for manufacturing a leak-proof coating |
DE102017009230A1 (en) * | 2017-10-04 | 2018-11-08 | Daimler Ag | Apparatus, wire and method for electric arc wire spraying |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
JPS63121648A (en) * | 1986-11-11 | 1988-05-25 | Toyota Motor Corp | Formation of thermally sprayed layer of metal-based composite material |
US4788402A (en) * | 1987-03-11 | 1988-11-29 | Browning James A | High power extended arc plasma spray method and apparatus |
US4762977A (en) * | 1987-04-15 | 1988-08-09 | Browning James A | Double arc prevention for a transferred-arc flame spray system |
US5019686A (en) * | 1988-09-20 | 1991-05-28 | Alloy Metals, Inc. | High-velocity flame spray apparatus and method of forming materials |
US5296667A (en) * | 1990-08-31 | 1994-03-22 | Flame-Spray Industries, Inc. | High velocity electric-arc spray apparatus and method of forming materials |
-
2003
- 2003-03-31 EP EP03405214A patent/EP1358943B1/en not_active Expired - Lifetime
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE102012112488A1 (en) * | 2012-12-18 | 2014-06-18 | Gebr. Heller Maschinenfabrik Gmbh | Twin wire arc spray coating method for component e.g. cylinder bore of internal combustion engine, involves detecting and supplying process variables influencing coating process to process controller that controls variables |
DE102012112488B4 (en) * | 2012-12-18 | 2017-07-13 | Gebr. Heller Maschinenfabrik Gmbh | Arc wire spray coating method for cylinder bores of internal combustion engines |
Also Published As
Publication number | Publication date |
---|---|
EP1358943A1 (en) | 2003-11-05 |
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