EP1925688B1 - Metallization method - Google Patents
Metallization method Download PDFInfo
- Publication number
- EP1925688B1 EP1925688B1 EP07119585.3A EP07119585A EP1925688B1 EP 1925688 B1 EP1925688 B1 EP 1925688B1 EP 07119585 A EP07119585 A EP 07119585A EP 1925688 B1 EP1925688 B1 EP 1925688B1
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- EP
- European Patent Office
- Prior art keywords
- coolant
- metallization
- component
- wall
- cooling
- Prior art date
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- 238000000034 method Methods 0.000 title claims description 28
- 238000001465 metallisation Methods 0.000 title claims description 27
- 239000002826 coolant Substances 0.000 claims description 26
- 238000001816 cooling Methods 0.000 claims description 19
- 229910052751 metal Inorganic materials 0.000 claims description 17
- 239000002184 metal Substances 0.000 claims description 17
- 239000012530 fluid Substances 0.000 claims description 12
- 238000000151 deposition Methods 0.000 claims description 11
- 229910001234 light alloy Inorganic materials 0.000 claims description 11
- 230000008021 deposition Effects 0.000 claims description 10
- 238000007789 sealing Methods 0.000 claims description 6
- 239000007769 metal material Substances 0.000 claims description 5
- 239000012809 cooling fluid Substances 0.000 claims description 4
- 230000003247 decreasing effect Effects 0.000 claims description 3
- 239000006185 dispersion Substances 0.000 claims description 3
- 239000002923 metal particle Substances 0.000 claims description 3
- 239000000758 substrate Substances 0.000 description 9
- 238000000576 coating method Methods 0.000 description 5
- 239000002245 particle Substances 0.000 description 5
- 239000011248 coating agent Substances 0.000 description 4
- 238000002485 combustion reaction Methods 0.000 description 4
- 238000005299 abrasion Methods 0.000 description 3
- 238000005452 bending Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 230000006835 compression Effects 0.000 description 2
- 238000007906 compression Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000009661 fatigue test Methods 0.000 description 2
- 230000009466 transformation Effects 0.000 description 2
- 238000011282 treatment Methods 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- -1 chromium carbides Chemical class 0.000 description 1
- 239000000567 combustion gas Substances 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 238000009533 lab test Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000012188 paraffin wax Substances 0.000 description 1
- 239000000843 powder Substances 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000005480 shot peening Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000003746 surface roughness Effects 0.000 description 1
- 230000001131 transforming effect Effects 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
Images
Classifications
-
- 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
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
- C23C4/129—Flame spraying
-
- 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
-
- 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
- B05B7/20—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 by flame or combustion
Definitions
- the present invention relates to a method for the metallization of light alloys.
- light alloy components such as aluminium alloys
- the process of application on light alloy substrates causes an excessive surface heating, given by the impact of the particles (and by the partial transformation of their kinetic energy into heat) and by the impact of the combustion gas at a high temperature. Since the mechanical properties of light alloys quickly decay in the presence of relatively low temperatures (a little above 120°C), with any method used the metallization imparts no surface improvement to light alloy components.
- the problem of the present invention is to solve the limits and disadvantages mentioned with reference to the prior art.
- reference numeral 4 globally denotes an apparatus for metallization, suitable for providing a metal coating on a component 8, preferably a component of metal material in a light alloy.
- Apparatus 4 comprises means 12 for depositing a metal layer on a component, said deposition means 12 being directly facing a wall to be coated 16 of said component 8 so as to address a flow of metal material on a first surface 20 of said wall to be coated 16.
- said apparatus 4 comprises a cooling head 24 suitable for sending a cooling fluid flow on a second surface 28 of said wall to be coated 16, the second surface 28 being opposite the first surface 20 so as to not be impinged by the flow of metal material.
- component 8 may be a globally cylindrical component, wherein the first surface 20 consists of the outer side surface or portion thereof and the second surface 28 consists of the inner side surface or portion thereof.
- the deposition means 12 comprise a metallization gun 29 suitable for performing an HVOF (High Velocity Oxyfuel) method for metal coating.
- HVOF High Velocity Oxyfuel
- Pressure in the combustion chamber 32 is monitored constantly to ensure proper combustion and constant pressure.
- the particle speed is directly related to the pressure of chamber 32; the gun comprises a converging-diverging nozzle 33 having such shape and size as to create a supersonic jet. Particles of metal powder, which make up the coating, are introduced downstream of the diverging portion through inlets 34 and are then brought to such temperature as to make them partially plastic. A flow of metal particles 40 at high speed is therefore obtained wherein the metal particles exit at a high speed from an outlet 35 of gun 29 and thus impact against the wall to be coated, thus transforming the high kinetic energy into a plastic deformation and heat during the impact and creating the adhesion to the component substrate.
- Gun 29 preferably comprises also inlet and outlet ducts 36, 38 for a cooling circuit.
- the cooling head 24 comprises a delivery duct 44, in fluid connection to a cooling fluid circuit 48, said delivery duct 44 being provided with at least one delivery hole 52 for the dispersion of coolant on said second surface 28 of the wall to be coated 16.
- Said delivery duct 44 comprises a plurality of delivery holes 52 for fluid dispersion, said holes 52 being for example equally spaced along a prevailing extension axis X of the delivery duct 44.
- the delivery holes 52 are arranged according to an axial-symmetric arrangement relative to said prevailing extension axis X of the delivery duct 44.
- the cooling head 24 comprises at least one collecting duct 56 suitable for collecting the coolant after this has come into contact with the second surface 28 of the wall to be coated 16 and for conveying it in removal from said head 24 in said cooling circuit 48.
- the collecting duct 56 is in fluid connection with coolant recirculation means (not shown) suitable for conveying the coolant coming from the collecting duct 56 in a heat exchanger 60, for decreasing the temperature of the coolant.
- coolant recirculation means (not shown) suitable for conveying the coolant coming from the collecting duct 56 in a heat exchanger 60, for decreasing the temperature of the coolant.
- the recirculation means are in fluid connection with exchanger 60 so as to deliver the coolant, previously cooled by the exchanger, into the delivery duct 44.
- the collecting duct 56 is arranged coaxially to the delivery duct 44 relative to the prevailing extension axis X.
- the cooling head 24 comprises, preferably on an outer portion 64 of the collecting duct 56, sealing means 68 suitable for realising a seal between head 24 and the second surface 28 of the wall to be coated 16 of component 8.
- head 24 is inserted into the component so as to be surrounded by the second surface 28 of component 8, having the delivery holes 52 directly facing the second surface 28; the sealing means abut against said second surface so as to prevent the coolant to escape through the air space between the cooling head and the second surface 28 of component 8.
- the sealing means 68 force the coolant, after this has contacted the second surface 28, to flow back into the collecting ducts 56 and leave head 24 and component 8 through said collecting ducts to be reintroduced into coolant 48.
- apparatus 4 comprises motor means (not shown) of said component 8, suitable for rotating said component 8 relative to a working axis preferably coinciding with said prevailing extension axis X.
- the metallization method of a metal component comprises the steps of providing means of deposition of a metal layer on a component, addressing by said deposition means, a flow of metal material on a first surface of a wall to be coated of the metal component, the method being characterised in that during the deposition of the metallization flow on a first surface, there is provided the step of addressing a coolant flow, by a cooling head, on a second surface of the wall to be coated, opposite said first surface and not impinged by the metallization flow.
- the metallization method comprises the steps of providing a collecting duct for collecting the coolant after it has contacted the wall and conveying said fluid away from said head.
- said recirculation means of the coolant convey the coolant coming from the collecting duct in a heat exchanger, for decreasing the temperature of the coolant and send the fluid thus cooled in said delivery duct.
- the sealing means 68 realise a seal between the cooling head 24 and the second surface 28 of the wall to be coated 16 of component 8 so as to convey all the coolant into the collecting duct 56, after the fluid has contacted the second surface of component 28.
- the sealing means 68 force the coolant, after this has contacted the second surface 28, to flow back into the collecting ducts 56 and leave head 24 and component 8 through said collecting ducts to be reintroduced into coolant 48.
- the component metallization comprises the step of rotating said component 8 relative to a working axis coinciding with the extension axis X of head 24 both during the metal deposition through gun 29 and in the cooling step through the delivery of coolant from the cooling head 24.
- the component wall Thanks to the high thermal exchange between the component wall and the coolant, which continuously flows into the component, it is possible to control the rise of temperature of the component wall preventing it from undergoing a decrease of the mechanical properties, with particular reference to hardness.
- the component rotation relative to the cooling head ensures a constant cooling on the entire wall to be coated, at both the first and the second surface.
- figure 4 shows the profiles of hardness obtained by applications of tungsten carbide on aluminium substrates having thickness of about one millimetre, by prior art processes.
- the hardness values shown are of the Vickers type and have been measured with a standard load equal to 0.1 kg.
- the hardness values are affected by the layer concerned by the temperature induced by the metallization technique, so the mechanical features decrease along with the fatigue resistance of the application-substrate assembly.
- moving from the surface directly impinged by the metallization flow, and thus subject to higher heating, to the inner wall portion it may be noted how micro-hardness increases.
- this result is stronger when the thickness of the wall to be metallized is greater, since an increasingly larger portion of wall is subject to an excessive heating, with subsequent decay of the mechanical features up to the wall core.
- ⁇ FAF it is meant the limit of alternating bending fatigue, that is, the strain below which the fatigue breakage for an alternating bending stress does not occur.
- the application thickness was of about 0.1 millimetres.
- the fatigue test results, with the same load applied, are as follows: Specimen not coated Specimen coated n. of break cycles 20,000-25,000 n. of break cycles 625,000-640,000
- the coatings made on light alloys according to the present invention considerably increase (up to more than 20 times) the number of loading cycles that lead to fatigue breakage.
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Description
- The present invention relates to a method for the metallization of light alloys.
- Surface hardening processes are known in the art, aimed at improving the resistance of mechanical components stressed to fatigue. In fact, such fatigue resistance is strongly influenced by the features of the surface of the components themselves. For example, the surface roughness is one of the first parameters that must be kept into account in the design and manufacture of components subject to fatigue. Also the residual tensions, at the surface as well, greatly influence the behaviour at fatigue; in fact compression tensions greatly increase the resistance capacity while tractions drastically reduce resistance. Mechanical treatments are used to induce residual compression tensions, such as shot-peening or rolling, whereas to improve the mechanical features, on the surface as well, thermo-chemical treatments such as case hardening or ammonia hardening are used.
- Over the last decades, in order to improve abrasion resistance characteristics, various metallization processes have been introduced that allow coating substrates with a poor abrasion resistance with materials having high hardness. For example, in the petrochemical field it has been a decade since the valve balls are coated with tungsten or chromium carbides to prevent abrasion problems due to very hard particles found in the fluids. Such processes use instruments capable of sending a supersonic flow directly against the surface to be coated.
- As regards light alloy components, such as aluminium alloys, the process of application on light alloy substrates causes an excessive surface heating, given by the impact of the particles (and by the partial transformation of their kinetic energy into heat) and by the impact of the combustion gas at a high temperature. Since the mechanical properties of light alloys quickly decay in the presence of relatively low temperatures (a little above 120°C), with any method used the metallization imparts no surface improvement to light alloy components.
- To solve this technical problem it is known to cool the surface of the parts to be metallized by gas jets at a low temperature, generally nitrogen. This allows reducing the temperature of the applied layer, but it does not considerably reduce the temperature of the application/substrate interface, due to the high thermal exchange induced by the transformation of the kinetic energy into heat during the impact of the particles.
- In fact, no suitable surface hardness is obtained by applying metal layers on light alloy layers. The smaller the thickness of the component to be metallized, the stronger this limitation. The solutions of prior art are known form
EP 0621348 B1 ,JP 3236460 A EP 0360482 A1 ,WO 99/22041 A1 EP1186348 B1 . - In the prior art, therefore, there are no apparatus or methods of metallization of light alloy components suitable for significantly improving the surface features thereof.
- The problem of the present invention is to solve the limits and disadvantages mentioned with reference to the prior art.
- Such disadvantages and limits are solved with a method in accordance with
claim 1. - Further embodiments according to the invention are described in the following claims.
- Further features and the advantages of the present invention will appear more clearly from the following description of preferred non-limiting embodiments thereof, wherein:
-
figure 1 shows a schematic view of an apparatus in an operating step; -
figure 2 shows a schematic view of the apparatus offigure 1 in a further operating step;figure 3 shows a schematic view of a detail of the apparatus offigure 1 ; -
figure 4 shows a diagram that illustrates the mechanical features of a specimen obtained according to prior art metallization techniques; -
figure 5 shows a diagram that illustrates the mechanical features of a specimen obtained according to the apparatus and the method of the present invention. - Elements or parts of elements in common between the embodiments described below are referred to with the same reference numerals.
- With reference to the above figures, reference numeral 4 globally denotes an apparatus for metallization, suitable for providing a metal coating on a
component 8, preferably a component of metal material in a light alloy. - Apparatus 4 comprises means 12 for depositing a metal layer on a component, said deposition means 12 being directly facing a wall to be coated 16 of said
component 8 so as to address a flow of metal material on afirst surface 20 of said wall to be coated 16. - advantageously, said apparatus 4 comprises a
cooling head 24 suitable for sending a cooling fluid flow on asecond surface 28 of said wall to be coated 16, thesecond surface 28 being opposite thefirst surface 20 so as to not be impinged by the flow of metal material. - For example,
component 8 may be a globally cylindrical component, wherein thefirst surface 20 consists of the outer side surface or portion thereof and thesecond surface 28 consists of the inner side surface or portion thereof. - According to an embodiment, the deposition means 12 comprise a
metallization gun 29 suitable for performing an HVOF (High Velocity Oxyfuel) method for metal coating. - In this method (
figure 3 ) the combustible, typically paraffin and the comburent, typically oxygen, get mixed and they atomise after passing throughrespective inlet orifices combustion chamber 32 wherein the combustion takes place by the use of a spark plug 32'. - Pressure in the
combustion chamber 32 is monitored constantly to ensure proper combustion and constant pressure. - The particle speed is directly related to the pressure of
chamber 32; the gun comprises a converging-divergingnozzle 33 having such shape and size as to create a supersonic jet. Particles of metal powder, which make up the coating, are introduced downstream of the diverging portion throughinlets 34 and are then brought to such temperature as to make them partially plastic. A flow ofmetal particles 40 at high speed is therefore obtained wherein the metal particles exit at a high speed from anoutlet 35 ofgun 29 and thus impact against the wall to be coated, thus transforming the high kinetic energy into a plastic deformation and heat during the impact and creating the adhesion to the component substrate.Gun 29 preferably comprises also inlet andoutlet ducts - The
cooling head 24 comprises adelivery duct 44, in fluid connection to acooling fluid circuit 48, saiddelivery duct 44 being provided with at least onedelivery hole 52 for the dispersion of coolant on saidsecond surface 28 of the wall to be coated 16. - Said
delivery duct 44 comprises a plurality ofdelivery holes 52 for fluid dispersion, saidholes 52 being for example equally spaced along a prevailing extension axis X of thedelivery duct 44. - Preferably, the
delivery holes 52 are arranged according to an axial-symmetric arrangement relative to said prevailing extension axis X of thedelivery duct 44. - According to an embodiment, the
cooling head 24 comprises at least onecollecting duct 56 suitable for collecting the coolant after this has come into contact with thesecond surface 28 of the wall to be coated 16 and for conveying it in removal from saidhead 24 in saidcooling circuit 48. - For example, the
collecting duct 56 is in fluid connection with coolant recirculation means (not shown) suitable for conveying the coolant coming from thecollecting duct 56 in aheat exchanger 60, for decreasing the temperature of the coolant. - The recirculation means are in fluid connection with
exchanger 60 so as to deliver the coolant, previously cooled by the exchanger, into thedelivery duct 44. - Preferably, the
collecting duct 56 is arranged coaxially to thedelivery duct 44 relative to the prevailing extension axis X. - The
cooling head 24 comprises, preferably on anouter portion 64 of thecollecting duct 56, sealing means 68 suitable for realising a seal betweenhead 24 and thesecond surface 28 of the wall to be coated 16 ofcomponent 8. In other words (figure 2 ),head 24 is inserted into the component so as to be surrounded by thesecond surface 28 ofcomponent 8, having thedelivery holes 52 directly facing thesecond surface 28; the sealing means abut against said second surface so as to prevent the coolant to escape through the air space between the cooling head and thesecond surface 28 ofcomponent 8. In the practice, the sealing means 68 force the coolant, after this has contacted thesecond surface 28, to flow back into thecollecting ducts 56 and leavehead 24 andcomponent 8 through said collecting ducts to be reintroduced intocoolant 48. - Preferably, apparatus 4 comprises motor means (not shown) of said
component 8, suitable for rotating saidcomponent 8 relative to a working axis preferably coinciding with said prevailing extension axis X. - The metallization method of a metal component according to the present invention shall now be described.
- The metallization method of a metal component according to the present invention comprises the steps of providing means of deposition of a metal layer on a component, addressing by said deposition means, a flow of metal material on a first surface of a wall to be coated of the metal component, the method being characterised in that during the deposition of the metallization flow on a first surface, there is provided the step of addressing a coolant flow, by a cooling head, on a second surface of the wall to be coated, opposite said first surface and not impinged by the metallization flow.
- Preferably, the metallization method comprises the steps of providing a collecting duct for collecting the coolant after it has contacted the wall and conveying said fluid away from said head.
- Advantageously, said recirculation means of the coolant convey the coolant coming from the collecting duct in a heat exchanger, for decreasing the temperature of the coolant and send the fluid thus cooled in said delivery duct.
- The sealing means 68 realise a seal between the
cooling head 24 and thesecond surface 28 of the wall to be coated 16 ofcomponent 8 so as to convey all the coolant into thecollecting duct 56, after the fluid has contacted the second surface ofcomponent 28. - In the practice, the sealing means 68 force the coolant, after this has contacted the
second surface 28, to flow back into thecollecting ducts 56 and leavehead 24 andcomponent 8 through said collecting ducts to be reintroduced intocoolant 48. - The component metallization comprises the step of rotating said
component 8 relative to a working axis coinciding with the extension axis X ofhead 24 both during the metal deposition throughgun 29 and in the cooling step through the delivery of coolant from thecooling head 24. - As can be appreciated from the description, the apparatus and the method according to the invention allow overcoming the disadvantages of the prior art.
- Thanks to the high thermal exchange between the component wall and the coolant, which continuously flows into the component, it is possible to control the rise of temperature of the component wall preventing it from undergoing a decrease of the mechanical properties, with particular reference to hardness. The component rotation relative to the cooling head ensures a constant cooling on the entire wall to be coated, at both the first and the second surface.
- Thanks to the geometrical continuity of the application made along the cylindrical surface of the component or specimen, preferably by rotation of the component during the step of deposition of the metal layer, it is possible to apply a metal layer having highly even geometrical and mechanical features.
- To prove the considerable advantages obtained by the present invention, some laboratory tests have been carried out trying to compare the results obtained with the apparatus according to the invention with the results obtained by the known metallization technique.
- For example
figure 4 shows the profiles of hardness obtained by applications of tungsten carbide on aluminium substrates having thickness of about one millimetre, by prior art processes. The hardness values shown are of the Vickers type and have been measured with a standard load equal to 0.1 kg. - As can be seen, the hardness values are affected by the layer concerned by the temperature induced by the metallization technique, so the mechanical features decrease along with the fatigue resistance of the application-substrate assembly. In other words, moving from the surface directly impinged by the metallization flow, and thus subject to higher heating, to the inner wall portion, it may be noted how micro-hardness increases. Of course this result is stronger when the thickness of the wall to be metallized is greater, since an increasingly larger portion of wall is subject to an excessive heating, with subsequent decay of the mechanical features up to the wall core.
- An application of tungsten carbide has therefore been made on the same substrate (about one millimetre), by the apparatus and the method according to the present invention. The results are shown in
figure 5 . As can be clearly seen, the substrate hardness has not been considerably altered unlike the clear decay of the hardness found with the prior art (seefigure 4 ). - Moreover, it has been noted that thanks to the metallization obtained according to the present invention, also the fatigue resistance of the components thus coated is greatly increased, with special reference to light alloy components.
- To prove what stated, experimental tests have been carried out using specimens of alloy 6082 at state T6, with rectangular section of about 180x15x8 mm, subject to bending fatigue on four points. The thickness of the application is about 1/10 of millimetre, and the application has been made on one face only of the specimens.
- The fatigue tests gave the results shown in the following table:
Specimen not coated Specimen coated σFAf=152+/-18 MPa σFAf=319+/-29 MPa - By σFAF it is meant the limit of alternating bending fatigue, that is, the strain below which the fatigue breakage for an alternating bending stress does not occur. Moreover, the execution of the application on hollow specimens of the same alloy was experimented, having a 32 millimetre diameter with a substrate thickness of 1.1 millimetres.
- Also in this case, the application thickness was of about 0.1 millimetres. The fatigue test results, with the same load applied, are as follows:
Specimen not coated Specimen coated n. of break cycles 20,000-25,000 n. of break cycles 625,000-640,000 - Therefore it has been noticed that the coatings made on light alloys according to the present invention considerably increase (up to more than 20 times) the number of loading cycles that lead to fatigue breakage.
- A man skilled in the art may make several changes and adjustments to the methods described above in order to meet specific and incidental needs, all falling within the scope of protection defined in the following claims.
Claims (4)
- Metallization method of a metal component in a light alloy, comprising the steps of:- providing deposition means (12) of a metal layer on a component (8),- addressing, by said deposition means (12), a flow of metal material (40) on a first surface (20) of a wall to be coated (16) of the metal component (8)wherein
during the deposition of the metallization flow (40) on the first surface (20) it comprises the step of addressing a flow of coolant, by a cooling head (24), on a second surface (28) of the wall to be coated (16), opposite said first surface (20) and not impinged by the metallization flow (40),
characterised in that
the cooling fluid is delivered by the cooling head (24) comprising a delivery duct (44), in fluid connection to a cooling fluid circuit (48), said delivery duct (44) being provided with a plurality of delivery holes (52) for the dispersion of coolant on said second surface (28) of the wall to be coated (16), said holes (52) being equally spaced along a prevailing extension axis X of the delivery duct (44), the method further comprising the step of rotating said component (8) relative to a working axis during the metallization and cooling step, wherein said working axis coincides with a prevailing extension axis (X) of the cooling head (24), the component rotating relative to the cooling head,
and wherein said deposition means comprise a metallization gun (29) suitable for realising a supersonic jet of metal particles to be addressed towards the wall to be metallized. - Metallization method of a metal component according to claim 1, comprising the steps of providing a collecting duct (56) for collecting the coolant after it has contacted the wall (16) and conveying said fluid away from said cooling head (24).
- Metallization method of a metal component according to claim 2, comprising the steps of:providing recirculation means of the coolant suitable for conveying the coolant coming from the collecting duct (56) in a heat exchanger (60), for decreasing the temperature of the coolant and sending the fluid thus cooled in said delivery duct (44).
- Metallization method of a metal component according to any one of claims 1 to 3, comprising the steps of providing, on an outer portion (64) of the collecting duct (56), sealing means (68), suitable for realising a seal between the head (24) and said wall (16) of the component (8) so as to convey all the coolant into the collecting duct (56), after the fluid has contacted the second surface (28) of the component (8).
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
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IT000201A ITBS20060201A1 (en) | 2006-11-22 | 2006-11-22 | METALIZATION SYSTEM FOR METALLIC COMPONENTS AND ITS METALIZATION METHOD |
Publications (3)
Publication Number | Publication Date |
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EP1925688A2 EP1925688A2 (en) | 2008-05-28 |
EP1925688A3 EP1925688A3 (en) | 2011-03-09 |
EP1925688B1 true EP1925688B1 (en) | 2017-03-01 |
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EP07119585.3A Active EP1925688B1 (en) | 2006-11-22 | 2007-10-30 | Metallization method |
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IT (1) | ITBS20060201A1 (en) |
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FR2224991A5 (en) * | 1973-04-05 | 1974-10-31 | France Etat | |
DE68908057T2 (en) * | 1988-09-14 | 1993-11-18 | Hitachi Chemical Co Ltd | Process for producing a metallic strip coated with flame-sprayed ceramic. |
JP2681302B2 (en) * | 1990-02-13 | 1997-11-26 | 株式会社オティックス | Method and apparatus for thermal spraying of direct hit type valve lifter |
US5436426A (en) * | 1993-04-19 | 1995-07-25 | Sulzer Metco (Us), Inc. | Fixture and method for cooling tubular substrate during thermal spraying |
FR2770156B1 (en) * | 1997-10-27 | 1999-12-24 | Rosenmund Ag | METHOD AND DEVICE FOR MAKING A SLEEPING BAR USABLE IN THE PAPER INDUSTRY |
US6305459B1 (en) * | 1999-08-09 | 2001-10-23 | Ford Global Technologies, Inc. | Method of making spray-formed articles using a polymeric mandrel |
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EP1925688A2 (en) | 2008-05-28 |
EP1925688A3 (en) | 2011-03-09 |
ITBS20060201A1 (en) | 2008-05-23 |
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