Fully readable thermal spray coating
A thermal spraying, coating technology, applied in the direction of coating, metal material coating process, layered products, etc., can solve problems such as loss of readability
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Embodiment 1
[0169] Extensive experiments were performed to quantify the effect of oxidation on the difference between the chemical composition of the feedstock and the coating chemical composition of the coating produced by the twin-wire arc spray process. The purpose of this experiment was to determine the oxygen content to be used in modeling of future alloys discovered in this disclosure. The three alloys sprayed by the twin-wire arc spraying process in this example are listed according to the chemical composition of the raw materials in Table 5 below. In addition to the X3 alloy described above, alloys E1-E3, which are known and unreadable thermal spray alloys, were also sprayed. Table 5: List of Feedstock Chemical Compositions Provided in Example 1, Used to Develop Oxidation Modes Employed in Design Methods Used in This Disclosure
[0170] alloy
Al
Cr
mn
Mo
Nb
Si
Ti
V
W
E1
2
0
5
13
0
10
0
0
0
E2
0
...
Embodiment 2
[0181] In order to qualify the adhesive properties, the following tests were performed.
[0182] Both alloys X3 and X4 discussed above were tested. A sample is placed on a fixed fixture and a robotic arm with a spray gun is rastered across the sample, allowing a controlled coating thickness to be built. To quantify the effect of coating angle, samples were held at 90°, 60° and 45° angles to the spray direction. In addition, samples were sprayed at different spray distances of 6" and 9". The purpose of the spray tests is to gauge the potential of these alloys to adhere effectively to substrates under a variety of plausible spray conditions. The substrates were 3" x 3" x 1 / 4" steel coupons and were blasted to a minimum 2.5 mil blast profile. The samples were sprayed with the following spray parameters, referred to herein as "Spray Parameter 1"
[0183] ·TAFA 8830 Blue Air Cap
[0184] 60psi
[0185] 32V
[0186] 250 amps
[0187] Each alloy was sprayed to a target 20 mil ...
Embodiment 3
[0193] In order to qualify X3 and X4 for use as twin wire arc spray products, deposition efficiency was measured. Deposition efficiency is a measure of how much material by weight is attached to the substrate divided by how much material is sprayed by weight. Sufficiently high deposition efficiencies, typically >60% (or >about 60%), are advantageous for use. In this experiment, alloys X3 and X4 were spray coated onto a 12" x 12" rotating steel plate. Hold the spray gun stationary in such a way that the entire spray pattern intersects the steel plate. The weight of the wire used and the weight of the coating accumulated on the plate was measured for each material to determine deposition efficiency. The X3 measured deposition efficiencies of 64% and 67% in two measurements. The deposition efficiency of the X4 was measured at 70%, 71% and 76% in three measurements.
[0194] Similar deposition efficiency tests were performed using the X11 alloy. The deposition efficiency was ...
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