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Method for coating a substrate

a substrate and coating technology, applied in the direction of coating, molten spray coating, metal material coating process, etc., can solve the problems of unfavorable surface finish, unfavorable surface finish, and high pretreatment cos

Inactive Publication Date: 2014-11-13
GEORG FISCHER AUTOMOTIVE SUZHOU +2
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The invention provides a method for coating a substrate using thermal spraying with a simple and cost-effective pretreatment process. The surface of the substrate is pretreated without material deposition and then a process beam is generated to coat the surface. This method requires only one plasma spray device and minimizes contamination of the surface. It is particularly advantageous when the time span between the pretreatment and the application of the same region with the process beam is at most five or one minute, respectively.

Problems solved by technology

As a rule the pretreatment is very demanding in time and also requires special substances, such as corundum, sand or, for example, high pressure water beams.
An additional problem results therefrom that for many activation methods, for example, on corundum blasting, additional cleaning steps or drying steps are necessary before the thermal spraying can begin.
Furthermore, despite careful cleaning it can happen that sand particles or corundum particles remain at the surface and remain in the layer on the subsequent coating thereof.
Such foreign bodies can later lead to undesired formations of cracks which could have serious consequences, for example, in the case of coated hip joint prosthesis.
However, even when no corundum particles remain at the surface, the surface roughness, in particular of high strength substances, generated by means of the roughening process can lead to the formation of fatigue cracks.

Method used

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Examples

Experimental program
Comparison scheme
Effect test

example 1

[0058]The pretreatment took place with the following plasma parameters:

[0059]Current: 400 A

[0060]Process gas: argon 60 SLPM (standard liters per minute), hydrogen 5 SPLM, nitrogen 4 SPLM.

[0061]Spacing D between the plasma spray device 3 and the surface to be coated: 30 mm

[0062]Number of repetitions: 3

[0063]Thereafter a bond layer of the nickel-based alloy Diamalloy 4008NS of Sulzer Metco AG (Switzerland) is initially applied at a spacing D of 30 mm and a layer of a low alloy steel, to which 30 wt.-% molybdenum is admixed, is applied thereon as a cover layer at a spacing of 45 mm in a manner known per se. In this connection the steel and the molybdenum are not present as an alloy in the starting material as a powder mixture. The thereby generated coating shows a very good adhesion.

example 2

[0064]The pretreatment took place with the following plasma parameters:

[0065]Current: 410 A

[0066]Process gas: argon 60 SLPM (standard liters per minute), hydrogen 5 SPLM, nitrogen 4 SPLM.

[0067]Additionally a cover gas for covering the plasma flame with 16 SLPM is used.

[0068]Spacing D between the plasma spray device 3 and the surface to be coated: 45 mm

[0069]Number of repetitions: 3

[0070]In this example no bond layer is applied, but rather a layer of the material F4301 of Sulzer Metco AG (Switzerland) is directly applied at a spacing of 45 mm as a cover layer in a manner known per se onto the surface pretreated with the plasma flame.

[0071]The thereby generated coating shows a very good adhesion.

example 3

[0072]The pretreatment took place with the following plasma parameters:

[0073]Current: 550 A

[0074]Process gas: argon 60 SLPM (standard liters per minute), hydrogen 6 SPLM, nitrogen 4 SPLM.

[0075]Additionally a cover gas for covering the plasma flame with 16 SLPM is used.

[0076]Spacing D between the plasma spray device 3 and the surface to be coated: 45 mm

[0077]Number of repetitions: 3

[0078]In this example no bond layer is applied, but rather a layer of the material F2071 of the Sulzer Metco AG (Switzerland) is subsequently directly applied in a manner known per se as a cover layer at a distance of 45 mm onto the surface pretreated with the plasma flame. This material is a metal matrix compound material having a mixture of 65 wt.-% of a corrosion-resistant steel and 35 wt.-% of a ceramic, for example, Al2O3 / ZrO2 at a ratio of 80 to 20.

[0079]The thereby generated layer shows a very good adhesion.

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Abstract

A method of coating a substrate is proposed, in which a starting material in the form of a process beam is sprayed onto a surface of the substrate by means of thermal spraying, wherein the surface of the substrate is initially pretreated with a plasma flame of a plasma spray device without material deposition and the process beam including the starting material is subsequently applied onto the surface.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS[0001]This application is a National Stage of International Application No. PCT / EP2012 / 074594, filed on Dec. 6, 2012, and published in German as WO / 2013 / 083671 A1 on Jun. 13, 2013. This application claims the benefit and priority of European Application Nos. 11192846.1, filed on Dec. 9, 2011 and 12168281.9, filed on May 16, 2012. The entire disclosures of the above applications are incorporated herein by reference.BACKGROUND[0002]This section provides background information related to the present disclosure which is not necessarily prior art.[0003]1. Technical Field[0004]The invention relates to a method of coating a substrate.[0005]2. Discussion[0006]Nowadays, thermal spray methods are frequently used for the coating of substrates, such as, for example, plasma spraying; high velocity flame spraying (HVOF), light arc spraying and / or light arc wire spraying.[0007]Layers are generated on a substrate using these methods, wherein the substrate is, ...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C23C4/12C23C4/02C23C4/06
CPCC23C4/127C23C4/06C23C4/02C23C4/134
Inventor ERNST, PETERWIPF, JUERGLOEHKEN, THOMAS
Owner GEORG FISCHER AUTOMOTIVE SUZHOU