A Sauer Engineering Training Overview 2011

8/6/2019 A Sauer Engineering Training Overview 2011

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Thermal Spray Training

Sample Outline

2011

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Introduction Sauer Engineering

o n . auer . .

Principal Consultant and Trainer

20 yrs in Thermal Spray

20 yrs in Coating Evaluation In conjunction with

12 years in Coating Processing

abs on the spray floor

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Philosophy

Hands-on training in the booth

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Time Schedule

2 days of hands-on (two sessions)

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Goals

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General theory of Thermal Spray (TS) Low velocity combustion

Plasma

Wire

Other

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OutlineGrit Blast and Cleaning Equipment

Cleanin

How? With what?

What type?

Air pressure control Grit size

Control of grit

er ng Surface roughness

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Outline

General Overall Design

Different types of gases-combinations any eren gun es gns

Control of process

erent types o n ect on Powder delivery

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Hands-onSystem Maintenance HVOF Gun

HVOF Gun Console Powder Feeder

Rebuilding of gun and when to rebuild

Rebuilding of Powder Feeder Hopper and when to rebuild ar e equ pment system ssues t at can ar se

Powder feeder issues

Spark Igniter and Flame Out Detector

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OutlineProcess Control

Temperature control and monitoring

Placement and calibration of IR

Types of assisting equipment that can be used in conjunction

with spray equipment: such as Accuraspray.

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OutlineTest Pieces What types of test pieces are used?

Tensile buttons Metallography

Almen

Bend ny spec a xtures o ers

Part and coupon sample preparation

What do they do?

Methods of measurements

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OutlineCooling

What type Cooling method is used, (Shop Compressed Air,CO2, Liquid Nitrogen)?

P acement of coo ing air or system

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OutlineMasking of Parts Ta es/com ounds/hard metal/shadow

Are any Spray Tapes used to mask parts? Is Shadow Masking used?

Is Hard Masking used?

Is Rubber used? Are any Putty Type masks used?

Current methods

Tapes

Mac-Block

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Putties


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OutlineHVOF History and Theory Why use HVOF now?

Why are we using HVOF vs. Plasma?

How is it the same?

How is it different?

Critical Issues with HVOF

Residual stress

Almen

Fatigue

Temperature measurement

Different types of guns/systems

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OutlineSpray Booths What type of manipulation equipment is used, (Robot or

Gantry)? Turntable and traverse speed calculations

Degrees of free om on ro ot

Make-up air and flow

Are temperature measuring devices used, (Manufacturer and

Model)?

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OutlineSpray Equipment

a ype equ pmen s e ng use

Type of console

Special parts caps, etc

Feeder T e?

Special parts hoses, etc

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OutlineSpray Equipment (contd) What Type Fuel Gas is used, (Hydrogen, Natural Gas,

Propane, Propylene, Ethylene, Kerosene, Argon, Helium)?

How is it stored?

F ow issues??

What is the Carrier Gas, (Nitrogen or Argon)?

Flow issues??

Com ressed air

How is it generated?

Flow issues??

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OutlineSpray Equipment (contd)

Is Gun hand held or machine mounted?

Rebuild guns?

Rebuild owder ho er?

Equipment calibration-flow meters

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OutlineParts that are Sprayed What t es of arts are bein s ra ed?

What are the substrates of the parts? What size are the parts?

What is the geometry of the parts, (round, flat, complex

shapes)? o t ese parts o a ot o eat

How are parts prepped for spray, (cleaning, masking, grit

blastin ?

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Hands-onDemonstration using equipment to show

Vary parameters

Air flow

Combustion gas

Stoichiometric ratio Powder feed rate

Spray distance

erent pow er ots an manu acturers

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Hands-onDemonstration using equipment to show Troubleshootin console

Troubleshooting and rebuilding of gun Troubleshooting and rebuilding of powder feeder

With a generic part, how to:

Clean r as

Mask

Spraying generic part and test samples with cooling set-up

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Hands-onPart Processing Hands-on A proto-type part should be used during the training as a guide

to demo the process of qualifying a product part using the

Plasma/HVOF process.

Grit blasting of part and coupon

Masking Techniques - Hard Masking, Tapes and other types of

masking material that could be used.

De-masking techniques Trail runs and set-ups with coupon preparation, spray, temp

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,


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Schedule

Da 3

Morning Process Control

Plasma Booth Hands-on

Afternoon

Process Control Hands-on

Maintenance

Wrap-up Session

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Schedule-Hands-on

Morning Mask Cool

Morning HVOF Gun Re-build

Mask Cool Hands-on

Afternoon

Powder Hopper Re-build

Afternoon

HVOF Systems

Q and A Session

-

Facility Problems

Wrap up session

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IMR Back round

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Course Goals

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Course Schedule

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The Plasma Process

2011

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Acknowledgments

Praxair TAFA

NRC

Wikipedia Marcel VanWonderen

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Plasma Process

Create a plasma

Different types of gases-combinations

Many different gun designs Control of process

Powder delivery

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-

blasting, cooling, robotics,traverse speeds, etc.)

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Simply Put

Select powder delivery and injection systems

Apply a high DC voltage to

Anode or nozzle Cathode or electrode

Regulate power and current

Plastifies/Melts and accelerate powder

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What is plasma?

What is plasma?

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Plasma Plasma is often referred to as the fourth state of

matter. Plasma, like the other three states of matter

(Solid, Liquid and Gas) has its own unique properties.

Just as most materials it will become solid if cooled

enough, any substance will become a plasma if heated

enough.

In a plasma the electrons are stripped from the atoms

creating a substance that resembles a gas but that

.

earth in flames, electrical discharges, lightning bolts,

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.


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Plasma

,

discharge from a high frequency arc startery - o e g ses e c u y o ze

Remainder concentrates plasma plume andprotects t e wa o t e nozz e ore aga nst

wear

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Gun Theory

Cathode orElectrode

Anode orNozzle

Coolin channels Gas distribution ring

What does each part accomplish??

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Gun Theory

Water cooled

Usually thoriatedBetter pics

Consumable

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Electrode

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Gun Theory

Location where shape and velocity of plume is

e e m e

Diameter of hole

Shape or configuration

With Accuraspray results, showing the influence

o erent nozz es on ve oc ty

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Gun Theory

What do we want?? eat trans er

Size/shape of plume

Velocity??

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Gun Theory

Simply insulates the cathode-electrode from the-

Sometimes serves as both the insulator and gas

distribution mechanism

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Gun Theory

Number of holes

Diameter of holes

e a e o gas s ze an

energy/velocity desired

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The HVOF Process

General

2011

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Acknowledgments

Praxair TAFA

Stellite

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HVOF History and Theory Why use HVOF now?

Why are we using HVOF (D-Gun) vs. plasma? How is it the same?

How is it different?

Critical Issues with HVOF

Residual stress

Almen

Fatigue

Temperature measurement

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HVOF


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HVOF

A. Papyrin et al.

Advanced Materials & Processes /September 2001 p.49

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HVOF


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HVOF

HVOF is now capturing a bigger part of the

With HVOFs lower heat input and less,

fatigue critical applications where plasma was

Can obtain compressive residual stresses and a

ense m cros ruc ure w en compare o ens eresidual stress with plasma

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C A li ti


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Common Applications

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HVOF


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HVOF

D-Gun or detonation gun was really first on

VERY VERY Proprietary Process by Praxair

Praxair exploited the market for many years,

only performing the process at THEIR shops

Evolution of HVOF has hurt that market

Can obtain similar ro erties

Many specs use HVOF-D-Gun interchangably

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D G


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D-Gun

Claim 760 m/s

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S per D G n


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Super D-Gun

Claim 900 m/s

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D Gun or Super D Gun


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D-Gun or Super D-Gun

accelerates the powderocess s e e e m y mes e seco

Nitrogen gas is used to purge the barrel after

eac etonat on

Like a rapid fire spark plug and machine gun

sound

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HVOF vs D Gun


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HVOF vs. D-Gun

HVOF not proprietary

HVOF vs. D-Gun can obtain similar properties

really needs Super D-Gun velocities in many

Anybody can buy an HVOF system and

eve op coa ngs an process specs

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HVOF vs Plasma


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HVOF vs. Plasma

important so we try to melt the powder with

HVOF is a process that depends more on

hammer

ume n smuc sma er

t an p asma

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HVOF vs Plasma


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HVOF vs. Plasma

Can we use the same powders for.

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HVOF vs Plasma


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HVOF vs. Plasma

balls to marbles, how will we be able to make

Need to cut off the high and low end of the

work in HVOF systems

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HVOF vs Plasma


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HVOF vs. Plasma

What are the normal QC tests we use for a

Normal QC tests

Hardness (Macro and/or Micro)

Tensile Bend?

Erosion?

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HVOF vs Plasma


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HVOF vs. Plasma

What is special about qualification of the

There are two major differences

Residual stress for fatigue

Almen (deposition rate similarity)

IR Tem erature Control

Bend testing

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HVOF vs Plasma


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HVOF vs. Plasma

You can spray HVOF with very different parameter, ,

tensile

The residual stress and subse uentl the fati uewill be VERY DIFFERENT!!

Coolin can make a tremendous difference!!

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Fatigue Bars


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Fatigue Bars

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A Typical HVOF System


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A Typical HVOF System

good

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Specific HVOF System


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Spec c VO Syste

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HVOF Systems


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y

Jetkote

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HVOF Systems


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y

Varied HVOF Guns

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Different Systems


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y

DJ System from Sulzer Metco Jetkote from Stellite

Liquid JP 5000-8000 from Praxair-TAFA

-

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A Sauer Engineering Training Overview 2011

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