eGun Technology Presentation ITSC-16 (2)

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May 2016M.P. Zwetsloot

Ethanol-fueled HVOFITSC, Shanghai China, May 2016

ADDED VALUE THROUGH KNOW -HOW Systems Consumables Services www.fst.n l

Ethanol Fuel of the Future

“The fuel of the future is going to come from fruit or from

apples, weeds, sawdust – almost anything,”

– Henry Ford, Ford Motor Company, 1925

2015 United Nations Climate Change Conference, Paris

• set a goal of limiting global warming to less than 2

degrees Celsius (°C)

• calls for zero net anthropogenic greenhouse gas

emissions to be reached during the second half of the

21st century


Ethanol as a fuel choice

Cost:

Ethanol and Kerosene costs

are comparable. Less oxygen required. Less cooling required. Overalloperating costs are lower.

Widely Available:

Ethanol is produced around the world and easily available

Consistency:

Ethanol is a very consistent fuel providing repeatable & reproducible coating (C2H5OH)

No Ash Formation:

There is no contamination of a coating by carbon, even if fuel rich mixtures are used


Environmentally friendly:

Sustainable fuel life-cycle

100% natural product

Carbon neutral

30% less toxic emissions than a petroleum based fuel.

The cleaner HVOF liquid fuel alternative



Safety:

Ethanol is a relatively safe fuel

Ethanol is approved as an indoor table burner, heating or cooking stove fuel

Less toxic fumes and particulate matter

Legislation

Local Laws do apply since ethanol is alcohol.



eGun – fuel power variation

*The power is estimated based on the full and ideal, stoichiometric combustion process. Conditions in the combustion chamber are not taken into account anyhow. The enthalpy of combustion if calculated for liquid organic compound(s) and gaseous products of reaction.

Mixture Energy / liter Power of flame (20L/h)

Unit MJ/L kW

CDA (UK,) 19.91 110

Cargill at (95%et.) 20.09 111

Pure ethanol (100%) 20.38 113

E95 (95%, 5%gasoline) 20.89 116

E85 (85%, 15%gasoline) 21.96 122

Ethanol + 5%wt. of water 19.36 107

Kerosene - C12H26 - C18H38 35.57 197


More efficient combustion - smaller chamber - less cooling power required

Optimized Combustion


Typical parameters

WC-Co-Cr 86/10/4 Cr3C2-NiCr 75/25

Kerosene Ethanol Kerosene Ethanol

Oxygen 1050 l/min 530 l/min 800 l/min 480 l/min

Fuel 24 l/h 28 l/h 21 l/h 23 l/h

Combustion chamber pressure 8 bar 11 bar 7 bar 11 bar

Cooling capacity 80-90 kW 25-30 kW 80-90 kW 25-30 kW

Average particle velocity 650-750 m/sec 750-850 m/sec 630-720 m/sec 810-860 m/sec


eGun™ results

Cr2C3-NiCr 75/25 Alloy 625 NiCrBSi 60HRc

WC-NiMoCrFeCo Tribaloy 400 Alloy 6


Operating Window:

Ethanol allows combustion mixtures

that are oxygen rich or neutral as

well as fuel rich, this significantly

increasing the operating window in

comparison with kerosene, creating

new advanced coatings opportunities.

Oxygen Flow Rate

Fuel rich

Oxygen rich



The eGun™ torch design operates a high combustion

chamber pressures resulting in higher particle velocities.

Ethanol HVOF

9 bar = 150kw 27kw to water



Kerosene HVOF

8 bar = 280kw 70/90kw to water

(Depending on Barrel Length)

Chamber Pressure

Fla

me V

elo

cit

yHigher Pressure

=

Higher Velocity

Operating window ethanol vs. kerosene


eGun™ flame studies

Higher combustion chamber pressures, higher particle

velocities

At 13 bar combustion chamber pressure, average particle

velocity for WC/CoCr -45+15µm of >800m/s


Positioning the eGun™


Process Characterisation

Design of Experiment:

- Injection optimisation (6 – 12 NLPM)

- Spray distance optimisation (200 – 500mm)

- Spray parameters optimisation:- λ – stoichiometry

- (1.2 - oxy rich, 1 - stoichiometric, 0.8 fuel rich)

- Mass flow fuel + oxygen mixture- 16 g/sec, 17.5 g/sec (nozzle optimum), 19 g/sec

- Deposition Efficiency Test


eGun™: WC-CoCr (-30/+5µ) spray distance

200mm 250mm 300mm

350mm 400mm 450mm

Spray distance optimisation (λ = 1, Mass flow – 17.5 g/s), magnification x100

D=245μm

Porosity=<0.5%

HV0.3=1398

HV0.3std.dev.=62

D=260μm

Porosity=<0.5%

HV0.3=1412

HV0.3std.dev.=47

D=290μm

Porosity=<0.5%

HV0.3=1332

HV0.3std.dev.=97

D=319μm

Porosity=<0.5%

HV0.3=1177

HV0.3std.dev.=80

D=357μm

Porosity=0.8%

HV0.3=1073

HV0.3std.dev.=116

D=369μm

Porosity=4.5%

HV0.3=913

HV0.3std.dev.=160

Po

wd

er

Fe

ed

ra

te: 7

5 g

r/m

in


eGun™: Scan Window

400

420

440

460

480

500

520

540

560

580

600

20 22 24 26 28 30 32 34 36 38 40

Oxyg

en

flo

w (

st.

L/m

in)

Ethanol flow (L/h)

Design nozzle parameters


400

420

440

460

480

500

520

540

560

580

600

20 22 24 26 28 30 32 34 36 38 40

Oxyg

en

flo

w (

st.

L/m

in)

Ethanol flow (L/h)

Design nozzle parameters



400

420

440

460

480

500

520

540

560

580

600

20 22 24 26 28 30 32 34 36 38 40

Oxyg

en

flo

w (

st.

L/m

in)

Ethanol flow (L/h)



eGun™: WC-CoCr (-30/+5µ)

Mass Flow

Oxy

rich

Fuel

rich

Fuel-Oxy

Stoichiom

etry

D=432μm

Porosity=0.45%

HV0.3=1035

HV0.3std.dev.=86

D=400μm

Porosity=0.53%

HV0.3=1075

HV0.3std.dev.=96

D=344μm

Porosity=0.18%

HV0.3=1194

HV0.3std.dev.=94

D=331μm

Porosity=0.25%

HV0.3=1134

HV0.3std.dev.=61

D=323μm

Porosity=0.15%

HV0.3=1261

HV0.3std.dev.=106

D=304μm

Porosity=0.09%

HV0.3=1193

HV0.3std.dev.=125

D=293μm

Porosity=0.10%

HV0.3=1261

HV0.3std.dev.=89

D=291μm

Porosity=0.07%

HV0.3=1368

HV0.3std.dev.=53

Po

wd

er

Fe

ed

ra

te: 7

5 g

r/m

in

D=316μm

Porosity=0.15%

HV0.3=1201

HV0.3std.dev.=149


Mass flow (g/s)

La

mb

da

(-)

19.018.518.017.517.016.516.0

1.2

1.1

1.0

0.9

0.8

>

–

–

–

–

–

–

–

–

<

1360

1040

1040 1080

1080 1120

1120 1160

1160 1200

1200 1240

1240 1280

1280 1320

1320 1360

HV

Harness HV0.3 vs lambda, mass flow

Mass flow (g/s)

La

mb

da

(-)

19.017.516.0

1.2

1.0

0.8

>

–

–

–

–

–

–

–

–

<

0.50

0.10

0.10 0.15

0.15 0.20

0.20 0.25

0.25 0.30

0.30 0.35

0.35 0.40

0.40 0.45

0.45 0.50

Porosity

Porosity vs lambda, mass flow

Mass flow (g/s)

La

mb

da

(-)

19.017.516.0

1.2

1.0

0.8

>

–

–

–

–

< 10

10 11

11 12

12 13

13 14

14

thick-pass

Thickness per pass vs lambda, mass flowFeature Value Unit

2D-Porosity <0.5 %

Hardness 1100-1350 HV0.3

Hard. STDDEV 34 - 50 HV0.3

Tensile strength >85 MPa

Ra 3.1 μm

DE 48 % (weight)




SAMPLE# GUNWEIGHT

LOSS

AVERAGE

LOSS

STANDARD

DEVIATION

STANDARD

DEVIATION

- - g g g %

16-032-1-1 eGun 0.216

16-032-1-2 eGun 0.233

16-032-1-3 eGun 0.213

16-032-2-1 eGun 0.245

16-032-2-2 eGun 0.236

16-032-2-3 eGun 0.237

16-032-3-1 eGun 0.164

16-032-3-2 eGun 0.327

16-032-3-3 eGun 0.316

16-033-1-0 JP5000 0.467

16-033-2-0 JP5000 0.461

16-033-3-0 JP5000 0.497

4.9

2.1

2.4

4.1

0.221

0.239

0.322

0.475

0.011

0.005

0.008

0.019

Rubber Wheel Test (ASTM G65)For comparison only – Abrasive material used Al2O3

JP-5000® is a trademark of Praxair


Feature Value Unit

2D-Porosity <1 %


Hard. STDDEV 95 - 130 HV0.3

Tensile strength - MPa

Ra 5.9 μm

DE 52 % (weight)

Feed Rate 75 Gr/min



eGun™: Cr3C2-NiCr 75/25, -30/+5µ

Feature Value Unit

Trade name Amperit 588.059 -

Chemistry Cr3C2-NiCr -

Grain size 30/5 μm

2D-Porosity <1 %


Tensile strength >85 Mpa

Ra 3.1 μm

DE 44 % (weight)

Powder Feed rate 75 Gr/min


Feature Value Unit


Chemistry Cr3C2-NiCr -

Grain size 45/15 μm

2D-Porosity <2 %



Ra 5-6 μm

DE 33 % (weight)

Powder feed rate 75 Gr/min

eGun™: Cr3C2-NiCr 75/25, -45/+15µ


Feature Value Unit


Chemistry NiCrAlY -


2D-Porosity <0.5% %


Ra 6.9 μm

DE 55 % (weight)

Powder Feed Rate 75 Gr/min

eGun™: NiCrAlY, -45+22µ


200mm 250mm 300mm 350mm

400mm 450mm

D=650μm

Porosity<0.1%

HV0.3=572

HV0.3std.dev.=48

D=588μm

Porosity<0.1%

HV0.3=504

HV0.3std.dev.=46

D=621μm

Porosity<0.1%

HV0.3=495

HV0.3std.dev.=25

D=658μm

Porosity<0.1%

HV0.3=487

HV0.3std.dev.=24

D=670μm

Porosity<0.1%

HV0.3=437

HV0.3std.dev.=38

D=661μm

Porosity=0.1%

HV0.3=405

HV0.3std.dev.=49

eGun™: NiCoCrAlReY, -45+22µ

Powder Feed rate: 75 gr/min


16 17.5 19

08

1.0

1.2

D=574μm

Porosity=0.2%

HV0.3=649

HV0.3std.dev.=33

D=597μm

Porosity<0.1%

HV0.3=637

HV0.3std.dev.=39

D=515μm

Porosity<0.1%

HV0.3=677

HV0.3std.dev.=64

D=622μm

Porosity=0.3%

HV0.3=537

HV0.3std.dev.=38

D=661μm

Porosity=0.1%

HV0.3=405

HV0.3std.dev.=49

D=523μm

Porosity<0.1%

HV0.3=582

HV0.3std.dev.=34

D=671μm

Porosity=0.1%

HV0.3=491

HV0.3std.dev.=24

D=601μm

Porosity=0.1%

HV0.3=510

HV0.3std.dev.=40

D=559μm

Porosity=0.1%

HV0.3=534

HV0.3std.dev.=27


Po

wd

er

Fe

ed

ra

te: 7

5 g

r/m

in



Feature Value Unit

Trade name Amperit 429 -

Chemistry NiCoCrAlReY -


2D-Porosity <0,5 %



Ra 7.0 μm

DE 52 % (weight)

Mass flow rate (g/s)

La

mb

da

(-)

19.017.516.0

1.2

1.0

0.8

>

–

–

–

–

–

< 17

17 18

18 19

19 20

20 21

21 22

22

Thick-pass

Thickness per pass vs lambda and mass flow

Mass flow rate (g/s)

La

mb

da

(-)

19.017.516.0

1.2

1.0

0.8

>

–

–

–

–

< 0.05

0.05 0.10

0.10 0.15

0.15 0.20

0.20 0.25

0.25

Porosity

Porosity vs lambda and mass flow


eGun™: Triballoy 400, -45+10µ

Feature Value Unit

Trade name T400 -

Chemistry CoCrMo -

Grain size -45/10 μm

2D-Porosity <1 %

Hardness 700 HV0.3

Ra 6 Μm

Powder feed rate 75 Gr/min


eGun™: Triballoy 800, -45/10µ

Feature Value Unit

Trade name T800 -

Chemistry CoMoCr -


2D-Porosity <1 %


Ra 5.8 μm


eGun™: Stellite 6, -45/+20µ

Feature Value Unit

Trade name M484.24 -

Chemistry CoCrWSi -


2D-Porosity <0.5 %

Hardness 600 HV0.3


Ra ~7.7 μm

DE 66 % (weight)

Powder Feed Rate 75 Gr/min


eGun™ : WC-Co 83/17, -45+15µ

Feature Value Unit

Trade name Amperit 526 -

Chemistry WC-Co -


2D-Porosity ~1% %


Ra 4.6 Μm

Powder Feed Rate 75 g/min


eGun™: Alloy625, 53/+20µ

Feature Value Unit

Trade name M-325.33 -

Chemistry NiCrMoNbFe -


2D-Porosity 0.5 %

Hardness 500 HV0.3

Ra 8.9 μm


eGun™ - Life of hardware

Requires long term spray testing

Dependent on sprayed materials (metals, carbides etc)

Requires correlation of wear with deterioration of coating

properties to establish replacement criteria

So far it’s has been only performed as qualitative analysis,

but lifetime of parts such as barrel and combustion chamber

appear to similar to parts of the JP-5000 Torch


eGun™: Conclusions

• Excellent microstructure achievable from wide process operation

window (Tolerant process)

• Consistent coating quality (Low Standard Deviation)

• Coating properties can be customised according to customer need

(hardness & porosity)

• For carbides we see results similar to the HVAF process when

using finer grades of powder. Thus coating quality ranging from

HVOF to HVAF.

• Flexible process – allows for more oxy - fuel variation for further

process development possibilities

• Promising DE results

• Excellent bond strength of

coatings, especially for metallics


Already over 25 systems sold

Some first feedback

Operators love to work with the eGun™

Softer, more consistent starts

Easy to maintain

Cleaner gun parts

No smelly kerosene spills

Smaller and lighter torch

Less heat impact on parts

Excellent target efficiency

Lower extraction requirements than other LF systems


&

In addition to controlling the eGun™,

the system is also capable of operating

kerosene HVOF torches.

Ethanol HVOF technology will be introduced as the

eGun™ and will operate on the HV-50 or MP-50.

The HV-50 System


eGun™ example application

M-484.24 Alloy 6 CoCrWSi - Coating thickness 1,2 mm

ADDED VALUE THROUGH KNOW -HOW Systems Consumables Services www.fst.n lADDED VALUE THROUGH KNOW -HOW Systems Consumables Services www.fst.n l

May 2016M.P. Zwetsloot

Thank you for your attention

Please visit us at our booth for more information

eGun Technology Presentation ITSC-16 (2)

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Transcript of eGun Technology Presentation ITSC-16 (2)