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| Abstract No.: |
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Scheduled at:
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Wednesday, May 04, 2022, Hall G2 11:10 AM
Arc Spraying
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| Title: |
Influence of process parameters on overall costs of surfaces coated by wire-arc spraying
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| Authors: |
Martin Andreas Knoch* / Plasmatic Franken GmbH, Germany
Roland Wolf / W. Wolf GmbH, Germany
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| Abstract: |
Surface treatments and coatings are widely used to protect components from wear and corrosion. Of all available methods, thermal spraying is arguably the most versatile with regard to coating material and morphology. Surface roughness and porosity can be adjusted in a wide range depending on the requirements. However, as-sprayed coating surfaces inevitably exhibit a certain roughness necessitating post-treatment if a smooth surface is required.
The surface roughness of thermal spray coatings is usually determined by the used powder fraction and the particles’ melting degree. Using wires as feedstock material allows for a certain influence on the particle size distribution by adjusting process parameters. In this study, the influence of nozzle geometry and atomizing gas pressure on coating quality, surface roughness, deposition efficiency and cost-efficient post-treatments of wire-arc sprayed Fe- and Ni-based alloys with a wide hardness-range is investigated. To allow for easy transfer to real components, sample geometry and coating thicknesses are based on real world examples of coatings for new components and repair of worn parts. Using adapted process parameters and air-flow, the surface roughness could be adjusted to the target application and post-treatment respectively. Especially in repair coatings for large area applications requiring a smooth surface finish, significant runtime and cost reductions are feasible.
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