TECHNISCH SEMINARIE METAALSECTOR. Gent 27 maart 2015

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1 TECHNISCH SEMINARIE METAALSECTOR Gent 27 maart 2015

2 THERMISHE PROJECTIE: HIGH-TECH BESCHERMINGSLAGEN Claude Thomas / Sammy Lasseel

3 PIKOASUR Opgestart in 2000 door : Metrasur, Frankrijk, actief als thermische spuiter in de luchtvaartsector Pikotechnic, Finland, actief als thermische spuiter in de papiersector Aankoop door Hannecard Groep op 1/10/2014 Activiteiten : 1. Produktie en Herstellen van spreidwalsen 2. Voordraaien en Slijpen : zowel op werf als in eigen werkplaats 3. Thermisch Spuiten : zowel op werf als in eigen werkplaats

4 ACTIVITEITEN

5 1. Productie en herstellen van spreidwalsen Produktie en herstellen van alle merken spreidwalsen, zowel met rubber bekleed als verchroomd 75 walsen / jaar

6 2. Voordraaien en Slijpen Voordraaien en slijpen van zeer grote walsen zoals droogtrommels en perswalsen, zowel on-site als in eigen werkplaats OOK herstellen van astappen en zittingen : oplassen opspuiten verbussen

7 3. Thermisch Spuiten Verbeteren slijtageweerstand Verbeteren corrosieweerstand Verbeteren chemische weerstand Opdikken (herstellen van originele afmetingen) Controle van de frictiecoëfficiënt Arc Jet HVOF tov HP HVAF

8 3.1 Thermisch Spuiten : gereedschap

9 SOORTEN BEKLEDING

10 PIKOCAL Bekleding met een wolfram carbide Verbeteren van de slijtageweesrtand - dikte : meerdere mm - hardheid : 1300 HV - ruwheid : Ra < 0,05 µm

11 PIKOCHROME Bekleding met een chroomcarbide Verbeteren van de corrosieweerstand zeer vochtige omstandigheden & indien voedingsgeschiktheid vereist is - dikte : meerdere mm, typisch 250 µm - hardheid : 1000HV - ruwheid : Ra < 0.05µm

12 CARBUFLON DUBBELE BEKLEDING : Wolframcarbide + TEFLON Verbeteren van de slijtageweerstand + Aanbrengen van een anti-kleeflaag CARBUFLON - hardheid : 1150HV - ruwheid : Ra < 1.5 µm - kan gerakeld worden - niet voedingsgeschikt

13 PIKOGRIP Bekleding met een wolframcarbide Contrôle van de grip (frictiecoëfficient) - dikte : 60 µm à 200 µm - hardheid : 1150 HV - ruwheid Ra : 3µm < Ra < 12µm (ifv korrel)

14 MACHINES IN EIGEN WERKPLAATS

15 Eigen werkplaats Productiehal : 1350 m 2 Burelen : 225 m²

16 Draaibanken : 1 CNC + 2 conventionele Max. diameter : 1100 mm Lengte tussen punten : 10 m Max. gewicht : 15 ton

17 Spreidwalsen 5 verschillende werkposten

18 Rolbrug Capaciteit van 32 ton

19 Spuitcabine Breedte : 5m Lengte : 11m Lineaire beweging tov roterende rol

20 Voorbeeld van HP HVAF in spuitcabine 135 db 1650 C 1900 m/sec 30 kg/hr

21 Dit voelt aan als : + + +

22 Om finaal te komen tot :

23 Inleiding Mr. Claude Thomas Expert en consultant in thermisch spuiten : installaties toepassingen poeders Lid van European Thermal Spray Association Lid van experten van de AFNOR ( Franse normalisatie ) Docent aan verschillende ingenieursscholen en universiteiten

24 A mature technology, a new tool, result in the building of even more efficient coatings for further applications Increase life times of wear parts, increasing machine productivity Reduce the assets following a maintenance Improve surface finish rolls or cylinders Improve product quality manufactured Reduce the number of intervention for the maintenance of production facilities Reduce the cost of the replacement strategic part Remedy through new technology recurring wear problem

25 Thermal Spraying Coating Thermal spray principle Synopsis Adhesion Cohesiveness Porosity Unmelt particle Oxide Micro hardness

26 Thermal Spray : Basic Principle Addition Material : wire or powder Heat Source Fused Particles Acceleration Splashed onto the substrate surface

27 Coating Morphology Mechanical Bonding Lamellar Structure Porosity Oxide Splat Non fused particle Surface Roughness

28 Adhésion, ASTM C633

29 Micro Hardness Definition Hardness measured with an instrument having a smaller indenter and applying a lower force than the standard instrument, permitting measurements on smaller specimens or thinner sheets that are not amenable to measurement by normal instruments. Usually the indentations are so small that they must be measured with a microscope.

30 Coating particularity With Wire-Flame, Powder-Flame, ArcJet, Atmospheric Plasma Low Energy, Atmospheric Plasma High Energy, HVOF, coatings are in tension. When the coating is in tension, the high temperature in the coating is transferred to the substrate and the expansion between coating and substrate can result to cracks. The coating then unhooks from the substrate due to the particle stickiness. With HP/HVOF, D-Gun, SD-Gun, HFPD, HVAF, coatings are in compression. When the coating is in compression the high temperature in the coating goes to the substrate and the expansion between coating and substrate can make cracks but cannot unhook because the adhesion is very high and particle stickiness isn t concerned.

31 It s Elementary Chemical Compositions of thermal spray powders are applications driven Carbides for abrasion resistance Ceramics (oxides) for high temperatures Alloys for corrosion + general wear Composition directly affects M.O.M. Atomizing vs. SD+S vs. Crushed vs. HOSP Purity is very important: O 2, Tramp Mat ls

32 Apparently, Density is Important In general, high density particles will feed well, melt slowly and travel slower Low density particles won t feed as well, but will melt easily and accelerate easily AD is depending upon the nominal particle size and the breadth of the size distribution AD is a key control variable in most manufacturing processes

33 Equipment

34 Speed vs Temperature Température des particules, C Arc -fil Plasma H.V.A.F Vitesse des particules, m/s

35 HVAF ( High Velocity Air Propylen)

36 HP-HVAF Coatings aspect Surface preparation with sand blasting No surface preparation

37 HP-HVAF : WC and CrC coatings WC-10Co 4Cr Cr3C²-NiCr

38 HP/HVAF Coating Characteristics Adhesion > à 70MPa Coating in Compressive aspect Porosity < 1% in the case of carbide Micro-hardness 500 to 1500 HV0,3 Oxide content < à 2% Powder flow rate : more than 500 gr/mn More than 66 lbs/h

39 Achieving a High Quality Coating requires : The use of High Quality Materials A thermal Spraying Tool adapted with High Perform Knowledge flawless powder metallurgy And finally, the most comprehensive definition regarding the functionality of the part and the surface directly involved in the final quality of the treated product and the most complete scan possible to the working environment of the part (temperature, corrosive environment, wear, rotation speed, etc.)

40 DIFFERENT WEAR

41 Steel Industry, Thermal Spraying Coatings applications The Wear Abrasive Corrosive High temperature Chemical reaction What is temperature definition For Thermal Spraying Coating : 0 C T C 540 C = Cold 550 C T C 980 C = Hot T C 1000 C = Very Hot

42 Part which is located and works in a cold area Different coatings as : Mono-coating Tungsten Carbide Chrome Carbide Molybdenum Duplex coating Tungsten Carbide + Chemical Reactive Coating Chrome Carbide + Chemical reactive Coating

43 Part which is located and works in a hot area Different coatings as : Mono-coating Chrome Carbide MCrAlY s NiCoCrAlY s CoNiCrAlY s Duplex coating Chrome Carbide + Chemical Reactive Coating MCrAlY s + Chemical Reactive Coating CoNiCrAlY s + Chemical Reactive Coating

44 Chemical Reactive Coating What is it? Chemical reactive coating is a deposit, placed on the sprayed coating which confers significant characteristics such as: Hydrophobic surface (non-wettability) Porosity = 0 Good resistance against corrosion at high and low temperature Better surface roughness Micro-hardness > 2000 HV 0,05

45 Special case : Immersed rollers Zinc: Sink Roll Hard Coating + Chemical Reactive coating = Hydrophobic aspect Stabilizer Roll Hard Coating + Chemical Reactive coating = Hydrophobic aspect Corrector Roll Hard Coating + Chemical Reactive coating = Hydrophobic aspect Aluminium: Aluminium Pot Rolls Hard Coating + Chemical Reactive coating = Hydrophobic aspect

46 Last case : Continuous Casting Mold Plate Special duplex coating which give high hardness and a best shield to protect the nickel deposit and cause random degradation of the copper plate. Micro-hardness : up to 1500 HV 0,3 Coating porosity : less than 0,5% Oxide content : less than 1%

47 Steel industry application coatings Process rolls Deflector roll WC-CoCr coating Block S roll WC-12Co or WC-NiCr coating Accumulator roll WC-12Co coating Guiding roll WC-12Co coating Conductor roll CrC-80/20 NiCr coating WC-CoCr 86/10/4 coating

48 Steel industry application coatings Cold rolling WC-12Co WC-17Co WC-CrC-NiCr Sendzimir WC-CoCr 86/10/4 WC-NiCr Furnace roll CrC-NiCr coating

49 BEDANKT VOOR UW AANDACHT