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1
EN
The article presents the results of the preliminary research of tribological properties of flame sprayed nickel and aluminum coatings reinforced with carbon nanotubes made on the structural steel S235J0 substrate. The carbon material – carbon nanotubes Nanocyl NC 7000 (0.5 wt.% and 1 wt.%) was used for structural reinforcement. The properties evaluation was made by the use of optical microscopy, scanning electron microscopy, Raman spectroscopy, microhardness measurements, and by means of abrasion and erosion resistance laboratory tests. The obtained results were compared with pure nickel powder coatings 2N5 (Ni 99.5%) and with pure aluminum powder coatings (EN AW 1000 series). It was proved that the flame spraying of nickel and aluminum coatings reinforced with particles carbonaceous material can be an effective alternative for other more advanced surfacing technology. The preliminary test results will be successively extended by further experiments to contribute in the near future to develop innovative technologies, that can be implemented in the aviation industry and the automotive. The presented research is a continuation of the work previously published.
EN
Purpose: of this paper was comparison of the structure, hardness and erosive wear of aluminium coatings produced on non-alloy structural steel S355JR (EN 10025-2) using the powder flame spraying and wire arc spraying methods. Design/methodology/approach: The latest model of flame powder sprayer and wire arc sprayer was used in the experiments. This provided very reliable spraying conditions. The additional material for flame-spraying was of Metco 54NS-1 pure aluminium powder (EN AW 1100 series). In the arc spraying process the Metco Aluminium (EN AW 1100 series) 1.6 mm diameter pure aluminium thermal spray wire was used. In each spraying technology binding alloy, i.e. Ni-Al, was employed as a primer coating. The used spray processes produced dense, abrasion and erosion resistant coatings approximal 1.0 mm thick. Aluminium coatings were characterized in accordance with ASTM G 76-95 erosion resistance tests, ASTM C 633-01 adhesion strength, HV 0.1 hardness tests and metallographic analyses. The scope of research included: preparation material for spraying, selection of properly process parameters for each sprayed technique based on preliminary technological tests, coatings manufacturing, examining the structure and tribological properties of aluminium coatings, comparison of obtained samples. Findings: The obtained results have proven superior properties of arc sprayed aluminium material coatings and have shown to be promising in industrial applications. Research limitations/implications: The presented test results are a preliminary assessment of the properties of thermally sprayed aluminium coatings. Therefore, further research is required regarding the resistance of aluminium coatings to abrasion and corrosion. Practical implications: The study is focused on selecting the best and most economical technique for manufacturing of wear and corrosion resistance aluminium coatings with a thickness of approximately 1 mm. Originality/value: It has been demonstrated that the use of a Ni-Al primer coating improves the adhesion of flame and arc sprayed aluminium coatings to steel surfaces.
PL
W pracy przedstawiono własności i strukturę warstw nanokrystalicznych wykonanych łukowo metodą MMA nanostopem na osnowie żelaza na podłożu ze stali S355N w porównaniu do wybranych materiałów konstrukcyjnych odpornych na ścieranie stosowanych obecnie w przemyśle. Uzyskane napoiny poddano badaniom metalograficznym makro i mikroskopowym, określono wielkość ziarna z wykorzystaniem dyfraktometru rentgenowskiego Xpert PRO X-rey. Oceny własności użytkowych uzyskanych warstw nanokrystalicznych w porównaniu do obecnie stosowanych materiałów dokonano w oparciu o pomiar twardości oraz badania zużycia ściernego typu metal-minerał. Wyniki własności eksploatacyjnych warstw odniesiono do własności stali HARDOX 400.
EN
The present paper is the result of the investigations of the properties and structure of nanocrystalline layers deposited from iron-based nanoalloy on steel S355N substrate by manual metal arc welding method (MMA) compared to selected abrasion-resistant construction materials currently used in industry. The resultant deposit welds were subjected to macro and microscopic metallographic examination. Working properties of obtained nanocrystalline deposits weld compared to currently used materials were evaluated based on the hardness, abrasive wear of metal-to-mineral. The results of deposits weld working properties measurements were compared with property of wear resistant steel HARDOX 400 type used as reference material.
EN
In the paper, there were shown the results of research on the properties of overlay welds consisted of one and three layers deposited by three types of tubular electrodes of the Fe-Cr-C alloy, Fe-Cr-C-Nb-Mo-W-V alloy and composite consist of tungsten carbide particles in the Fe-Cr-C alloy matrix. The study of hardfacing deposits included: test of metal-mineral abrasion resistance, metallographic examinations, analysis of chemical composition, and hardness tests. The test of abrasive usage in metal-mineral friction was made according to the procedure A of the ASTM G 65 standard.
PL
W artykule przedstawiono wyniki badania własności napoin jedno- i trójwarstwowych wykonanych trzema rodzajami elektrod rurkowych ze stopów Fe-Cr-C, Fe-Cr-C-Nb-Mo-W-V oraz kompozytu składającego się z cząstek węglika wolframu w osnowie ze stopu Fe-Cr-C. Badania napoin obejmowały: badania odporności na zużycie ścierne typu metal-minerał, badania metalograficzne, analizę składu chemicznego oraz pomiar twardości. Badanie odporności na zużycie ścierne typu metal-minerał przeprowadzono zgodnie z normą ASTM G 65, procedura A.
5
Content available remote Porównanie odporności na zużycie ścierne płyt trudnościeralnych
PL
W artykule przedstawiono wyniki badań dotyczących porównania odporności na zużycie ścierne kilku różnych płyt trudnościeralnych produkowanych przez producentów krajowych i zagranicznych w technologiach automatycznego napawania łukowego drutem proszkowym (FCAW), ręcznego napawania łukowego elektrodami otulonymi (MMAW) oraz spajania metalurgicznego stalowej płyty podkładowej z żeliwem stopowym o wysokiej odporności na ścieranie. W oparciu o wyniki badań odporności na zużycie ścierne prowadzone zgodnie z normą ASTM G65-00 względem materiału referencyjnego stali Hardox 400 oraz pomiar twardości warstw roboczych materiałów trudnościeralnych wg PN-EN ISO 6508-1:2016, wytypowano produkty o najlepszych parametrach użytkowych do zastosowań w aplikacjach narażonych na silne zużycie ścierne typu metal-minerał.
EN
In this article results of abrasive wear resistance of a few different steel wear plates made by domestic and foreign producers in technology of automatic FCAW and manual arc (MMAW) cladding and metallurgical bonding of wear resistant layer with base material were presented. Based on abrasive wear resistance tests according to ASTM G65-00, in regard to reference samples from Hardox 400 steel and hardness measurements according to PN-EN ISO 6508-1:2016 standard, products with best performance parameters on metal-mineral abrasion conditions were chosen.
EN
The article discusses tests results concerning the joining of duplex steel pipes performed using the TIG and A-TIG (with the addition of activating flux) orbital welding technology. The shielding gas used in related tests contained pure argon as well as argon with an addition of nitrogen. Technological welding tests were performed using a closed head without the feeding of a filler metal. The research work included visual and penetrant tests as well as macro and microscopic observations and ferrite meter-aided measurements of the ferrite content in welds.
PL
Omówiono wyniki badań dotyczących łączenia rur ze stali duplex z wykorzystaniem technologii spawania orbitalnego TIG i A-TIG (z dodatkiem topnika aktywującego). Jako gaz osłonowy stosowano zarówno sam argon, jak również argon z dodatkiem azotu. Przeprowadzono próby technologiczne spawania z użyciem głowicy zamkniętej bez podawania materiału dodatkowego. Wykonano badania wizualne i penetracyjne, następnie badania makro i mikroskopowe, a także pomiary zawartości ferrytu w spoinach z wykorzystaniem ferrytomierza.
7
EN
This article presents the results of an examination of the properties of thermal flame sprayed coatings produced by material in the form of four powders (two polymers: PA11 and PA12 CastoPlast, and two high purity: tin and aluminum) on the substrate of the unalloyed structural steel of S235JR grade. Investigations of coating properties are based on metallography tests (SEM and CLSM), measurement of microhardness (acc. to PN-EN ISO 6507-1:2007), anticorrosive (acc. to PN-EN ISO 9227:2017-06) and bend testing. Results demonstrate properties of flame sprayed coatings that are especially promising in the industrial applications where corrosion-resistant coating properties are required. Consequently, performed experiments show that the highest corrosion resistance is demonstrated by steel samples with a polyamide anti-corrosion system. Accelerated corrosion tests showed the lowest corrosion resistance of the tin coating system, however, they do not fully correspond to the corrosion processes in operating conditions.
EN
The article presents the results of the study on exploitation properties of flame sprayed ceramic coatings produced by oxide ceramic material in the form of powder based on the aluminum oxide Al2O3 matrix with addition of 3% titanium oxide TiO2 and also on the zirconium oxide (ZrO2) matrix with 30% calcium oxide (CaO) on the substrate of unalloyed structural steel of S235JR grade. The buffer layer was produced by metallic powder on the base of Ni-Al-Mo. Plates with dimensions of 5x200x300 mm and also front surfaces of ø40x50 mm cylinders have been flame sprayed. The buffer coatings were produced using RotoTec 80 torch and external specific coatings were produced by CastoDyn DS 8000 torch. Investigations of coating properties were based on metallography tests, phase composition research, measurement of microhardness, coating adhesion to the substrate research, abrasive wear resistance (acc. to ASTM G65 standard) and erosion wear resistance (acc. to ASTM G76-95 standard) and thermal stroke study. The coatings were characterized by high adhesion to the substrate and also high erosion and abrasive wear resistance and the resistance for cyclic thermal stroke.
EN
The present paper is the result of the investigations of the properties and structure of nanocrystalline layers deposited from iron-based nanoalloy on steel S355N substrate by manual metal arc welding method (MMA). In the process of welding a 100 A current intensity was used with desiccation preheating at 80°C while maintaining the interpass temperature at range of 200°C. The resultant deposit welds were subjected to macro and microscopic metallographic examination, X-ray phase analyses and crystallite size was analyzed by X-ray diffractometry (XRD), additionally EDX chemical composition analysis of precipitates during scanning electron microscopy was performed. Working properties of the obtained nanocrystalline deposit welds were evaluated based on hardness and metal-to-mineral abrasive wear. The results of the deposit welds working properties measurements were compared with the properties of wear resistant steel HARDOX 400 type used as the reference material.
EN
In this article results of studies on cracks formation susceptibility in braze-welded joints of thin aluminum sheets and double-sided zinc galvanized steel sheets for car body parts made by laser brazing with high power diode laser ROFIN DL 020 and CMT MIG-brazing, with filler material in form of powder and wire accordingly, were presented. Optimal welding parameters were determined by visual acceptance criteria. On joints made with optimal parameters further examinations were carried. Results of macro- and microscopic metallographic examinations, structural roentgenography, EDS microanalysis and hardness tests were presented. Causes of brittle intermetallic Fe-Al phases formation in Al-matrix filler metal in dissimilar aluminum – zinc plated carbon steel joints were pointed.
PL
W przemyśle motoryzacyjnym, technologii budowy maszyn, w urządzeniach przemysłowych, a także w podzespołach elektronicznych i kompozytach coraz częściej zachodzi konieczność łączenia ze sobą materiałów konstrukcyjnych o odmiennych właściwościach.
PL
W artykule przedstawiono wyniki badań dotyczących przyczyn pękania lutospoin w różnoimiennych złączach zakładkowych wykonanych laserem diodowym dużej mocy ROFIN DL 020 z użyciem materiału dodatkowego w postaci proszku aluminium, na przykładzie łączenia cienkiej blachy aluminiowej z blachą stalową pokrytą elektrolitycznie powłoką cynkową. Przedstawiono wyniki badań metalograficznych makroskopowych i mikroskopowych. Wskazano na problemy oraz przedstawiono sugestie dotyczące technologii lutospawania laserowego materiałów znacznie różniących się własnościami fizycznymi i składem chemicznym.
EN
A study on cracking phenomena during laser braze welding of dissimilar lap joints between aluminum thin plate and galvanized low carbon sheet steel is described. The experiments were carried out using a high power diode laser Rofin DL020 and aluminum powder as filler metal. Macro and microstructure analysis of the joints were analysed. Issues and problems in laser braze welding of materials having different chemical composition and physical properties are presented.
PL
W artykule przedstawiono wyniki badań dotyczących skłonności do tworzenia się pęknięć w lutospoinach złączy zakładkowych cienkich blach aluminiowych i karoseryjnych blach stalowych obustronnie galwanizowanych cynkiem, które wykonywano laserem diodowym dużej mocy (HPDL) ROFIN DL 020 oraz łukowo metodą CMT z użyciem materiału dodatkowego odpowiednio w postaci proszku i drutu litego. Przedstawiono wyniki badań metalograficznych makroskopowych i mikroskopowych, rentgenografii strukturalnej, mikroanalizy rentgenowskiej EDS oraz pomiarów twardości. Wskazano na przyczyny powstawania w lutospoinach na osnowie aluminium, złączy różnoimiennych typu aluminium - ocynkowana stal niestopowa, kruchych faz międzymetalicznych typu Fe-Al.
EN
In this article results of studies on cracks formation susceptibility in braze-welded joints of thin aluminum sheets and double-sided zinc galvanized steel sheets for car body parts made by laser brazing with high power diode laser ROFIN DL 020 and CMT MIG-brazing, with filler material in form of powder and wire accordingly, were presented. Results of macro- and microscopic metallographic examinations, structural roentgenography, EDS microanalysis and hardness tests were presented. Causes of brittle intermetallic Fe-Al phases formation in Al-matrix filler metal in dissimilar aluminum - zinc plated carbon steel joints were pointed.
EN
The paper presents the results of the properties of flame sprayed ceramic coatings using oxide ceramic materials coating of a powdered aluininiuni oxide (Al2O3) matrix with 3% titanium oxide (TiO2) applied to unalloyed S235JR grade structural steel. A primer consisting of a metallic Ni-Al-Mo based powder has been applied to plates with dimensions of 5X200X300 mm and front surfaces of ø40x50 mm cylinders. Flame spraying of primer coating was made using a RotoTec 80 torch, and an external coating was made with a CastoDyn DS 8000 torch. Evaluation of the coating properties was conducted using metallographic testing, phase composition research, measurement of microhardness, substrate coating adhesion (acc. to EN 582:1996 standard), erosion wear resistance (acc. to ASTM G76-95 standard), and abrasive wear resistance (acc. to ASTM G65 standard) and thermal impact. The testing performed has demonstrated that flame spraying with 97% Al2O3 powder containing 3% TiO2 performed in a range of parameters allows for obtaining high-quality ceramic coatings with thickness up to ca. 500 μni on a steel base. Spray coating possesses a structure consisting mainly of aluminium oxide and a small amount of NiAl10O16 and NiAl32O49 phases. The bonding primer coat sprayed with the Ni-Al-Mo powder to the steel substrate and external coating sprayed with the 97%Al2O3 powder with 3% TiO2 addition demonstrates mechanical bonding characteristics. The coating is characterized by a high adhesion to the base amounting to 6.5 MPa. Average hardness of the external coating is ca. 780 HV. The obtained coatings are characterized by high erosion and abrasive wear resistance and the resistance to effects of cyclic thermal shock.
EN
The introduction of new reinforcing materials continues to be investigated to improve the final behaviour of AMCs as well as to avoid some drawbacks of using ceramics as reinforcement. The present work investigates the structure, properties and ability of joining aluminium EN-AW 6061 matrix composite materials reinforced with Ti3Al particles by resistance butt welding as well as composite materials produced by mechanical milling, powder metallurgy and hot extrusion techniques. Mechanically milled and extruded composites show finer and better distribution of reinforcement particles, which leads to better mechanical properties of the obtained products. Finer microstructure improves mechanical properties of obtained composites. The hardness increases twice in the case of mechanically milled composites also, a higher reinforcement content results in higher particle dispersion hardening, for 15 wt.% of intermetallics reinforcement concentration composites reach about 400 MPa UTS. Investigation results of joints show that best hardness and tensile properties of joints can be achieved by altering soft conditions of butt welding process e.g. current flow time 1.2 s and current 1400 A. To improve mechanical properties of butt welding joints age hardening techniques can also be used.
PL
W artykule przedstawiono zastosowanie technologii lutospawania łukowego z wykorzystaniem niskoenergetycznego procesu CBT (Controlled. Brigde. Transfer) na przykładzie łączenia stalowych blach wysokostopowych z blachami miedzianymi. Przedstawiono wyniki badań metalograficznych makro- i mikroskopowych oraz właściwości wytrzymałościowych otrzymanych połączeń. Wskazano na problemy występujące podczas lutospawania materiałów znacznie różniących się właściwościami oraz przedstawiono korzyści związane z wykorzystania niskoenergetycznych technologii lutospawania. Otrzymane wnioski pozwalają na stwierdzenie, że lutospawanie łukowe metodą CBT jest jedną z lepszych metodą łączenia stali wysokostopowych z miedzią.
EN
Low heat input CBT (Controlled Bridge Transfer) braze welding technology of joining high alloy stainless steel with cooper plates were described in this paper. Results of macro-, microscopic and mechanical properties tests were shown. Indicated the main problems during braze welding of material with significant different properties and shown a lot of benefits of using this technology. Achieved results can indicates that one of the better technologies of joining steels with cooper is braze welding.
17
Content available remote Ocena jakości i odporności erozyjnej powłok natryskiwanych łukowo
PL
W artykule przedstawiono wyniki badań odporności erozyjnej powłok natryskiwanych łukowo wybranymi stopami typu Fe-Cr-Ti-Si-Mn, Fe-Cr-B-Si-Mn, Ni-Cr-Mo-Fe-Nb, Ni-WC-Cr-B-C oraz nano stopem na osnowie żelaza wzmacnianym wydzieleniowo węglikiem boru Fe-Si-Mn-Cr-Mo-Nb-W-B, na płyty ze stali niestopowej ASTM A516, Grade 55 przeznaczonej do pracy w podwyższonej temperaturze. Do natryskiwania łukowego zastosowano najnowszej generacji urządzenie spawalnicze Eutronic Arc Spray 4 zapewniające wysoką stabilność przebiegu procesu oraz użyto druty proszkowe metaliczne EuTronic Arc 502, EuTronic Arc 547, EuTronic Arc 595, EuTronic Arc 599 i EnDOtec DO*390N o średnicy 1,6 mm. Natryskiwano łukowo powłoki o grubości około 0,8 mm, odznaczające się zróżnicowaną twardością oraz odpornością na zużycie erozyjne.
EN
The article presents the results of the study on erosion resistance of arc sprayed coatings made of selected alloys such as Fe-Cr-Ti-Si-Mn, Fe-Cr-B-Si-Mn, Ni-Cr-Mo-Fe-Nb, Ni-WC-Cr-B-C, and also nano alloy based on the iron matrix, strengthened by precipitations of boron carbide Fe-Si-Mn-Cr-Mo-Nb-W-B, on plates made of unalloyed steel ASTM A516, Grade 55 designed for for operation at elevated temperature. The latest generation of welding device Eutronic Arc Spray 4 for arc spraying was applied in the investigations, which ensure high stability of the process. Cored metallic wires such as EuTronic Arc 502, EuTronic Arc 547, EuTronic Arc 595, EuTronic Arc 599 i EnDOtec DO*390N with the diameter of 1,6 mm were used as the additional material. The coating produced by arc spraying were approx. 0,8 mm thick and had different hardness as well as different erosion wear resistance.
18
Content available remote Selected properties of thermally sprayed oxide ceramic coatings
EN
The article presents the results of the study on exploitation properties of flame sprayed ceramic coatings produced by oxide ceramic material in the form of powder on the aluminum oxide Al2O3 matrix with 3% titanium oxide TiO2 addition and also on the zirconium oxide (ZrO2) matrix with 30% calcium oxide (CaO) on the substrate of unalloyed structural steel of S235JR grade. As a primer powder, metallic powder on the base of Ni-Al-Mo has been applied. Plates with dimensions of 5×200×300 mm and also front surfaces of ∅40×50 mm cylinders have been flame sprayed. Spraying of primer coating has been done using RotoTec 80 torch and external specific coating has been done with CastoDyn DS 8000 torch. Investigations of coating properties are based on metallography tests, phase composition research, measurement of microhardness, coating adhesion to the ground research (acc. to EN 582:1996 standard), abrasive wear resistance (acc. to ASTM G65 standard) and erosion wear resistance (acc. to ASTM G76-95 standard) and thermal stroke study. Performed tests have shown that the flame spraying with 97%Al2O3 powder containing 3% TiO2 and also by the powder based on zirconium oxide (ZrO2) containing 30% calcium oxide (CaO) performed in a wide range of technological parameters allow to obtain high quality ceramic coatings with thickness up to ca. 500 μm on a steel substrate. The primer coating sprayed with the Ni-Al-Mo powder to the steel substrate and external coatings sprayed has the of mechanical bonding character. The coatings are characterized by high adhesion to the substrate and also high erosion and abrasive wear resistance and the resistance for cyclic thermal stroke.
PL
Nowoczesne technologie łączenia, dzięki zastosowaniu systemów sterowania cyfrowego, pozwalają kontrolować łuk spawalniczy poprzez sposób przenoszenia metalu oraz ilością ciepła wprowadzanego do materiału. Uzyskane połączenia odznaczają się mniejszymi odkształceniami spawalniczymi, zachowanymi właściwościami fizycznymi i wysoką estetyką. Niskoenergetyczne metody spawania MIG/MAG umożliwiają łączenie cienkościennych elementów, blach.
20
Content available remote Analiza właściwości powłokowych barier cieplnych natryskiwanych płomieniowo
PL
W artykule porównano wyniki badań dotyczących właściwości eksploatacyjnych powłok ceramicznych natryskiwanych płomieniowo, materiałami ceramicznymi tlenkowymi w postaci proszku na osnowie tlenku aluminium Al2O3 oraz tlenku cyrkonu ZrO2, na podłoże z konstrukcyjnej stali niestopowej S235JR. Oceny dokonano w oparciu o badania metalograficzne, przyczepności powłoki do podłoża, odporności na ścieranie, odporności na zużycie erozyjne oraz udar cieplny.
EN
This article compares the results of studies on the operational properties of the flame sprayed ceramic coatings, ceramics oxide powder on the base of aluminum oxide and zirconium oxide Al2O3 ZrO2, on the ground of non-alloy structural steel S235JR. The assessments were based on metallographic examination, the adhesion, abrasion resistance, resistance to erosive wear and thermal shock.
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