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1

Properties of Al2O3/TiO2 and ZrO2/CaO flame sprayed coatings

Czupryński A.

Spajanie Materiałów Konstrukcyjnych

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2017

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Nr 2 (36)

32--39

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.

2

Testing of flame sprayed Al2O3 matrix coatings containing TiO2

Czupryński A., Górka J., Adamiak M., Tomiczek B.

Archives of Metallurgy and Materials

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2016

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Vol. 61, iss. 3

1363--1370

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.

3

Effect of Laser Feeding on Heat Treated Aluminium Alloy Surface Properties

Labisz K., Tański T., Janicki D., Borek W., Lukaszkowicz K., Dobrzański L. A.

Archives of Metallurgy and Materials

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2016

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Vol. 61, iss. 2A

741--746

EN

In this paper are presented the investigation results concerning microstructure as well as mechanical properties of the surface layer of cast aluminium-silicon-copper alloy after heat treatment alloyed and/ or remelted with SiC ceramic powder using High Power Diode Laser (HPDL). For investigation of the achieved structure following methods were used: light and scanning electron microscopy with EDS microanalysis as well as mechanical properties using Rockwell hardness tester were measured. By mind of scanning electron microscopy, using secondary electron detection was it possible to determine the distribution of ceramic SiC powder phase occurred in the alloy after laser treatment. After the laser surface treatment carried out on the previously heat treated aluminium alloys, in the structure are observed changes concerning the distribution and morphology of the alloy phases as well as the added ceramic powder, these features influence the hardness of the obtained layers. In the structure, there were discovered three zones: the remelting zone (RZ) the heat influence zone (HAZ) and transition zone, with different structure and properties. In this paper also the laser treatment conditions: the laser power and ceramic powder feed rate were investigated. The surface laser structure changes in a manner, that there zones are revealed in the form of. This carried out investigations make it possible to develop, interesting technology, which could be very attractive for different branches of industry.

4

Microstructure and properties of the hot work tool steel gradient surface layer obtained using laser alloying with tungsten carbide ceramic powder

Jonda E., Labisz K., Dobrzański L. A.

Archives of Materials Science and Engineering

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2016

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Vol. 78, nr 1

37--44

EN

Purpose: The aim of the paper is to present the innovatory investigation results of the impact of laser treatment consisting of multiple remelting and alloying using tungsten carbide ceramic powder on the microstructure and properties of hot work tool steel X40CrMoV5-1 surface layer. Design/methodology/approach: Laser heat treatment allows the production of gradient surface layer with a thickness reaching from of tenths of a millimetre even to few millimetres with specific functional properties, including high hardness and abrasion resistance, while maintaining the properties of the substrate material. Findings: Preliminary investigations of the effects of laser radiation on steel surface have showed, that in the surface layer there occur changes concerning the microstructure as well as in the chemical composition different from those occurring during conventional heat treatment. Research limitations/implications: There was determined the effect of laser power on the remelting depth, the depth of the heat affected zone and the width of the laser tray face. There was also measured and compared to the hardness and roughness of the steel processed by remelting with different process parameters. Practical implications: The current application areas for hot work tool steels are constantly growing, and the intensive development of techniques requires the use of new technologies, what leads to production of specific surface layer on materials, in order to meet the extremely difficult working conditions of modern tools. Originality/value: The effect of a HPDL laser melting on the hot work tool steel, especially on their structure and hardness has been studied.

5

Selected properties of thermally sprayed oxide ceramic coatings

Czupryński A.

Advances in Materials Science

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2015

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Vol. 15, nr 3(45)

17--32

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.

6

Mikrostruktura powłokowych barier cieplnych natryskiwanych metodą APS z zastosowaniem nowych proszków ceramicznych

Sosnowy P., Góral M., Dudek S., Drajewicz M., Gancarczyk T.

Przegląd Spawalnictwa

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2012

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R. 84, nr 8

23-27

PL

W artykule przedstawiono wyniki badań mikrostruktury oraz odporności na utlenianie powłokowych barier cieplnych wytworzonych metodą APS. Jako podłoże zastosowano stop Rene 80. Międzywarstwę stanowił wieloskładnikowy stop MeCrAlY. Zewnętrzną warstwę ceramiczną stanowiły proszki tlenku cyrkonu stabilizowane tlenkami itru, magnezu i wapnia. Proszki te mogą być stosowane zarówno w procesie natryskiwania metodą APS, jak i w warunkach obniżonego ciśnienia – LPPS. Badania przeprowadzono z zastosowaniem mikroskopii świetlnej i elektronowej mikroskopii skaningowej. Wykonane zostały także pomiary porowatości wytworzonej warstwy. Wykazano, że zastosowanie nowych proszków ceramicznych zapewnia możliwość wytworzenia powłokowych barier cieplnych, jednak ich maksymalna temperatura pracy, poza konwencjonalnym tlenkiem cyrkonu stabilizowanym tlenkiem itru, jest niższa i nie zapewnia ochrony przed utlenianiem powierzchni elementów silnika lotniczego.

EN

The article presents the results of microstructure and oxidation resistance of thermal barrier coatings produced by APS. Rene 80 alloy is used as substrate and MeCrAlY alloy as an interlayer. For outer ceramic layer are used zirconium oxide powders stabilized with yttrium, magnesium and calcium oxides. These powders may be used in both the APS spraying method as in conditions of low pressure – LPPS. The study was carried out with the use of light microscopy and scanning electron microscopy. The effective porosity of layer were also measured. It shows that the use of new ceramic powders provides the ability to produce thermal barrier coatings, but their maximum operating temperature, except the conventional zirconium oxide stabilized with yttrium oxide, is lower and does not provide protection against oxidation of the surface of aircraft engine components.

7

Comparison of 32CrMoV12-28 steel alloyed with WC, VC and TaC powder using HPDL laser

Dobrzański L., Labisz K., Bonek M., Klimpel A.

Journal of Achievements in Materials and Manufacturing Engineering

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2008

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Vol. 30, nr 2

187-192

EN

Purpose: This work presents the investigation results of laser remelting and alloying especially the laser parameters and its influence on the structure and properties of the surface of the 32CrMoV12-28 hot work steel, using the high power diode laser (HPDL). In this paper there are presented the investigation results of mechanical properties and microstructure with ceramic particle powders vanadium carbide VC, tungsten carbide WC and tantalum carbide TaC. The purpose of this work was also to determine the laser treatment conditions for surface layer treatment of the investigated steels. Design/methodology/approach: The purpose of this work was the determination of technological conditions for alloying and remelting of the surface layer particularly the laser power. There is studying the influence of treatment on the remelting depth of the surface layer to achieve high layer hardness for protection of the steel and also make the surface more resistant for work. Findings: As a result structure changes in form of fragmentation were determined. For alloying the tungsten carbide, tantalum carbide and vanadium carbide powders were used. Three phases of carbides: TaC, VC and WC, were observed. Research limitations/implications: The remelted layers which were formed on the surface of the investigated hot work steel were examined metallographically and analyzed using a hardness and micro hardness testing, X-ray diffraction, EDS microanalysis, electron scanning microscope. Practical implications: This work helps to use the new developed laser treatment technique for alloying and remelting of hot work tool steel tools for hot working conditions. Originality/value: The originality of this work is based on applying of High Power Diode Laser for improvement of steel mechanical properties as well the thermal fatigue and wear resistance.