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1

Properties of flame spraying coatings reinforced with particles of carbon nanotubes

Czupryński A., Mele C.

Advances in Materials Science

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2021

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Vol. 21, nr 1(67)

57--76

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.

2

The properties of thermal sprayed aluminium coatings on non-alloy structural steel

Czupryński A.

Journal of Achievements in Materials and Manufacturing Engineering

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2019

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Vol. 95, nr 2

64--73

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.

3

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.

4

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.

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

Badanie właściwości powłoki nanostrukturalnej natryskiwanej łukowo

Klimpel A., Czupryński A., Czylok P., Melcer M.

Archiwum Technologii Maszyn i Automatyzacji

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2010

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Vol. 30, nr 1

51-58

PL

W artykule przedstawiono wyniki badań właściwości powłoki z nanostopu na osnowie żelaza z dużą ilością drobnych wydzieleń w postaci węglików, natryskiwanej łukowo na płyty ze stali niestopowej ASTM A516, Grade 55 przeznaczonej do pracy w podwyższonej temperaturze. Do natryskiwania łukowego wykorzystano najnowszej generacji urządzenie spawalnicze Eutronic Arc Spray 4, zapewniające dużą stabilność procesu. W badaniach posłużono się metalicznym drutem proszkowym EnDOtec DO*390N o średnicy 1,6 mm. Wykonano powłokę grubości 1,0 mm, odznaczającą się dużą odpornością na zużycie ścierne i erozyjne.

EN

Study of the laser powder cladding of titanium alloy Ti6A14V plates by nickel based powder are presented. The high power diode HPDL, with a rectangular beam spot and a uniform, multi-mode energy distribution across the spot, was used for cladding trials. Influence of the basic parameters of laser cladding on the shape and quality of surface layers was determined. High quality and cracks free surface layers with smooth face and regular shape were produced on titanium alloy substrate by laser cladding with HPDL laser and nickel based powder. To ensure high quality of the surface layers during laser cladding of titanium alloy, gas shielding of the weld pool and also the solidified clad must be applied by high purity argon. Moreover the range of optimal laser cladding parameters is very narrow.

7

Badanie właściwości warstwy nanostrukturalnej natryskiwanej łukowo

Klimpel A., Czupryński A., Czylok P., Melcer M.

Spajanie Materiałów Konstrukcyjnych

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2009

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Nr 4 (6) 2009 - Nr 1 (7) 2010

17--21

PL

W artykule przedstawiono wyniki badań nad właściwościami warstwy natryskiwanej łukowo nanostopem na osnowie żelaza z dużą ilością drobnych wydzieleń w postaci węglików, 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. W badaniach użyto drutu proszkowego metalicznego EnDOtec DO*390N o średnicy 1,6 mm. Wykonano warstwy o grubości 1,0 mm, odznaczające się wysoką odpornością na zużycie ścierne i erozyjne.

EN

Comprehensive study of nano-material wire arc spraying technology were conducted to establish optimum properties of very high wear resistance coatings of nano-material sprayed on ASTM A516, Grade 55 base metal sheets. Newest model of wire arc spraying equipment - Eutronic Arc Spray 4, was used during experiments, providing very reliable spraying conditions. Messer-Castolin-Eutectic powder metal cored wire EnDOtec DO*390N 1,6 mm dia, was used to produce, dense, very high abrasion and erosion resistant coatings of thickness approx. 1.0 mm. Nano-material coatings characterization was done in accordance to ASTM G 65-00 Procedure A abrasion resistance test. ASTM G 76-95 erosion resistance tests, ASTM C 633-01 adhesion strength, HV 0,1 hardness tests and metallographic examinations. Results have proved high properties of arc sprayed nanomaterial coatings and have shown promising industrial applications.

8

Abrasive and erosive wear resistance of GMA metal cored wire cermetal deposits

Klimpel A., Janicki D., Klimpel A. S., Rzeźnikiewicz A.

Journal of Achievements in Materials and Manufacturing Engineering

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2007

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Vol. 20, nr 1-2

37-44

EN

Purpose: Purpose of these researches was to determine influence of GMA metal cored wire surfacing parameters on the abrasive and erosive wear resistance of the one layer and three layer weave bead cermetal deposits. Design/methodology/approach: One layer and three layer wave bead deposits were GMA surfaced using metal cored wire (nickel based - 54%WC) 1.6 [mm] dia. To determine quality of deposits Visual Inspection, MT examinations, hardness HRC and HV10 measurements on the ground surface of deposits, macrostructure and microstructure observations, abrasive and erosion wear resistance tests were done. Findings: Hardness of deposits tested is in the range from 453-517 HV 10(44.5-47.9 HRC) and is a function of the value of heat input of surfacing. WC carbides population density, size and distribution in nickel alloy matrix of deposits tested is a function of GMA heat input of surfacing. Low heat input of surfacing insures uniform distribution of WC carbides on the cross section of deposits. The low heat input GMA surfaced weave bead deposits provide 10 times higher abrasion wear resistance and 4.2 times higher erosion wear resistance than HARDOX 400 steel plate. Research limitations/implications: Results of this paper is to increase quality of GMA cermetal deposits. Originality/value: Hardness of deposits can not be treated as the abrasion and erosion wear resistance indicator.

9

Mikrostruktura, odporność na zużycie abrazyjne i erozyjne natryskiwanych cieplnie kompozytowych powłok FeAl-TiAl-Al2O3, FeAl-TiC-Al2O3.

Formanek B., Hetmańczyk M., Szymański K., Szala J., Szopiński K., Pająk L.

Inżynieria Materiałowa

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1999

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R. XX, nr 5

570-581

PL

W artykule przedstawiono i potwierdzono koncepcję materiałową i technologiczną otrzymywania kompozytowych proszków i powłok FeAl-TiAl-Al2O3, FeAl-TiC-Al2O3 przeznaczonych do natryskiwania cieplnego. Określono skład fazowy i morfologię proszków otrzymanych w wariantach samorozwijającej się syntezy wysokotemperaturowej o zmiennym składzie chemicznym substratów. Przedstawiono procedurę technologiczną otrzymania proszków przeznaczonych dla natryskiwania cieplnego powłok. Określono mikrostrukturę i skład fazowy powłok w badaniach na mikroskopie świetlnym, skaningowym, oraz metodą EDX i rentgenograficznej analizy fazowej. Wyniki przedstawionych testów abrazyjnych i erozyjnych przy różnych kątach padania ścierniwa potwierdziły wysoką odporność na zużycie badanych powłok. Powłoki są przeznaczone do zwiększania odporności metalicznych powierzchni w złożonych warunkach zużycia erozyjno-korozyjnego w podwyższonych temperaturach.

EN

The article presents and confirms the material and technological conceptions of obtaining composite powders FeAl-TiAl-Al2O3, FeAl-TiC-Al2O3 and coatings intended for thermal spraying. The phase composition and morphology of powders obtained in variants of self-propagating high temperature synthesis of variable chemical composition of substrates. Technological procedure of production of powders for thermally sprayed coatings was presented. Light and scanning microscopes and EDX and X-ray phase analysis determined a microstructure and phase composition of coatings. The results of presented abrasion and erosion tests at different angels of abrasive impact, confirmed high wear resistance of tested for increasing the metallic surface resistance in complex erosion-corrosion wear condition at elevated temperatures.