Ingor Baumann

Sliding and Rolling Wear Behavior of HVOF-Sprayed Coatings Derived from Conventional, Fine and Nanostructured WC-12Co Powders

Fine structured and nanostructured materials represent a promising class of feedstock for future applications, which has also attracted increasing interest in the thermal spray technology. Within the field of wear protection, the application of fine structured or nanostructured WC-Co powders in the High Velocity Oxy-Fuel flame spraying technique (HVOF) provides novel possibilities for the manufacturing of cermet coatings with improved mechanical and tribological characteristics. In this study the tribological behavior of HVOF sprayed coatings derived from conventional, fine and nanostructured WC-12Co powders under sliding and rolling wear are investigated and the results are compared to C45 steel (Mat.-No. 1.0503). In addition, sliding and rolling wear effects on a microscopic level are scrutinized. It has been shown that under optimized spray conditions the corresponding fine and nanostructured WC-12Co coatings are able to obtain higher wear resistances and lower friction coefficients than the conventional coatings. This can be attributed to several scaling effects of the microstructure and to the phase evolution of the coating, which are discussed.

Aspects of Die Design for the Electromagnetic Sheet Metal Forming Process

Within the electromagnetic sheet metal forming process, workpiece velocities of more than 300m/s can occur, causing typical effects when forming into a die, which will be described and discussed in the present paper. These effects make numerous demands regarding the die design. In order to analyze these requirements, experimental as well as numerical investigations have been carried out. Thereby, special focus is put on the possibilities to accomplish these requirements, which are discussed in the following.

Near-Net-Shape and Dense Wear Resistant Thermally Sprayed Coatings

Deep drawing of high strength steels imposes high tribological requirements on forming tools. Thermal spraying is regarded as a promising technology to improve the tool’s performance and the service life of the forming tool, as long as ambitious demands of the coating process are matched. In order to qualify a thermal spraying process for a surface technology in deep drawing it is crucial that the coating obtains an extremely dense structure and a smooth, near-net-shape surface. The study presented considers two different approaches to achieve those goals. The application of fine-scaled powders (<10

Desirability-Based Multi-Criteria Optimisation of HVOF Spray Experiments

m) spraying through HVOF technique offers the opportunity to deposit dense coatings with very smooth surfaces. In contrast, it is also feasible to achieve very smooth and dense coatings by combining conventional powders with a subsequently densification procedure

Desirability-Based Multi-Criteria Optimization of HVOF Spray Experiments to Manufacture Fine Structured Wear-Resistant 75Cr3C2-25(NiCr20) Coatings

The reduction of the powder grain size is of key interest in the thermal spray technology to produce superfine structured cermet coatings. Due to the low specific weight and a high thermal susceptibility of such fine powders, the use of appropriate process technologies and optimised process settings are required. Experimental design and the desirability index are employed to find optimal settings of a high velocity oxygen fuel (HVOF) spraying process using fine powders (2 − 8 μm). The independent factors kerosene, hydrogen, oxygen, gun velocity, stand-off distance, cooling pressure, carrier gas and disc velocity are considered in a 12-run Plackett-Burman Design, and their effects on the deposition efficiency and on the coating characteristics microhardness, porosity and roughness are estimated. Following an examination of possible 2-way interactions in a 25 − 1 fractional-factorial design, the three most relevant factors are analysed in a central composite design. Derringer’s desirability function and the desirability index are applied to find optimal factor settings with respect to the above characteristics. All analyses are carried out with the statistics software “R”. The optimisation of the desirability index is done using the R-package “desiRe”.