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EP3896190B1 - Installation and method for producing a metallic coating on a borehole wall - Google Patents

Installation and method for producing a metallic coating on a borehole wall Download PDF

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Publication number
EP3896190B1
EP3896190B1 EP20169797.6A EP20169797A EP3896190B1 EP 3896190 B1 EP3896190 B1 EP 3896190B1 EP 20169797 A EP20169797 A EP 20169797A EP 3896190 B1 EP3896190 B1 EP 3896190B1
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EP
European Patent Office
Prior art keywords
coating
plasma
bore
rpm
particles
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP20169797.6A
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German (de)
French (fr)
Other versions
EP3896190C0 (en
EP3896190A1 (en
Inventor
Marc Kesting
Roland Baier
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Sturm Maschinen und Anlagenbau GmbH
Original Assignee
Sturm Maschinen und Anlagenbau GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Sturm Maschinen und Anlagenbau GmbH filed Critical Sturm Maschinen und Anlagenbau GmbH
Priority to EP20169797.6A priority Critical patent/EP3896190B1/en
Priority to HUE20169797A priority patent/HUE067596T2/en
Priority to CN202180011888.7A priority patent/CN115003850A/en
Priority to US17/904,363 priority patent/US20230056126A1/en
Priority to PCT/EP2021/055470 priority patent/WO2021209190A1/en
Publication of EP3896190A1 publication Critical patent/EP3896190A1/en
Application granted granted Critical
Publication of EP3896190C0 publication Critical patent/EP3896190C0/en
Publication of EP3896190B1 publication Critical patent/EP3896190B1/en
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Classifications

    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B13/00—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00
    • B05B13/06—Machines or plants for applying liquids or other fluent materials to surfaces of objects or other work by spraying, not covered by groups B05B1/00 - B05B11/00 specially designed for treating the inside of hollow bodies
    • B05B13/0627—Arrangements of nozzles or spray heads specially adapted for treating the inside of hollow bodies
    • B05B13/0636—Arrangements of nozzles or spray heads specially adapted for treating the inside of hollow bodies by means of rotatable spray heads or nozzles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/14—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying for coating elongate material
    • C23C4/16—Wires; Tubes

Definitions

  • the invention relates to a method for metallic coating, wherein a coating lance with an anode and a cathode is axially inserted into the bore and rotated about its longitudinal axis, an arc is generated between the anode and the cathode, into which a plasma gas mixture is introduced and ionized, wherein a plasma stream is generated, a coating powder is fed into the plasma stream and the plasma stream with the particles is sprayed onto the bore wall and a coating is formed on the bore wall, according to the preamble of claim 1.
  • the following description relates to a system for metallically coating a bore wall of a bore by means of a coating lance with an anode and a cathode, wherein the coating lance can be inserted axially into the bore and can be rotated about its longitudinal axis, a power source by means of which an arc can be generated between the anode and the cathode, into which a plasma gas mixture can be introduced via an introduction device, which is ionized in the arc to generate a plasma current, a feed device for feeding a coating powder into the plasma current and an injection nozzle which is aligned with the bore wall, wherein a coating is formed on the bore wall by the plasma current.
  • a bore wall with a special coating.
  • Various methods are known for this type of coating, such as flame spraying, laser spraying, plasma powder deposition welding or arc spraying with a melting wire electrode.
  • So-called atmospheric plasma spraying is a particularly efficient method of applying a coating.
  • a plasma flow with a high temperature of up to 2000 K or more is generated by means of an arc and the introduction of a conveying gas. Fine coating particles can be introduced into this hot plasma flow, which melt in the plasma flow and are applied to the bore wall with the plasma flow at high speed.
  • the invention is based on the object of specifying a method with which a metallic coating can be efficiently applied to a bore wall.
  • the object is achieved according to the invention on the one hand by a method with the features of claim 1.
  • Preferred embodiments of the invention are specified in the dependent claims.
  • the method according to the invention is characterized in that the coating lance is inserted into the bore at an axial feed rate of 3.8 mm/rev to 4.5 mm/rev and is rotated at a rotational speed of 420 rpm to 520 rpm and at a volume flow of conveying gas from 30 l/min to 70 l/min of coating powder is injected at a feed rate of 90 g/min to 130 g/min.
  • the ratio between the rotational speed of the burner lance in the bore and the feed rate of coating powder is crucial for producing a particularly advantageous coating.
  • a relatively high feed rate of 90 g/min to 130 g/min is provided, while a moderate rotational speed of 420 rpm to 520 rpm is provided.
  • This results in a relatively high material application per revolution which according to a finding of the invention is advantageous for a microporous structure of the coating.
  • the coating particles are sufficiently melted, at least on their outside, so that they form a solid bond.
  • the degree between melting and rapid cooling is particularly advantageous, resulting in a desired microporous layer structure. This is further supported by setting the feed gas in a range of 30 l/min to 70 l/min.
  • a preferred embodiment of the method consists in setting an axial feed rate of 4.1 mm/rev to 4.2 mm/rev. This results in a particularly stable layer structure with the desired structure. It is particularly preferred if the axial feed rate is 4.13 mm/rev.
  • a particularly good heating of the plasma current is achieved by setting a discharge current of 300 A to 400 A, in particular 360 A, between the anode and the cathode.
  • a good surface application to the bore wall is also achieved by spraying the plasma stream with the particles using an injection nozzle that has a diameter of 1 mm to 2 mm, preferably 1.5 mm.
  • the lance is located in the middle of the bore, which preferably has a diameter of 7 cm to 15 cm.
  • a flat nozzle with the same or a similar opening area can also be used, which can, for example, have a size of 1 mm by 3 mm.
  • the injection nozzle is inclined upwards by 5° to 20°, in particular between 8° and 12°, particularly preferably by 10°, relative to the longitudinal axis. This allows a largely radially directed material application to be achieved, since the inclination can compensate for a deviation caused by the axial feed.
  • the coating can be applied in a single axial application.
  • a particularly stable coating structure can be achieved according to a process variant according to the invention by building up the coating using several coating layers, in particular three to six coating layers, with each coating layer being formed by an axial overflow of the coating lance. It is particularly advantageous if four axial overflows are made with the coating lance over the bore wall.
  • a particularly stable coating is achieved by forming a layer thickness of 150 ⁇ m to 300 ⁇ m, in particular 250 ⁇ m. With four overflows, a layer thickness of between 60 ⁇ m and 70 ⁇ m can be applied.
  • the plasma gas mixture can basically be formed in any suitable way. According to a further development of the invention, it is particularly advantageous that the plasma gas mixture is formed using argon, hydrogen, nitrogen and/or helium. These elements lead to a particularly effective plasma flow for the coating process.
  • the coating powder can be supplied by a carrier gas.
  • the rotational speed of the coating lance it is particularly advantageous to set a rotational speed of 450 rpm to 465 rpm, in particular 459 rpm. According to a finding of the invention, a particularly good and stable material application results in this speed range.
  • a preferred setting range is to set a volume flow of the plasma gas mixture between 40 l/min and 50 l/min, preferably 44 l/min. This can ensure a good conveying effect for the coating powder. can be achieved, whereby at the same time a necessary but not excessive cooling of the plasma stream occurs.
  • argon at 40 l/min and hydrogen at 4 l/min can be used to form the plasma gas mixture.
  • the feed rate of the coating powder is set to 110 g/min.
  • commercially available coating powder for plasma spraying can be used for the coating.
  • a coating powder with iron particles and/or other metals with an average particle size of between 100 nanometers and 100 ⁇ m. It is particularly preferred that these particles melt completely or incompletely in the heated plasma stream, i.e. only on their upper side, and thus have a droplet shape when they hit the coating wall.
  • This allows a coating to be composed of approximately spherical elements, which, through targeted cooling, form a coating structure with micro-free spaces in between.
  • there is no continuous solid connection but the melted and cooling coating particles are only connected to one another in certain areas, with preferably between 2% and 20% of the coating volume being formed by pore cavities.
  • the described system is characterized in that a control is provided and designed so that the coating lance can be inserted into the bore at a uniform axial feed rate of 3.8 mm/rev to 4.5 mm/rev and can be rotated at a rotational speed of 420 rpm to 520 rpm and a volume flow of conveying gas of 30 l/min to 70 l/min and a feed rate of coating powder in a plasma flow of 90 g/min to 130 g/min is set.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electromagnetism (AREA)
  • Coating By Spraying Or Casting (AREA)

Description

Die Erfindung betrifft ein Verfahren zur metallischen Beschichtung, wobei eine Beschichtungslanze mit einer Anode und einer Kathode axial in die Bohrung eingefahren und dabei um ihre Längsachse gedreht wird, zwischen der Anode und der Kathode ein Lichtbogen erzeugt wird, in welchen ein Plasmagasgemisch eingeleitet und ionisiert wird, wobei ein Plasmastrom erzeugt wird, ein Beschichtungspulver in den Plasmastrom zugeführt wird und der Plasmastrom mit den Partikeln auf die Bohrungswand gedüst wird und an der Bohrungswand eine Beschichtung gebildet wird, gemäß dem Oberbegriff des Anspruchs 1.The invention relates to a method for metallic coating, wherein a coating lance with an anode and a cathode is axially inserted into the bore and rotated about its longitudinal axis, an arc is generated between the anode and the cathode, into which a plasma gas mixture is introduced and ionized, wherein a plasma stream is generated, a coating powder is fed into the plasma stream and the plasma stream with the particles is sprayed onto the bore wall and a coating is formed on the bore wall, according to the preamble of claim 1.

Weiterhin betrifft die folgende Beschreibung eine Anlage zur metallischen Beschichtung einer Bohrungswand einer Bohrung mittels einer Beschichtungslanze mit einer Anode und einer Kathode, wobei die Beschichtungslanze axial in die Bohrung einfahrbar und dabei um ihre Längsachse drehbar ist, einer Stromquelle, durch welche zwischen der Anode und der Kathode ein Lichtbogen erzeugbar ist, in welchen über eine Einleiteinrichtung ein Plasmagasgemisch einleitbar ist, welches in dem Lichtbogen zur Erzeugung eines Plasmastromes ionisiert wird, einer Zuführeinrichtung zum Zuführen eines Beschichtungspulvers in den Plasmastrom und einer Injektionsdüse, welche auf die Bohrungswand ausgerichtet ist, wobei durch den Plasmastrom auf der Bohrungswand eine Beschichtung gebildet wird.Furthermore, the following description relates to a system for metallically coating a bore wall of a bore by means of a coating lance with an anode and a cathode, wherein the coating lance can be inserted axially into the bore and can be rotated about its longitudinal axis, a power source by means of which an arc can be generated between the anode and the cathode, into which a plasma gas mixture can be introduced via an introduction device, which is ionized in the arc to generate a plasma current, a feed device for feeding a coating powder into the plasma current and an injection nozzle which is aligned with the bore wall, wherein a coating is formed on the bore wall by the plasma current.

Insbesondere im Motorenbau ist es erforderlich, die Laufflächen von Zylinderbohrungen mit einer speziellen metallischen Beschichtung zu versehen, damit hinreichende Reibungs- und Schmierbedingungen zwischen der Zylinderlauffläche und einem Zylinderkolben gewährleistet sind. Dies gilt vor allem dann, wenn sowohl das Motorengehäuse als auch der Zylinderkolben aus demselben Metall, etwa aus Aluminium, gefertigt sind.In engine construction in particular, it is necessary to provide the running surfaces of cylinder bores with a special metallic coating to ensure sufficient friction and lubrication conditions between the cylinder running surface and a cylinder piston. This is especially true if both the engine housing and the cylinder piston are made of the same metal, such as aluminum.

Hierzu ist es bekannt, eine Bohrungswand mit einer speziellen Beschichtung zu versehen. Für eine derartige Beschichtung sind verschiedene Verfahren bekannt, so etwa das sogenannten Flammspritzen, das Laserspritzen, das Plasma-Pulver-Auftragsschweißen oder ein Lichtbogenspritzen mit aufschmelzender Drahtelektrode. Ein besonders effizientes Aufbringen einer Beschichtung stellt das sogenannte atmosphärische Plasmaspritzen dar. In einer Brennerlanze wird dabei mittels eines Lichtbogens und Einleiten eines Fördergases ein Plasmastrom mit einer hohen Temperatur von bis zu 2000 K oder mehr erzeugt. In diesen heißen Plasmastrom können feine Beschichtungspartikel eingeleitet werden, welche in dem Plasmastrom aufschmelzen und mit dem Plasmastrom mit hoher Geschwindigkeit auf die Bohrungswand aufgebracht werden.For this purpose, it is known to provide a bore wall with a special coating. Various methods are known for this type of coating, such as flame spraying, laser spraying, plasma powder deposition welding or arc spraying with a melting wire electrode. So-called atmospheric plasma spraying is a particularly efficient method of applying a coating. In a burner lance, a plasma flow with a high temperature of up to 2000 K or more is generated by means of an arc and the introduction of a conveying gas. Fine coating particles can be introduced into this hot plasma flow, which melt in the plasma flow and are applied to the bore wall with the plasma flow at high speed.

Ein gattungsgemäßes Verfahren geht beispielsweise aus der EP 2 933 352 A1 hervor. Die WO 2017/202852 A1 offenbart ein Verfahren gemäß dem Oberbegriff aus Anspruch 1.A generic procedure is based, for example, on the EP 2 933 352 A1 The WO 2017/202852 A1 discloses a method according to the preamble of claim 1.

Beim Aufbringen der Beschichtung ist es maßgeblich, dass diese stabil ausgebildet wird. Diese muss insbesondere bei einem Einsatz im Motorenbau eine lange Lebensdauer von vielen Jahren aufweisen, wobei die Beschichtung hohen thermischen, mechanischen und chemischen Beanspruchungen ausgesetzt ist. Dabei kann bereits ein Lösen selbst kleinerer Bestandteile der Beschichtung zu schweren Motorschäden führen.When applying the coating, it is important that it is stable. This must have a long service life of many years, especially when used in engine construction, where the coating is exposed to high thermal, mechanical and chemical stresses. Even the loosening of small components of the coating can lead to serious engine damage.

Der Erfindung liegt die Aufgabe zugrunde, ein Verfahren anzugeben, mit welchen eine metallische Beschichtung auf eine Bohrungswand effizient aufbringbar ist.The invention is based on the object of specifying a method with which a metallic coating can be efficiently applied to a bore wall.

Die Aufgabe wird nach der Erfindung zum einen durch ein Verfahren mit den Merkmalen des Anspruchs 1 gelöst. Bevorzugte Ausführungen der Erfindung sind in den abhängigen Ansprüchen angegeben. Das erfindungsgemäße Verfahren ist dadurch gekennzeichnet, dass die Beschichtungslanze mit einer axialen Vorschubgeschwindigkeit von 3,8 mm/U bis 4,5 mm/U in die Bohrung eingefahren und mit einer Drehgeschwindigkeit von 420 U/min bis 520 U/min gedreht wird und bei einem Volumenstrom an Fördergas von 30 l/min bis 70 l/min Beschichtungspulver mit einer Zufuhrrate von 90 g/min bis 130 g/min eingedüst wird.The object is achieved according to the invention on the one hand by a method with the features of claim 1. Preferred embodiments of the invention are specified in the dependent claims. The method according to the invention is characterized in that the coating lance is inserted into the bore at an axial feed rate of 3.8 mm/rev to 4.5 mm/rev and is rotated at a rotational speed of 420 rpm to 520 rpm and at a volume flow of conveying gas from 30 l/min to 70 l/min of coating powder is injected at a feed rate of 90 g/min to 130 g/min.

Nach der Erfindung wurde erkannt, dass für das Erzeugen einer besonders vorteilhaften Beschichtung es maßgeblich auf ein Verhältnis zwischen der Rotationsgeschwindigkeit der Brennerlanze in der Bohrung zu einer Zuführrate an Beschichtungspulver ankommt. Dabei wird bei dem erfindungsgemäßen Verfahren eine relativ hohe Förderrate von 90 g/min bis 130 g/min vorgesehen, während eine mäßige Drehgeschwindigkeit von 420 U/min bis 520 U/min vorgesehen werden. Es erfolgt so ein relativ starker Materialauftrag pro Umdrehung, wobei nach einer Erkenntnis der Erfindung dies vorteilhaft für einen mikroporösen Aufbau der Beschichtung ist. Gleichzeitig werden die Beschichtungspartikel zumindest an ihrer Außenseite so hinreichend aufgeschmolzen, dass diese einen festen Verbund bilden. Bei einer erhöhten Zuführrate pro Umdrehung in dem angegebenen Einstellbereich ist der Grad zwischen Aufschmelzung und schneller Erkaltung besonders vorteilhaft, so dass sich ein gewünschter mikroporöser Schichtaufbau ergibt. Dieser wird noch durch die Einstellung des Fördergases in einem Bereich von 30 l/min bis 70 l/min unterstützt.According to the invention, it was recognized that the ratio between the rotational speed of the burner lance in the bore and the feed rate of coating powder is crucial for producing a particularly advantageous coating. In the method according to the invention, a relatively high feed rate of 90 g/min to 130 g/min is provided, while a moderate rotational speed of 420 rpm to 520 rpm is provided. This results in a relatively high material application per revolution, which according to a finding of the invention is advantageous for a microporous structure of the coating. At the same time, the coating particles are sufficiently melted, at least on their outside, so that they form a solid bond. With an increased feed rate per revolution in the specified setting range, the degree between melting and rapid cooling is particularly advantageous, resulting in a desired microporous layer structure. This is further supported by setting the feed gas in a range of 30 l/min to 70 l/min.

Eine bevorzugte Ausführungsform des Verfahrens besteht darin, dass eine axiale Vorschubgeschwindigkeit von 4,1 mm/U bis 4,2 mm/U eingestellt wird. Hierbei ergibt sich ein besonders stabiler Schichtaufbau mit der gewünschten Struktur. Besonders bevorzugt ist es, wenn die axiale Vorschubgeschwindigkeit 4,13 mm/U beträgt.A preferred embodiment of the method consists in setting an axial feed rate of 4.1 mm/rev to 4.2 mm/rev. This results in a particularly stable layer structure with the desired structure. It is particularly preferred if the axial feed rate is 4.13 mm/rev.

Eine besonders gute Aufheizung des Plasmastroms wird nach einer Weiterbildung der Erfindung dadurch bewirkt, dass zwischen der Anode und der Kathode ein Entladungsstrom von 300 A bis 400 A, insbesondere von 360 A, eingestellt wird.According to a further development of the invention, a particularly good heating of the plasma current is achieved by setting a discharge current of 300 A to 400 A, in particular 360 A, between the anode and the cathode.

Ein guter Flächenauftrag auf die Bohrungswand wird weiterhin dadurch erzielt, dass der Plasmastrom mit den Partikeln mit einer Injektionsdüse aufgedüst wird, welche einen Durchmesser von 1 mm bis 2 mm, vorzugsweise von 1,5 mm aufweist. Die Lanze befindet sich dabei in der Mitte der Bohrung, welche vorzugsweise einen Durchmesser von 7 cm bis 15 cm aufweist. Neben einer zylindrischen Düse kann auch eine Flachdüse mit gleicher oder ähnlicher Öffnungsfläche zum Einsatz kommen, welche beispielsweise eine Größe von 1 mm mal 3 mm haben kann.A good surface application to the bore wall is also achieved by spraying the plasma stream with the particles using an injection nozzle that has a diameter of 1 mm to 2 mm, preferably 1.5 mm. The lance is located in the middle of the bore, which preferably has a diameter of 7 cm to 15 cm. In addition to a cylindrical nozzle, a flat nozzle with the same or a similar opening area can also be used, which can, for example, have a size of 1 mm by 3 mm.

Für einen gezielten Materialauftrag ist es im Hinblick auf den relativ großen axialen Vorschub vorteilhaft, dass die Injektionsdüse gegenüber der Längsachse um 5° bis 20°, insbesondere zwischen 8° bis 12°, besonders bevorzugt um 10° nach oben geneigt wird. Hierdurch kann ein weitgehend radial gerichteter Materialauftrag erreicht werden, da durch die Neigung eine Abweichung durch den axialen Vorschub kompensiert werden kann.For a targeted material application, it is advantageous in view of the relatively large axial feed that the injection nozzle is inclined upwards by 5° to 20°, in particular between 8° and 12°, particularly preferably by 10°, relative to the longitudinal axis. This allows a largely radially directed material application to be achieved, since the inclination can compensate for a deviation caused by the axial feed.

Grundsätzlich kann die Beschichtung in einem einzigen axialen Auftrag erfolgen. Eine besonders stabile Struktur der Beschichtung kann nach einer erfindungsgemäßen Verfahrensvariante dadurch erzielt werden, dass die Beschichtung durch mehrere Beschichtungslagen, insbesondere drei bis sechs Beschichtungslagen, aufgebaut wird, wobei eine Beschichtungslage jeweils durch einen axialen Überlauf der Beschichtungslanze gebildet wird. Besonders vorteilhaft ist es, wenn vier axiale Überläufe mit der Beschichtungslanze über die Bohrungswand erfolgen.In principle, the coating can be applied in a single axial application. A particularly stable coating structure can be achieved according to a process variant according to the invention by building up the coating using several coating layers, in particular three to six coating layers, with each coating layer being formed by an axial overflow of the coating lance. It is particularly advantageous if four axial overflows are made with the coating lance over the bore wall.

Eine besonders stabile Beschichtung ergibt sich insbesondere dadurch, dass eine Schichtdicke von 150 µm bis 300 µm, insbesondere von 250 µm gebildet wird. Bei vier Überläufen kann so insbesondere eine Schichtdicke zwischen 60 µm bis 70 µm aufgebracht werden.A particularly stable coating is achieved by forming a layer thickness of 150 µm to 300 µm, in particular 250 µm. With four overflows, a layer thickness of between 60 µm and 70 µm can be applied.

Das Plasmagasgemisch kann in grundsätzlich jeder geeigneten Weise ausgebildet sein. Besonders vorteilhaft ist es nach einer Weiterbildung der Erfindung, dass das Plasmagasgemisch unter Verwendung von Argon, Wasserstoff, Stickstoff und/oder Helium gebildet wird. Diese Elemente führen zu einem besonders wirksamen Plasmastrom für das Beschichtungsverfahren. Das Beschichtungspulver kann durch ein Trägergas zugefördert werden.The plasma gas mixture can basically be formed in any suitable way. According to a further development of the invention, it is particularly advantageous that the plasma gas mixture is formed using argon, hydrogen, nitrogen and/or helium. These elements lead to a particularly effective plasma flow for the coating process. The coating powder can be supplied by a carrier gas.

Hinsichtlich der Drehzahl der Beschichtungslanze ist es besonders vorteilhaft, dass eine Drehgeschwindigkeit von 450 U/min bis 465 U/min, insbesondere von 459 U/min, eingestellt wird. Nach einer Erkenntnis der Erfindung ergibt sich in diesem Drehzahlbereich ein besonders guter und stabiler Materialauftrag.With regard to the rotational speed of the coating lance, it is particularly advantageous to set a rotational speed of 450 rpm to 465 rpm, in particular 459 rpm. According to a finding of the invention, a particularly good and stable material application results in this speed range.

Hinsichtlich des Plasmagasgemisches liegt ein bevorzugter Einstellbereich darin, dass ein Volumenstrom des Plasmagasgemisches von 40 l/min bis 50 l/min, vorzugsweise von 44 l/min, eingestellt wird. Hierdurch kann eine gute Förderwirkung für das Beschichtungspulver erzielt werden, wobei sich gleichzeitig eine notwendige aber nicht zu hohe Abkühlung des Plasmastromes ergibt. Vorzugsweise kann dabei Argon mit 40 l/min und Wasserstoff mit 4 l/min zum Bilden des Plasmagasgemisches zum Einsatz kommen.With regard to the plasma gas mixture, a preferred setting range is to set a volume flow of the plasma gas mixture between 40 l/min and 50 l/min, preferably 44 l/min. This can ensure a good conveying effect for the coating powder. can be achieved, whereby at the same time a necessary but not excessive cooling of the plasma stream occurs. Preferably, argon at 40 l/min and hydrogen at 4 l/min can be used to form the plasma gas mixture.

Weiterhin ist es besonders zweckmäßig, dass die Zuführrate des Beschichtungspulvers auf 110 g/min eingestellt wird. Für die Beschichtung kann grundsätzlich handelsübliches Beschichtungspulver zum Plasmaspritzen eingesetzt werden.Furthermore, it is particularly useful that the feed rate of the coating powder is set to 110 g/min. In principle, commercially available coating powder for plasma spraying can be used for the coating.

Besonders vorteilhaft ist es dabei, dass ein Beschichtungspulver mit Eisenpartikeln und/oder weiteren Metallen verwendet wird, wobei eine durchschnittliche Größe der Partikel zwischen 100 Nanometer bis 100 µm liegt. Besonders bevorzugt ist es dabei, dass diese Partikel in dem aufgeheizten Plasmastrom vollständig oder nicht vollständig aufschmelzen, also nur an ihrer Oberseite, und so eine Tropfenform beim Auftreffen auf die Beschichtungswand aufweisen. Hierdurch kann sich eine Beschichtung aus etwa kugelförmigen Elementen zusammensetzen, welche durch ein gezieltes Erkalten eine Beschichtungsstruktur mit dazwischen liegenden Mikrofreiräumen bilden. Insbesondere ergibt sich keine durchgehende feste Verbindung, sondern die aufgeschmolzenen und erkaltenden Beschichtungspartikel sind nur bereichsweise miteinander verbunden, wobei vorzugsweise zwischen 2 % bis 20 % des Beschichtungsvolumens durch Porenhohlräume gebildet sind.It is particularly advantageous to use a coating powder with iron particles and/or other metals, with an average particle size of between 100 nanometers and 100 µm. It is particularly preferred that these particles melt completely or incompletely in the heated plasma stream, i.e. only on their upper side, and thus have a droplet shape when they hit the coating wall. This allows a coating to be composed of approximately spherical elements, which, through targeted cooling, form a coating structure with micro-free spaces in between. In particular, there is no continuous solid connection, but the melted and cooling coating particles are only connected to one another in certain areas, with preferably between 2% and 20% of the coating volume being formed by pore cavities.

Die beschriebene Anlage ist dadurch gekennzeichnet, dass eine Steuerung vorgesehen und ausgelegt ist, so dass die Beschichtungslanze mit einer gleichmäßigen axialen Vorschubgeschwindigkeit von 3,8 mm/U bis 4,5 mm/U in die Bohrung einfahrbar und mit einer Drehgeschwindigkeit von 420 U/min bis 520 U/min drehbar ist und ein Volumenstrom an Fördergas von 30 l/min bis 70 l/min und einer Zuführrate an Beschichtungspulver in einen Plasmastrom von 90 g/min bis 130 g/min eingestellt ist.The described system is characterized in that a control is provided and designed so that the coating lance can be inserted into the bore at a uniform axial feed rate of 3.8 mm/rev to 4.5 mm/rev and can be rotated at a rotational speed of 420 rpm to 520 rpm and a volume flow of conveying gas of 30 l/min to 70 l/min and a feed rate of coating powder in a plasma flow of 90 g/min to 130 g/min is set.

Claims (12)

  1. Method for the metal coating of a bore wall of a bore in a workpiece, in particular a running surface of a cylinder bore in an engine block, by means of atmospheric plasma spraying, wherein
    - a coating lance having an anode and a cathode is moved axially into the bore and, in doing so, is rotated about its longitudinal axis,
    - between the anode and the cathode an arc is produced, into which a plasma gas mixture is introduced and ionized, wherein a plasma flow is produced,
    - a coating powder is supplied into the plasma flow,
    - the plasma flow with the particles is sprayed onto the bore wall and on the bore wall a coating is formed, and
    - the particles of the coating powder are melted in the plasma flow and a coating provided with micropores is produced,
    characterized in that
    the coating lance is moved into the bore at an axial feed speed and is rotated at a rotational speed of 420 rpm to 520 rpm and, at a volume flow of plasma gas mixture of 30 l/min to 70 l/min, coating powder is injected at a supply rate of 90 g/min to 130 g/min, and
    in that an axial feed speed of 3.8 mm/rev to 4.5 mm/rev is set.
  2. Method according to claim 1,
    characterized in that
    an axial feed speed of 4.1 mm/rev to 4.2 mm/rev is set.
  3. Method according to claim 1 or 2,
    characterized in that
    between the anode and the cathode a discharging current of 300 A to 400 A, in particular of 360 A, is set.
  4. Method according to any one of claims 1 to 3,
    characterized in that
    the plasma flow with the particles is sprayed on with an injection nozzle having a diameter of 1 mm to 2 mm, preferably of 1.5 mm.
  5. Method according to any one of claims 1 to 4,
    characterized in that
    the injection nozzle is inclined upwards with respect to the longitudinal axis by 5° to 20°, in particular between 8° to 12°.
  6. Method according to any one of claims 1 to 5,
    characterized in that
    the coating is built up by several coating layers, in particular three to six coating layers, wherein one coating layer is formed in each case by an axial overflow of the coating lance.
  7. Method according to any one of claims 1 to 6,
    characterized in that
    a layer thickness of 150 µm to 300 µm, in particular of 250 µm is formed.
  8. Method according to any one of claims 1 to 7,
    characterized in that
    the plasma gas mixture is formed by using argon, hydrogen, nitrogen and/or helium.
  9. Method according to any one of claims 1 to 8,
    characterized in that
    a rotational speed of 450 rpm to 465 rpm, in particular of 459 rpm, is set.
  10. Method according to any one of claims 1 to 9,
    characterized in that
    a volume flow of the plasma gas mixture of 40 l/min to 50 l/min, preferably of 44 l/min, is set.
  11. Method according to any one of claims 1 to 10,
    characterized in that
    the conveying rate of the coating powder is set to 110 g/min.
  12. Method according to any one of claims 1 to 11,
    characterized in that
    a coating powder having iron particles and/or further metals is used, wherein an average size of the particles ranges between 100 nm to 100 µm.
EP20169797.6A 2020-04-16 2020-04-16 Installation and method for producing a metallic coating on a borehole wall Active EP3896190B1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
EP20169797.6A EP3896190B1 (en) 2020-04-16 2020-04-16 Installation and method for producing a metallic coating on a borehole wall
HUE20169797A HUE067596T2 (en) 2020-04-16 2020-04-16 Installation and method for producing a metallic coating on a borehole wall
CN202180011888.7A CN115003850A (en) 2020-04-16 2021-03-04 Method and apparatus for metal coating of bore walls
US17/904,363 US20230056126A1 (en) 2020-04-16 2021-03-04 Method and system for the metal coating of a bore wall
PCT/EP2021/055470 WO2021209190A1 (en) 2020-04-16 2021-03-04 Method and system for applying a metal coating to a bore wall

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP20169797.6A EP3896190B1 (en) 2020-04-16 2020-04-16 Installation and method for producing a metallic coating on a borehole wall

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EP3896190C0 EP3896190C0 (en) 2024-06-05
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WO (1) WO2021209190A1 (en)

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3958097A (en) * 1974-05-30 1976-05-18 Metco, Inc. Plasma flame-spraying process employing supersonic gaseous streams
DE10262198B4 (en) * 2001-12-03 2010-11-25 Nissan Motor Co., Ltd., Yokohama-shi Process for the preparation of a product
US20120100299A1 (en) * 2010-10-25 2012-04-26 United Technologies Corporation Thermal spray coating process for compressor shafts
EP2784171B1 (en) * 2011-11-22 2018-05-09 Nissan Motor Company, Limited Manufacturing method for cylinder block
DE102012003306B4 (en) * 2012-02-18 2024-03-21 Amt Ag Plasma coating device
ES2710712T3 (en) 2014-04-17 2019-04-26 Sturm Maschinen & Anlagenbau Gmbh Installation and procedure for the metallic coating of a perforation wall
US20160130691A1 (en) * 2014-11-07 2016-05-12 GM Global Technology Operations LLC Surface activation by plasma jets for thermal spray coating on cylinder bores
BR112018074291B1 (en) * 2016-05-27 2022-08-23 Oerlikon Metco Ag, Wohlen COATING PROCESS, THERMAL COATING, AS WELL AS CYLINDER WITH A THERMAL COATING
CN107400847B (en) * 2017-09-07 2023-05-26 中国人民解放军陆军装甲兵学院 A system and process for remanufacturing waste cylinder components of aviation piston engines
DE102018208435A1 (en) * 2018-05-29 2019-12-05 Volkswagen Aktiengesellschaft Plasma spraying method for coating a cylinder bore of a cylinder crankcase of a reciprocating internal combustion engine
TWI674334B (en) * 2018-11-13 2019-10-11 國立臺灣科技大學 Manufacturing method of high entropy alloy coating
CN109778104A (en) * 2019-03-06 2019-05-21 扬州大学 Heat-insulating and wear-resistant composite coating for inner wall of cylinder liner and preparation method thereof
CN110643924A (en) * 2019-09-19 2020-01-03 成都正恒动力股份有限公司 Metal-based ceramic reinforced inner hole coating and preparation method and spraying method thereof

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EP3896190C0 (en) 2024-06-05
HUE067596T2 (en) 2024-10-28
CN115003850A (en) 2022-09-02
EP3896190A1 (en) 2021-10-20
US20230056126A1 (en) 2023-02-23
WO2021209190A1 (en) 2021-10-21

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