Title: Method and an apparatus for arc spraying
Abstract: A method is proposed for arc spraying by means of a spray gun (1). The spray gun includes two electrically conductive spray wires (2) and at least one first supply device (3) for supplying a fluid (4), with an electrical voltage being applied to the spray wires (2), the spray wires (2) being fed by means of a wire guide (5), an arc (6) being ignited by the electrical voltage, the spray wires (2) being converted into a melt (8) in a melting region (7) and the melt (8) being applied by the fluid (4) to the surface (9) of a body (10). In this connection, particles (11) from a storage container (12) are supplied to the melt (8) by the fluid (4).
Patent Number: 7,019,249 Issued on 03/28/2006 to Barbezat, et al.
| Inventors:
|
Barbezat; Gérard (Opfikon, CH);
Warnecke; Christian (Wehr, DE)
|
| Assignee:
|
Sulzer Metco AG (Wohlen, CH)
|
| Appl. No.:
|
402290 |
| Filed:
|
March 26, 2003 |
Foreign Application Priority Data
| Current U.S. Class: |
219/76.14; 427/449 |
| Current Intern'l Class: |
B23K 9/04 (20060101) |
| Field of Search: |
219/7614,761.2
427/449,450
|
References Cited [Referenced By]
U.S. Patent Documents
| 4762977 | Aug., 1988 | Browning.
| |
| 5206059 | Apr., 1993 | Marantz.
| |
| 5442153 | Aug., 1995 | Marantz et al.
| |
| 2002/0074422 | Jun., 2002 | Tudor et al.
| |
| Foreign Patent Documents |
| 0282310 | Sep., 1958 | EP.
| |
| 0361710 | Apr., 1990 | EP.
| |
| 63121648 | May., 1988 | JP.
| |
Primary Examiner: Shaw; Clifford C.
Attorney, Agent or Firm: Townsend and Townsend and Crew LLP
Claims
The invention claimed is:
1. A method of arc spraying by means of a spray gun which includes two electrically
conductive spray wires and at least one first supply device for supplying a fluid
to a melt of the spray wires, with an electrical voltage being applied to the spray
wires, the spray wires being fed by means of a wire guide, an arc being ignited
by the electrical voltage, the spray wires being converted into the melt in a melting
region, and the melt being applied by the fluid to a surface of a body, characterized
in that particles from a storage container are supplied to the melt by fluid from
a second supply device, and in that the electrical arc supplies substantially all
the heat required for forming the melt and applying the melt and the particles
to the surface.
2. A method in accordance with claim 1, in which the fluid acts upon the melt
with an adjustable working pressure.
3. A method in accordance with claim 1, in which the fluid includes a gas, in
particular a noble gas such as helium or argon, or nitrogen or oxygen.
4. A method in accordance with claim 1, in which the particles include a ceramic
material, in particular Al2O3, Cr2O3, TiO2, ZrO2 and/or a carbide, in particular
WC, Cr3C2, TiC, TaC, Fe3C, diamond niobium carbide, vanadium carbide and/or a boride
and/or a nitride, in particular cBN or hBN, and/or a metal and/or a metal alloy.
5. A method in accordance with claim 1, in which the size of the particles is
selected to be between 1 μm and 200 μm, preferably between 5 μm
and 80 μm.
6. A method in accordance claim 1, in which the wire guide includes a controllable
or regulatable wire feed.
7. A method in accordance with claim 1, in which the working pressure of the
fluid and/or the supplied amount and/or kind of particles and/or the wire feed
and/or any desired further process parameter can be set individually by means of
a freely programmable control unit.
8. A method in accordance with claim 1, in which particles of different materials
and/or particles of different size are supplied to the fluid from different storage
containers to change the composition of the particle flow.
9. A wear part, in particular a brake disc for a vehicle, or smooth or Yankee
or crepe cylinders for paper making, which was coated in accordance with a method
in accordance with claim 1.
10. An apparatus for arc spraying comprising a spray gun which includes a wire
guide for feeding two electrically conductive spray wires and a first supply device
for supplying a fluid, a source of heat defined solely by an electrical voltage
to be applied to said spray wires such that an arc can be ignited and thereby the
spray wires can be converted into a melt in a melting region, with the melt being
applied to the surface of a body by the fluid, characterized by a second supply
device supplying particles from a storage container into the melt.
11. A method of arc spraying a material layer onto a surface of a body comprising
advancing electrically conductive first and second spray wires towards a melt region,
directing a first fluid flow towards the melt region, entraining particles to be
included in the material layer in a second fluid flow, applying sufficient electric
energy to the spray wires to heat the melt region sufficiently for melting portions
of the spray wires, transporting the molten portions with the first fluid flow
towards the surface of the body, combining the first and second fluid flows at
the melt region, and directing the combined fluid flows, including the particles
and the molten portions of the spray wires entrained therein, towards the surface
of the body to thereby form the layer.
12. An arc spraying method comprising feeding first and second consumable electrodes
towards a melt region, at the melt region generating an electric current between
the electrodes to generate substantially all the heat required for arc spraying,
directing a first fluid flow to the melt region, entraining particles in a second
fluid flow, heating the first fluid flow at the melt region with heat generated
by the electrodes, transporting the molten portions with the first fluid flow towards
the surface of the body, combining the first and second fluid flows in a vicinity
of the melt region, and directing the combined first and second fluid flows, including
entrained particles and molten portions of the spray wires, from the melt region
onto a surface to thereby form a layer comprising the molten spray wire portions
and the particles entrained in the fluid.
13. Apparatus for arc spraying a material layer onto a surface of a body comprising
a feeder for feeding first and second consumable electrodes to a melt region, a
conduit for flowing a first fluid to the melt region and in a direction towards
the surface of the body, a mixer for entraining particles into a second fluid flow
upstream of the melt region, an electric power supply operatively coupled to the
first and second electrodes sufficient to supply all of the heat energy required
for melting the portions of the consumable electrodes and applying the particles
and molten portions as the material layer to the surface of the body, and means
for transporting the molten portions with the first fluid flow towards the surface
of the body, combining the first and second fluid flows downstream of the melt
region, whereby the combined fluid flows carry the entrained particles and molten
portions of the consumable electrodes towards the surface of the body to form the
material layer comprised from molten portions of the consumable electrodes and
the particles.
Description
BACKGROUND OF THE INVENTION
The invention relates to a method of arc spraying, and to an apparatus for arc spraying.
Arc spraying, frequently also more accurately called arc wire thermal spraying
in the technical literature, is a conventional technology for the manufacture of
surface coatings on workpieces which should be protected, for example, against
mechanical wear, corrosion or against chemical or thermal strains.
With arc spraying, a wire-like or tube-like spray medium in the form of two
spray wires is melted in an electrical arc using a spray gun and sprayed onto a
workpiece surface by an atomizing gas, e.g. by nitrogen, a noble gas or simply
by air, under a pre-settable pressure. In this connection, the arc is initiated
between the two ends of the spray wires by application of an electrical voltage
and contact ignition. This is different from so-called "flame spraying", a method
in which the thermal energy to melt the spray wire is applied by a combustible
gas/oxygen flame, whereas in arc spraying, the electrical energy released in the
arc supplies the required thermal energy to melt the spray wires.
Since the material of the spray wires is converted into the melt in the region
of the arc and is sprayed onto the surface of the material, the spray wire must
be continuously fed from a wire store by a wire feed. Depending on the application,
stationary spray guns are known which are frequently used in automated operation
for the processing of large series, but also relatively small hand spray guns can
be used which allow a more flexible employment. The device for the wire feed can
here be either installed in the spray gun itself or, however, be effected by a
wire feed unit lying outside the spray gun.
In this connection, the properties of the sprayed layers can be directly influenced
by different parameters such as the wire diameter, the material of the spray wire,
the speed of the wire feed, the electrical voltage for the generation of the arc
or the electrical current for the maintaining of the arc, the selection of the
atomizing gas and its working pressure or the spray distance. That is, as a rule,
a change of one or more of these parameters (or also of other parameters not named
here) will result in layers with different properties and quality. Since the previously
named parameters can generally be easily influenced by a selection of the materials
or by electronic control and/or regulation devices, the arc spraying is characterized
by high flexibility. For example, among other things, the spray droplet size, or
the kinetic energy of the spray droplet, can easily be set automatically, or also
during an on-going coating procedure, depending on the demand. Moreover, the spray
procedure itself can take place under a normal ambient atmosphere, in a vacuum
chamber or in an insert gas environment. A wide selection of the most varied workpieces
with the most varied demands on properties and quality can thereby be provided
with protective surfaces using the method of arc spraying.
A disadvantage of the known methods of arc spraying can be seen in the fact that
quite specific demands are to be made on the wire materials which come into question
for the manufacture of the spray wires. For instance the spray wires must have
a sufficient ductility, that is, a sufficiently high deformability and/or elasticity
and a sufficiently high conductivity. If components with electrically poor conductivity
or no conductivity or relatively hard, that is, less ductile, components such as
ceramic materials should also be introduced into a layer to be sprayed, so-called
filler wires must be made use of. Filler wires are understood to be spray wires
with which additional components, usually in the form of discrete particles, are
included in the base material of the spray wire, which do not melt or only start
to melt in the arc, and are also installed in the surface layer sprayed on. In
this connection, the particles are very limited in their volumes and can partly
already be changed in their structure by the melting procedure of the spray wire,
which frequently results in undesired modifications in the layer. The volume portion
of the particles in the melt can also practically not be changed in a controlled
manner since it is fixedly predetermined by the distribution of the particles in
the filler wire. The size, shape and type of the particles can also only be changed
by replacing the filler wire and thus not be changed during the spray procedure
itself. In addition, electrically non-conductive particles in the spray wire can
disturb the stability of the arc and thus influence the quality of the sprayed
surface layer in a substantially negative manner. Furthermore, the manufacture
of filler wires is correspondingly complex and expensive in comparison with usual
spray wires.
SUMMARY OF THE INVENTION
It is therefore an object of the invention to propose a method of arc spraying
by means of a spray gun which allows additional solid particles, in particular
particles with electrically poor conductivity or no conductivity and/or less ductile
particles, to be introduced into the melt produced from the base material of the
spray wires in a controlled manner such that the stability of the arc is not impaired
and the use of filler wires can be omitted. It is further an object of the invention
to propose a corresponding apparatus for arc spraying with a spray gun.
In accordance with the invention, a method of arc spraying is thus proposed by
means of a spray gun which includes two electrically conductive spray wires and
at least one first supply device for the supply of a fluid, with an electrical
voltage being applied to the spray wires, the spray wires being fed by means of
a wire guide, an arc being ignited by the electrical voltage, the spray wires being
converted into a melt in a melting range and the melt being applied onto the surface
of a body by the fluid. In this connection, particles from a storage container
are supplied to the melt by the fluid. Additional particles can be introduced into
the melt, and thus into the surface layer to be produced by using the method in
accordance with the invention, and the use of filler wires can be dispensed with.
In a preferred embodiment, an apparatus having a spray gun known per se is used
for the carrying out of the method of arc spraying in accordance with the invention.
The apparatus for arc spraying includes a spray pistol, a wire guide for supplying
two spray wires, a gas supply which makes available a fluid, preferably a gaseous
fluid under an adjustable working pressure, an energy source which is suitable
to supply the spray wires with electrical energy, and a freely programmable control
unit for the setting of different process parameters. The spray wires are supplied
from a storage device to a wire guide which includes a wire feed and a guide device.
The wire feed, which can be accommodated either in the spray gun itself or in an
external device, transports the spray wires from the storage device via the guide
device into a melting region such that an arc ignites between both spray wires
in the melting region and can be kept stable over a pre-settable time. The guide
device is preferably designed such that it can be connected as an electrically
conductive device to the energy source and is electrically conductively in contact
with the spray wire such that the electrical energy required for the production
of the arc can be supplied to the spray wire via the guide device. The guide device
can also be electrically insulated against the spray wires, with the electrical
energy then being supplied to the spray wires in another manner. Since the material
of the spray wire is converted into a melt continuously in the melting region with
arc spraying, the spray wire must be continuously fed to the melting region by
the wire guide to maintain the arc.
The gas supply is connected via a first supply device, which can be designed,
for example, in the form of a pressure line, to the melting region such that the
melt produced by the arc in the melting region from the material of the spray wire
is acted upon by the fluid with an adjustable working pressure and is thus applied
to the surface of a workpiece to be coated, with the fluid preferably being able
to include a gas, in particular a noble gas such as helium or argon, or an inert
gas such as nitrogen or also oxygen or ambient air.
The apparatus in accordance with the invention for arc spraying additionally
has—in comparison with the prior art—a storage container which, in
a preferred embodiment of the apparatus in accordance with the invention, is in
connection with the first supply device by suitable means such that solid particles
can be supplied to the fluid. The melt is thereby acted upon by the fluid flow,
which includes the fluid and the supplied solid particles, via the first feed device
with an adjustable working pressure such that the particles are supplied to the
melt and are applied to the surface of a body to be coated together with the smelt
formed from the spray wires. It is further possible for the particles from different
storage containers to be able to be supplied to the melt such that the number and
the kind of the materials supplied to the fluid in the form of particles can be
set in a controlled manner during the spray procedure. It is furthermore possible
for the storage container and the gas supply to be formed by a common container.
In another preferred embodiment of an apparatus for arc spraying in accordance
with a method in accordance with the invention, the particles are supplied to the
melt by the fluid by means of a second supply device. In this connection, the apparatus
includes in the same manner and function the already described components, in particular
also the first supply device which, however, optionally only serves to act on the
melt produced by the arc in the melting region from the material of the spray wire
by the fluid with an adjustable working pressure and so to apply the melt to the
surface of a workpiece to be coated.
This apparatus for arc spraying thus has—additionally to the first supply
device—a second supply device to which second supply device particles from
a storage container can be supplied by means of a fluid, with also two or more
storage containers being present. The storage containers are connected to a gas
supply which makes fluid available at a pre-settable working pressure for the transport
of the particles, with the same gas supply being in connection both with the first
supply device and with the storage container. However, two or more gas supplies
can also be present so that, for example, the first feed device, on the one hand,
and the storage containers, on the other hand, can be supplied with fluid from
different gas supplies. If a plurality of gas supplies are present, different fluids
can also be used at the same time in one spray process. It is thus possible, for
example, for the melt to be acted upon with working pressure with a first gas,
e.g. oxygen, from a gas supply through the first supply device, while the particles
acted upon from another gas supply with a second gas, for example by a noble gas,
with another working pressure, are supplied to the melt via the second supply device.
Depending on requirements, different fluids from the gases mentioned here by way
of example can also be considered. If a plurality of storage containers are present
which make available the same or different particles, each storage container can
also be fed from one or more gas supplies which can make available the same or
different fluids.
In this connection, the particles from the storage container are supplied to
the
melt by the fluid by means of the second supply device such that the particles
are mixed with the melt in the melting region and are applied to the surface of
the body by the fluid together with the melt and thus become an integral component
of the surface layer. The second supply device preferably includes a nozzle device
which is suitable to introduce the particles into the melt acted upon by the fluid
with working pressure.
It is also possible for particles to be supplied simultaneously to the melt via
the first supply device and via the second supply device, with an apparatus for
arc spraying in accordance with the invention furthermore being quite able to include
further supply devices in addition to the first supply device and the second supply device.
In this connection, the apparatus in accordance with the invention for arc spraying
preferably includes, as already mentioned, a freely programmable control unit which
allows different process parameters such as the working pressure of the fluid and/or
the supplied amount or type of particles and/or the wire feed and/or further process
parameters to be set individually according to a pre-settable scheme.
The particles from the storage container supplied to the fluid can include, in
a preferred embodiment, a ceramic material and/or a carbide and/or a boride and/or
a nitride, in particular hexagonal boric nitride (hBN) or cubic boric nitride (cBN)
and/or a metal and/or a metal alloy. The size of the particles lies between 1 μm
and 200 μm and is preferably selected between 5 μm and 80 μm.
The volume portion of the particles from the storage container, which are supplied
to the fluid, can be set variably or fixedly such that the volume portion of the
particles in the layer sprayed by the method in accordance with the invention amounts
to between 0.1% and 40% of the total volume of the surface layer applied. The volume
portion of the particles in the sprayed surface layer preferably lies between 1%
and 20%.
The apparatus in accordance with the invention can in this connection have a
plurality of storage containers with different types of particles, with the particles,
which can be made up of different materials and/or can be of different size, being
supplied to the fluid from the different storage containers and the composition
of the particle flow being changed continuously by the control unit in accordance
with a pre-settable scheme. It is thereby possible also to adapt both the structure
and the composition of the surface layer to be sprayed continuously during a spray
process, whereby workpieces with highly structured surfaces can also always be
ideally coated in all surface regions.
A particular advantage of the method in accordance with the invention for arc
spraying
consists of the fact that the particles are introduced into the melt with the fluid
and are not brought into the coating process by using a filler wire. The particles
are thereby much less restricted in their volume and have no negative effects on
the stability of the arc and of the melting process. Depending on the materials
used and/or on the parameters selected for the arc spraying, the particles introduced
into the melt can already be either fully or partly surrounded by the fusible phase,
for example inside small droplets which have formed during the atomizing of the
melt, during its path to the surface of the body to be coated, or only be surrounded
by the fusible phase on the surface of the body to be coated before or during the
solidifying during the layer formation.
In a particular variant of the method in accordance with the invention, the particles
for example include oxidic ceramic materials or carbides and are substantially
not melted in the spray process, but installed, in a matrix-like manner in the
sprayed surface layer, in a carrier layer which is largely made up of the material
of the spray wire. The surface layer thus created can, depending on the kind of
particles built in, have quite different properties. In comparison with surface
layers which were manufactured with known methods for arc spraying, a much improved
wear resistance of the sprayed surfaces can be achieved, for example, by the use
of hard ceramic particles. For example, wear protection layers for brake discs
can be manufactured by the method in accordance with the invention which can be
used, among other things, in vehicles whose brake discs are constantly under high
strain due to frequent braking processes. This applies, for example, to trucks,
streetcars, buses and other vehicles, in particular in local traffic, which have
to brake relatively large masses frequently and at short intervals. Due to the
use of the method in accordance with the invention, wear protection layers can
for the first time be sprayed onto the brake discs of such vehicles which even
survive the service life of the corresponding vehicle. The economic advantages
which result from the use of such wear protective layers are obvious. In this connection,
the method in accordance with the invention is not restricted to the manufacture
of wear protection layers for brake discs, but can, for example, also be used successfully
for the coating of smooth cylinders or Yankee and/or crepe cylinders (so-called
dryer cylinders) for the manufacture of paper in the paper-making industry or in
many other sectors. In addition to protective layers on surfaces of workpieces,
even free-standing bodies of MMC (metal matrix composite) can be sprayed.
It is furthermore possible for the particles to be substantially dry lubricants
such as hexagonal boric nitride (hBN) or other materials, whereby an increased
lubricating capability and/or improved abrasive properties of the surface can be
achieved. For example, movable components in turbines of all kind, which are exposed
to high temperatures and/or high mechanical strains and have certain sealing functions,
can thus be equipped with such layers by using the method in accordance with the invention.
It is moreover even possible for the particles likewise to be melted in the arc
such that a more or less homogeneous mixture of melt and melted particles is formed,
which then results in correspondingly more homogeneous structures in the surface
layer. For example, the particles, which are supplied to the fluid from the storage
container, can include materials such as metals or metal alloys. By supplying such
particles into the melt formed from the material of the spray wire, an alloy can,
for example, be formed in the melt which has a composition differing from the material
of the spray wire or having properties different from the material of the spray wire.
The properties of the sprayed surface layer can moreover also be influenced by
the fluid itself which is used in the spraying process to apply working pressure
to the melt and/or for the supply of the particles. For example, the fluid can
include an increased content of oxygen such that the materials including the melt
and/or the particles already oxidize to a certain degree in the spray process,
whereby the chemical and physical properties of the sprayed surface can be positively influenced.
The apparatus in accordance with the invention for arc spraying with a spray
gun includes a wire guide for feeding two electrically conductive spray wires and
at least one first supply device for the supply of a fluid, with an electrical
voltage being applied to the spray wires such that an arc can be ignited and thereby
the spray wires can be converted in a melting region into a melt, with the melt
being applied to the surface of a body by the fluid. In this connection, means
are provided at the apparatus in accordance with the invention to supply particles
from a storage container to the melt by the fluid.
Since means are provided to supply particles to the melt by the fluid, the
use of filler wires as spray wires can be omitted. Different sorts of particles
can be supplied to the fluid either separately from a plurality of different storage
containers or mixtures of different sorts of particles are available in one or
more storage containers and can be supplied to the fluid from the storage containers.
The invention will be described in more detail in the following with reference
to the drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 illustrates the important parts of an embodiment of an apparatus for
arc spraying in accordance with the invention;
FIG. 2 shows a further embodiment of an apparatus for arc spraying; and
FIG. 3 shows an example of a layer on a surface of a body, applied by arc spraying
in accordance with the method of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows in a schematic representation a preferred embodiment of an apparatus
in accordance with the invention for arc spraying comprising a spray gun
1,
a first supply device
3, a storage container
12 and a control unit
14 for arc spraying in accordance with a method in accordance with the invention.
The spray gun
1 includes, in a known manner, two electrically conductive
spray wires
2 which are connected to an energy source
16 for supply
with electrical energy such that an arc
6 can be ignited between the spray
wires
2 in a melting region
7 and can be maintained in a stable manner
over a pre-settable time. The spray wires
2 can be supplied from a storage
device (not shown) of a wire guide
5. The wire guide
5 includes a
wire feed
13 which is suitable to supply the spray wire
2 to the
melting region
7 through a guide device
17. The guide device
17
is preferably designed such that it can be connected as an electrically conductive
device to the energy source
16 and is in electrically conductive contact
with the spray wire
2 such that the electrical energy required for the production
of the arc
6 can be supplied to the spray wire
2 via the guide device
17. Since material of the spray wire
2 is continually converted into
a melt
8 in the melting region
7 in arc spraying, the spray wire
2 must be continuously fed to the melting region
7 by the wire guide
5 to maintain the arc
6.
The melt
8 formed from the material of the spray wire
2 in the
arc
6 is applied to a surface
9 of a body
10 by a fluid
4
via a first supply device
3 from a gas supply
19. The melt
8
is acted upon with a pre-settable pressure by the fluid
4, which is preferably
a gas, in particular oxygen, nitrogen, argon, helium, ambient air or another gas,
whereby the melt
8 is propelled onto the surface
9 of the body
10,
and the melt
8 condenses into a solid state on the surface
9 of the
body
10 and thus forms a surface layer
18 with pre-settable properties
on the surface
9 of the body
10.
An apparatus in accordance with the invention for arc spraying furthermore has
means
15 with which particles
11 can be supplied to the fluid
4
from a storage container
12, with—as shown by way of example in FIG.
1—also two or more storage containers
12 being present. In
this connection, the particles
11 from the storage container
12 are
supplied to the melt
8 by the fluid
4 such that the particles
11
are mixed with the melt
8 in the melting region
7 and are applied
to the surface
9 of the body
10 together with the melt
8 by
the fluid
4 and thus become an integral part of the surface layer
18.
The particles
11 preferably include a ceramic material, in particular aluminum
oxide (Al
2O
3), chromium oxide (Cr
2O
3),
titanium oxide (TiO
2), zirconium oxide (ZrO
2) and/or a carbide,
in particular tungsten carbide (WC), chromium carbide (Cr
3C
2),
titanium carbide (TiC), tantalum carbide (TaC), iron carbide (Fe
3C),
niobium carbide, vanadium carbide and/or a boride and/or a nitride such as hexagonal
boric nitride (hBN) or cubic boric nitride (cBN) and/or a metal and/or a metal
alloy. In this connection, the particles
11 are preferably substantially
not melted, but only integrated into the surface
18 in a matrix-like structure.
However, it is also conceivable for the particles
11 likewise to be melted
and to be mixed with the melt
8, e.g. while forming an alloy, in order thus
to form a substantially homogeneous surface layer
18.
For control and/or regulation, an apparatus in accordance with the invention
for arc spraying has a freely programmable control unit
14 with which the
working pressure, with which the fluid
4 acts upon the melt
8, and/or
the supplied amount and/or kind of particles
11 and/or the wire feed
13
and/or the electrical energy supplied to the spray wires
2 and/or a further
process parameter can be set individually. For this purpose, for example, the gas
supply
19 and/or the wire guide
5 and/or the storage container
12
and/or the energy source
16 and/or further components of the apparatus in
accordance with the invention are connected to the control unit
14 via control
lines
20. Furthermore, the control unit
14 can include sensor lines
21 by which different operating parameters such as current working pressure,
gas pressure in the process chamber, ambient pressure, temperature, electrical
operating parameters of the energy source, or other parameters, can be transmitted
to the control unit
14 by sensors (not shown).
FIG. 2 schematically shows a further embodiment of an apparatus for arc spraying
in accordance with a method of the invention having a spray gun
1, a first
supply device
3, a storage container
12 and a control unit
14.
In the embodiment shown here, the particles
11 are, however, supplied to
the melt
8 by the fluid
4 by means of a second supply device
31,
with the spray gun
1 including in the same manner and function the already
described known components of a spray gun
1 for arc spraying. The apparatus
shown in FIG. 2 also includes, likewise in the same manner and function, the already
described further components of an apparatus in accordance with the operation,
with the first supply device
3 optionally only being able to serve for the
supply of fluid
4 to act upon the melt
8 with working pressure. The
apparatus shown in FIG. 2 in particular also has an energy source
16 whose
representation has been omitted here for reasons of understandability.
The melt
8 formed from the material of the spray wire
2 in the
arc
6 is also applied here—analogously to the already described embodiment—to
a surface
9 of a body
10 by a fluid
4 via a supply device
3 from a gas supply
19. The melt
8 is acted upon with a pre-settable
working pressure by the fluid
4 which is preferably a gas, in particular
nitrogen, oxygen, argon, helium, ambient air or another gas, whereby the melt
8
is propelled onto the surface
9 of the body
10, and the melt
8
condenses on the surface
9 of the body
10 in a solid state and thus
forms a surface layer
18 with pre-settable properties on the surface
9
of the body
10.
The embodiment shown in FIG. 2 of an apparatus in accordance with the invention
for arc spraying further has means
15 with which particles
11 can
be supplied from a storage container
12 of a second supply device
31
by means of a fluid
4, with—as shown by way of example in FIG.
2—also
two or more storage containers
12 being present. The storage containers
12 are connected to a gas supply
19 which makes fluid
4 available
at a pre-settable working pressure for the transport of the particles
11.
In this connection, the same gas supply
19 can be in connection both with
the first supply device
3 and with the storage container
12 and/or
the second supply device
31. However, as shown by way of example in FIG.
2, two or more gas supplies
19 can also be present so that, for example,
the first supply device
3 and the storage containers
12 and/or the
second supply device
31 are supplied with fluid
4 from different
gas supplies
19. If a plurality of gas supplies
19 are present, different
fluids can also be employed simultaneously in one spray process. It is thus possible,
for example, for the melt
8 to be acted upon by oxygen with working pressure
through the first supply device
3 from a gas supply
19, while the
particles
11, for example acted upon by a noble gas with a different working
pressure, are supplied to the melt
8 from another gas supply
19 via
the second supply device
31. Depending on the demand, fluids
4 can
also be considered other than the gases listed here by way of example. If a plurality
of storage containers
12 are present which can make available the same or
different particles
11, each storage container can also be fed from one
or more gas supplies
19 which can make available the same or different fluids
4.
In this connection, the particles
11 from the storage container
12
are supplied to the melt
8 by the fluid
4 by means of the second
supply device
31 such that the particles
11 are mixed with the melt
8 in the melting region
7 and are applied to the surface
9
of the body
10 by the fluid
4 together with the melt
8 and
thus become an integral part of the surface layer
18. The second supply
device
31 preferably includes a nozzle device
32 which is suitable
to introduce the particles
11 into the melt acted upon with working pressure
by the fluid
4.
FIG. 3 shows—in a schematic representation—an example of a surface
layer
18 which was applied to the surface
9 of a body
10 by
arc spraying in accordance with a method of the invention. With the example shown
here, particles
11 from the storage container
12 are supplied to
the fluid
4 acted upon with working pressure and the melt
8 formed
in the arc
6 is propelled onto the surface
9 of the body
10
by the particle flow formed from the fluid
4 and the particles
11.
The particles
11 used in this embodiment were, in this connection, substantially
not melted, but installed in a matrix-like manner in a carrier layer
22
which largely includes the material of the spray wire
2 (from the material
melted by the arc
6). The surface layer
18 thus created can, for
example, depending on the kind of the particles
11 built in, have a much
improved wear resistance in comparison with surface layers
18 which were
made with known methods for arc spraying.
For example, surface layers
18 for brake discs can thus be manufactured
by the method in accordance with the invention which can be used, among other things,
in vehicles whose brake discs are constantly under high strain due to frequent
braking processes. This applies, among other things, to trucks, streetcars, buses
and other vehicles, in particular in local traffic, which have to brake relatively
large masses frequently and at short intervals. In this connection, the method
in accordance with the invention is not restricted to the manufacture of surface
layers
18 for brake discs, but can, for example, also be used successfully
for the coating of smooth cylinders or Yankee and/or crepe cylinders (so-called
dryer cylinders) for the manufacture of paper in the paper-making industry or in
many other sectors. In addition to surface layers
18 on surfaces
9
of workpieces, even free-standing bodies of MMC (metal matrix composite) can be sprayed.
It is further possible for the particles
11 to substantially include dry
lubricants such as hexagonal boric nitride or others, whereby an increased lubrication
capability and/or improved abrasive properties of the surface layer
18 are
achieved. It is also possible for the particles
11 likewise to be melted
in the arc
6 such that a more or less homogeneous mixture of melt
8
and melted particles
11 is formed, which then results in correspondingly
more homogeneous structures in the surface layer
18.
Since the supply of the particles
11 to the melt
8 can take place
from different storage containers
12 and the amount and/or kind of supplied
particles
11 can be set individually for each storage container
12,
it is also possible to manufacture surface layers
18 in one working step
whose properties vary over the surface layer
18 from point to point and/or
over the thickness of the surface layer
18; i.e. pre-settable concentration
profiles of particles can also be produced in the surface layer
18. It is
thus possible, for example, to manufacture surface layers
18 whose abrasive
properties and/or whose wear resistance vary from point to point or change in a
pre-settable manner as the layer removal increases.
The method in accordance with the invention for arc spraying by means of a spray
gun allows solid particles to be additionally introduced into the melt produced
from the material of the spray wires in a controlled manner by a fluid acted upon
with working pressure such that the use of expensive filler wires can be omitted.
Since the particles are supplied from different storage containers to the melt
by the fluid in accordance with a pre-settable scheme, as required, different particle
types of different size and chemical composition can be simultaneously introduced
into the layer to be sprayed. It thereby becomes possible to manufacture surface
layers with clearly improved properties and a greater variety of possible structures
and composition by arc spraying.
*
