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Modification of HVOF and cold spray deposited coatings via electron beam technology
Vacek, Petr ; Šiška, Filip (referee) ; Čížek, Jan (advisor)
The aim of this thesis was to modify microstructure and coating-substrate interface of CoNiCrAlY coatings deposited by HVOF and cold spray on Inconel 718 substrates. Electron beam remelting and annealing in a protective atmosphere were used to modify the coatings. Microstructure, chemical and phase composition were analyzed. The effect of beam current, transversal velocity and beam defocus on remelted depth was evaluated. As-sprayed microstructure and chemical composition of coatings were analyzed and compared with remelted samples. The effect of annealing of the as-sprayed and remelted samples was evaluated. Remelted layers exhibited dendritic structure. Chemical composition changed only after remelting of interface and part of a substrate. When only the coating was remelted, chemical composition remained the same. Phases coarsened after the annealing. Chemical composition changed after annealing due to the diffusion.
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Properties of Metallic Materials Prepared by Cold Spray Technology
Piňos, Jakub ; Šiška,, Filip (referee) ; Čížek, Jan (advisor)
Cold spray is a novel coating method. Due to its low-temperature character, it has a potential to replace the high-temperature thermal spray processes in some applications. The presented work analyzes the microstructure and the phase composition of pure metal coatings deposited by cold spraying and evaluates selected mechanical properties. Specimens prepared by readily used HVOF industrial technology were used for comparison purposes.
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Determination of properties of as-sprayed and EB-deposited coatings prepared by thermal spray technologies using scratch test and nano-indentation methods
Cének, Lukáš ; Tkachenko, Serhii (referee) ; Čížek, Jan (advisor)
Properties of samples and their coatings may be affected by the electron beam. This paper deals with the analysis of the microstructure, phase and chemical composition and the determination of mechanical characteristics of inconel steel substrate and CoNiCrAlY coatings deposited via different types of thermal spraying (HVOF, cold spray), in combination with modifications by the electron beam technology. During the study it was found that the deposition did not change the chemical composition. Further it was found that the interaction of the electron beam with the material did not change the chemical composition, but there is a change in the structure and a reduction of porosity and surface roughness, resulting in a change of mechanical properties such as decreasing hardness or increase of the modulus of elasticity.
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Microstructure and properties of YSZ thermal barier coatings deposited onto CoNiCrAlY bond coats remelted by electron beam
Slavíková, Barbora ; Jan, Vít (referee) ; Dlouhý, Ivo (advisor)
The master thesis is dealing with characterization of the structure and properties of the YSZ thermal barrier coating deposited by water hybrid plasma spray technology on the CoNiCrAlY bond coats modified by using electron beam and vacuum annealing. Deposition of the bond coats was performed via high velocity oxy-fuel technology and cold spray. In case of experimental evaluation, the microstructure and chemical composition of the ceramic top coat deposited with powder and suspension feedstock was analyzed. The same analysis procedure was used also for bond coats after electron beam remelting by using two sets of parameters. Furthermore, the changes in microstructure and chemical composition of the remelted and annealed bond coats was evaluated. Eventually, the micromechanical properties of the top coats and the bond coats were measured. The ceramic top coats deposited with powder feedstock exhibited the structure composed by splats, while the top coats deposited in form of suspension showed fine structure with columnar grains. The dendritic structure was observed on remelted bond coats. The annealing process had an influence on the structure in form of coarsened phases and the chemical composition was changed due to diffusion of the elements.
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Effect of modification of HVOF sprayed alloy NiCrBSi by electron beam on its structure
Pongrácz, Jakub ; Havlík, Petr (referee) ; Foret, Rudolf (advisor)
This thesis deals with surface re-melting by electron beam of thermal sprayed material NiCrBSi by method HVOF. The microstructure, chemical and phase composition, hardness and abrasive wear resistance were evaluated in depending on the electron beam parameters and modes of the electron beam 6-poinst and line. Observed microstructure was better after both methods of re-melting. The splats were not observed, coating porosity decreased and structure was more homogenous. Structure and phase analysis was acquired by light microscopy, scanning electron microscopy, energy dispersive spectroscopy and x-ray diffraction. A small change in hardness between modes of re-melting was observed, but measured hardness was higher than in sample without re-melting. Similar results were observed for abrasion resistance.
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The role of thermal spray parameters on structure and properties of cermet coatings
Vražina, Tomáš ; Čelko,, Ladislav (referee) ; Šulák, Ivo (advisor)
The diploma thesis investigates the influence of thermal spray process parameters on the properties of composite coatings, specifically WC-CrC-Ni and WC-Co-Cr coatings deposed onto an austenitic steel substrate. The main objectives were characterization of sprayed deposition and creation of process maps. The theoretical part included the most important details about the manufacturing process, properties, consolidation and application of cermet materials. The methodical part is devoted to a description of analytical methods and devices used for the characterization of coatings microstructure and its mechanical properties. The practical part provides information acquired from analytical devices. It contains details about surface roughness, hardness, porosity, indentation modulus, corrosion potential and corrosion current density. The chemical composition of coatings and powder mixtures was analyzed by energy dispersive spectroscopy (EDS). For more accurate determination of developed phases X-ray diffraction was used. During the coatings characterization various procedures were developed. It is expected that these procedures would be implemented in another optimization of spraying conditions. Results obtained in the practical part were discussed in discussion and compared with the results from several research studies. Conclusions summarize results obtained in practical part.
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Characterization of the thermally-sprayed metal-ceramic WC-CoCr coating on the AZ91 magnesium alloy
Knoflíčková, Lenka ; Wasserbauer, Jaromír (referee) ; Buchtík, Martin (advisor)
The aim of this bachelor thesis is to evaluate metal-ceramic coating WC-CoCr on magnesium alloy AZ91 to terms of microstructure, chemical and phase structure and mechanical properties. Deposition was made by HVOF (High Velocity Oxy-Fuel). The theoretical part is devoted to magnesium alloys focusing on alloy AZ91. Further there is said about methods of heat spraying. Where this part is focused on metal-ceramic WC-CoCr coatings made by HVOF method. The theoretical part is ended by current research, that is focused on characterization of WC-CoCr on magnesium alloys. Experimental part is about characterization of microstructure of alloy AZ91, WC-CoCr powder and WC-CoCr coating on magnesium alloy AZ91 with optical, SEM and XRD analysis. With heat spraying was observed that phase W2C was made by decay of phase WC in coating which leaded to dissolve of WC in matrix. For measuring of mechanical properties was used measurement by Vickers (hardness test). As result of WC-CoCr coating on surface of magnesium alloy AZ91 was increase of average hardness from 71 ± 5 HV0,3 to 1116 ± 109 HV0,3.
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Influence of ball material on the resulting fatigue life of thermal sprayed HVOF coatings in dynamic impact testing
Duliškovič, J. ; Daniel, Josef ; Houdková, Š.
Dynamic impact wear, i.e. contact between two components in the presence of high cyclic local loads, is a challenging failure mode that occurs in many mechanical applications. Many previous studies have confirmed that dynamic impact testing is suitable for evaluating the contact fatigue of thermal sprayed coatings. However, the effect of the test parameters on the resulting lifetime is unclear. The aim of this study describes the effect of the ball material used in the dynamic impact test on the resulting fatigue life of the HVOF thermal sprayed coating. Three test balls made of WC/Co alloy, Si3N4 silicon nitride and 440 C steel were chosen for this study. Dynamic impaction testing was carried out on the Cr3C2-NiCr coating, which was sprayed by HVOF on a 1.2376 high-speed steel substrate. The impact lifetime was described by the number of critical impacts, i.e. the number of impacts before coating fatigue occurs. Furthermore, the depth and volume of impact craters were measured. Using scanning electron microscopy (SEM), the surface of the impacts as well as the microstructure of the coating on the cross-section in the region of the impacts were observed. Furthermore, the mechanism of crack propagation in the coating and the microstructure of the indentor were investigated.
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INFLUENCE OF THE DEPOSITION PARAMETERS ON MICROSTRUCTURE AND PROPERTIES OF HVOF SPRAYED WC-CRC-NI COATING
Vražina, Tomáš ; Šulák, Ivo ; Poloprudský, Jakub ; Zábranský, K. ; Gejdoš, P. ; Hadraba, Hynek ; Čelko, L.
This paper investigates the influence of thermal spray parameters of the high-velocity oxygen fuel (HVOF) process on the properties of cermet coatings prepared from commercially available Amperit 551 WC-CrC-Ni powder. Three different processing parameters were applied to optimize the production process with the aim to achieve preeminent mechanical properties and fully dense material without microstructural defects. The deposition was carried out by a GLC5 gun. The velocity and temperature of powder particles in the spray stream were monitored by Accuraspray Tecnar diagnostic tool. The quality of deposited coatings was analyzed by means of light microscopy, scanning electron microscopy, and X-ray diffraction. The chemical composition of the used powder and sprayed WC-CrC-Ni coating was determined by energy dispersive spectroscopy. It was found that the spray parameters have a negligible effect on the resulting microstructure and phase composition of the coating. However, the porosity and surface roughness were significantly affected by the variation in process parameters. To assess the basic mechanical properties of HVOF sprayed coating instrumented Vickers hardness measurements were utilized. The coating hardness reached mean values over 1400 HV 0.1 and the indentation modulus varied from 152-279 GPa.
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High temperature corrosion studies of HVOF sprayed coatings in molten sulphate salts environment
Lencová, K. ; Česánek, Z. ; Houdková, Š. ; Lukáč, František ; Mušálek, Radek
The generally applied requirements on lowering of emission production in the field of power industry have led, among others, into the application of low-emission combustion process of coal fired power plants. Besides the emissions reduction, this process has led to an increase of boilers parts corrosion degradation due to the reducing atmosphere in low-emission boilers, responsible for sulphide corrosion and molten salt attack. In such environment, the protection of the exposed surfaces gains importance. Among others, the thermal spraying technology can offer a suitable way of surface corrosion protection. In the present work, the high temperature corrosion behaviour of CoCrAlYTaCSi and Cr3C2-25%NiCr High Pressure/High Velocity Oxygen Fuel (HP/HVOF) sprayed coatings is evaluated and compared to the behaviour of bare structural steel (SPT360) substrate. The specimens were exposed to a molten salt environment, i. e., 12% Na2SO4 + 82% Fe2(SO4)3 at 690 °C under cyclic condition, simulating the working environment in low-emission boilers of coal-fired power plants. The thermogravimetric method was used to establish the kinetics of corrosion. X-ray diffraction (XRD), scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS) techniques were used to analyse the corrosion products and determine the corrosion mechanism. The thermogravimetric measurement shows high oxidation rate of SPT360 steel. Cr3C2-25%NiCr coating provides slightly better performance compared to CoCrAlYTaCSi coating. Based on the obtained results, both coatings were found to have higher corrosion resistance than the SPT360 steel substrate, offering a sufficient surface protection in a given environment.
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