Development of Detonation Flame Sprayed Cu-Base Coatings Containing Large Ceramic Particles
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Wolfgang Tillmann, Evelina Vogli, and Jan Nebel (Submitted March 7, 2007; in revised form August 27, 2007) Metal-matrix composites (MMCs) containing large ceramic particles as superabrasives are typically used for grinding stone, minerals, and concrete. Sintering and brazing are the key manufacturing technologies for grinding tool production. However, restricted geometry flexibility and the absence of repair possibilities for damaged tool surfaces, as well as difficulties of controlling material interfaces, are the main weaknesses of these production processes. Thermal spraying offers the possibility to avoid these restrictions. The research for this paper investigated a fabrication method based on the use of detonation flame spraying technology to bond large superabrasive particles (150-600 lm, needed for grinding minerals and stones) in a metallic matrix. Layer morphology and bonding quality are evaluated with respect to superabrasive material, geometry, spraying, and powder-injection parameters. The influence of process temperature and the possibilities of thermal treatment of MMC layers are analyzed.
Keywords
composite coating, grinding tool, MMC, process detonation sprayed, process parameters, reproducibility, substrate temperature, superabrasive composite, treatment—preheating
1. Introduction Thermal spraying technologies are well known for producing wear-resistant coatings. Arc spraying, plasma spraying, high-velocity oxyfuel (HVOF), and detonation flame spraying are some of the common technologies commercially available to produce metal-matrix composites (MMCs) (Ref 1-3). Coatings based on WC-Co, Cr3C2NiCr, WC-NiCrBSi, and many more are state of the art (Ref 1-7). Though the technology is used for making wearresistant MMCs, it is not yet exploited for producing superabrasive composites for grinding applications. Superabrasive composite coatings are quite similar to wear-resistant MMCs, but differ significantly in size and shape of the hard particles embedded in the matrix. Small This article is an invited paper selected from presentations at the 2007 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Global Coating Solutions, Proceedings of the 2007 International Thermal Spray Conference, Beijing, China, May 1416, 2007, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2007. Wolfgang Tillmann, Evelina Vogli, and Jan Nebel, Institute of Materials Engineering, University of Dortmund, LeonhardEuler-Str. 2, 44227 Dortmund, Germany. Contact e-mail: [email protected].
Journal of Thermal Spray Technology
hard spherical particles with sizes less than 50 lm uniformly dispersed in a metal matrix provide high hardness and high ductility for wear resistance (Ref 4-8). Angular hard particles with sharp edges and a size of 150 to 600 lm (according to the grinding task) are needed for machining stones and concrete. Tungsten carbide (WC), c
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