Investigation about the Chrome Steel Wire Arc Spray Process and the Resulting Coating Properties

Abstract

Nowadays, wire-arc spraying of chromium steel has gained an important market share for corrosion and wear protection applications. However, detailed studies are the basis for further process optimization. In order to optimize the process parameters and to evaluate the effects of the spray parameters DoE-based experiments had been carried out with high-speed camera shoots. In this article, the effects of spray current, voltage, and atomizing gas pressure on the particle jet properties, mean particle velocity and mean particle temperature and plume width on X46Cr13 wire are presented using an online process monitoring device. Moreover, the properties of the coatings concerning the morphology, composition and phase formation were subject of the investigations using SEM, EDX, and XRD-analysis. These deep investigations allow a defined verification of the influence of process parameters on spray plume and coating properties and are the basis for further process optimization.

Systematic Investigation of the Diffusion Welding Behavior of the Austenitic Stainless Steel 304 (1.4301)

“…[1] However, the whole part is subjected to a heat treatment, vanishing cold work hardening effects, and possibly decreasing the mechanical properties of the raw material. In contrast to common welding techniques, no heat affected zone (HAZ) is formed.…”

Energy efficiency by thermal spraying

“…The average level of AAS parameters is 40% higher in comparison with both domestic and foreign AS guns, i.e. the spray angle is 10, DE is 85%, the degree of coating oxidation is 2.1-2.9%, the particle velocity is 140-500 m/s and the porosity is 2% (steel) [23][24][25]. The productivity and thermal efficiency of the process remained at the AS level.…”

Study of Particle Properties of Different Steels Sprayed by Arc Spray Process

“…The particles' size did not present significant differences during the flight; and the particles cooled down as they moved away from the gun, except the austenitic stainless steel and the FeMnCrSiNi alloy, which increased the droplets temperature during the travel. These alloys also presented more variation in chemical composition during flight.One of the various thermal spray processes is the Arc Spray Process (ASP) or Twin-Wire Electric Arc (TWEA), which consists of the fusion of metallic alloys due to arc electric caused by contact of two consumable metallic wires, and this molten material is carried by gas to a prepared surface [5,16], as shown in Figure 1a. This process has some advantages if compared to other thermal spray processes, like easy operation, mainly for manual applications and in field applications, low-cost equipment and high deposition rate [5,7].…”

“…An example of this substitution is the recovering of thickness of piping eroded or corroded on heat transfers or boilers [8,9].Coatings 2020, 10, x FOR PEER REVIEW 2 of 13One of the various thermal spray processes is the Arc Spray Process (ASP) or Twin-Wire Electric Arc (TWEA), which consists of the fusion of metallic alloys due to arc electric caused by contact of two consumable metallic wires, and this molten material is carried by gas to a prepared surface [5,16], as shown in Figure 1a. This process has some advantages if compared to other thermal spray processes, like easy operation, mainly for manual applications and in field applications, low-cost equipment and high deposition rate [5,7]. In some cases, the ASP can substitute the welding process, due to its lower heat input to the base material or substrate.…”

“…This heterogeneity of the particles' geometry produces different in-flight droplet behavior, from the gun to the substrate, bigger particles have more inertia to improve the velocity and to transfer heat to the environment, reaching the substrate hotter.The ASP process parameters have a direct influence on the size of the droplets. The droplets are smaller, as is the voltage and carrier gas pressure higher with current and wire diameter increase [5,19]. The droplet size influences the coating morphology, bigger droplets form large lamellae or pancakes.…”