Low dilution, low thickness coatings thanks to PTA-PHE

Transcription

1 Saint-Gobain Coating Solutions Ceramic materials Low dilution, low thickness coatings thanks to PTA-PHE 15 th ITSS XUZHOU October 23-25, 2012 Patrice FOURNIER

2 Contents SG Introduction PTA-PHE Description Materials & Coating morphology Benchmarking vs others PTA-PHE coating features Benefits Applications Conclusion PF 2

3 Chapter 1 Low dilution, low thickness coatings thanks to PTA-PHE Saint-Gobain introduction

4 Speciality Grain & Powder division - Coating Solutions Manufacturing Sales offices R&D locations Saint-Gobain, a global presence GLOBAL PRESENCE Worcester - MA, USA Tel: Fax: Shanghai, China Tel: Fax: São Paulo, Brasil Tel: Tel: Taipei, Taiwan Tel: Fax: Porz, Germany Tel: Fax: Osaka, JAPAN Tel: Fax: Avignon, France Tel: Fax: Seoul, Korea Tel: Fax: Worcester - MA, USA Weathfield, NY Avignon, FR DengFeng, CN Northampton - MA, USA Huntsfield, AL Cavaillon - FR Randan, CN Northborow, USA Shanghaï, CN PF 4

5 Products CCAV : 6 product lines Thermal spray Flexicords and flame spray guns ROKIDE rod spraying ProPlasma Spray systems Thermal Spray powders TUFCOTE hardfacing ropes PTA-PHE : Plasma Transferred Arc welding & cladding equipment PF 5

6 Our speciality : WE MANUFACTURE & WE SELL equipments & consumables for spraying & hardfacing - Flame spray - Plasma spray & TSP - Spray flexicords - Brazing flexicords - PTA torches PF 6

7 Chapter 2 Low dilution, low thickness coatings thanks to PTA-PHE PTA-PHE Description

8 PTA-PHE 2 in 1 equipment PTA HARDFACING 2 to 5mm thick PTA Hardware PTA welding parameters Low speed motion PHE HARDFACING 0,4 to 2mm thick PHE Hardware PHE welding parameters High speed motion PF 8

9 PTA-PHE + FANUC 6 axis robot PF 9

10 PTA-PHE ABB 6 axis robot PF 10

11 PTA-PHE + oscillation system + Arc Voltage Control PF 11

12 PTA 6PHE + 5 axis motion system PF 12

13 Chapter 3 Materials - Powder Main materials Deposit morphology

14 PTA Chart of the Major Powders Material Standard Hardness Corrosion Hot corrosion Abrasion wear Friction wear High temperature Application Corec 1 ST HRC R R RR RRR R Hot wear, corrosion Corec 6 ST HRC RR RR R R R Hot wear, corrosion Corec 12 ST HRC R RR RR RR R Hot wear, corrosion Corec 21 ST HRC RRR RR R Hot wear, corrosion Corec F F HRC R RRR RR RR R Hot wear, corrosion Corec 400 T HRC RR RR RR RR RR Hi temperature wear, metal to wetal wear Corec 800 T HRC RR RR RR RR RR Hi temperature wear, metal to wetal wear FEREC 02 NOREM HRC RR R R RR Friction and galling resistance FEREC M12 M12 steel HRC R R RRR Wear, cutting edges FEREC 307 AISI HRC R R Buffer layer, size rebuilding, self hardening upto 45HRC, versatile FEREC 309L AISI 309L 250 HB RR Buffer layer, size rebuilding, buffer layer for ferritic stainless steel FEREC 316 AISI RRR Size rebuilding for AISI 316L FEREC 410 AISI HRC R R R RR Corrosion, friction wear FEREC 420 AISI HRC R R R RR Corrosion, friction wear FEREC 430 AISI HRC R RR Buffer layer for AISI 410 and 420 NIREC 1 SF HRC RR R RR Corrosion, friction wear, abrasion wear NIREC 6 SF HRC RR R RR Corrosion, friction wear, abrasion wear NIREC 625 IN HB RRR RRR RRR High temperature corrosion NIREC 718 IN HB RRR RRR RRR High temperature corrosion NIREC HC Hastelloy C RRR RR RRR Corrosion and petroleum corrosion NIREC WCA Ni WCA >70 HRC RR Abrasion wear, friction wear NIREC WCS Ni WCS >70 HRC RRR Abrasion wear, friction wear PF 14

15 PTA-PHE - Typical coating morphologies Nirec alloy - NiCr based Corec grade 1 Corec grade 6 Angular tungsten carbide Spherical tungsten carbide High chrome PF 15

16 Benchmarking PTA-PHE versus other welding processes Chapter 4

17 Welding processes - reminder FLAME WELDING ELECTRODE GMAW rod nozzle fuel/o 2 flame metal skin dross nozzle wire shielding gas T.I.G. WELDING FLUX WELDING P.T.A. / P.H.E. TM rod nozzle argon tungstene flux wire contact tube flux shielding gas powder tungstene nozzle slag GMAW, TIG, FCAW = WELDING PROCESSES Use to be thick coatings (3 to 7 mm) Applied in several layers (Minimum 2 layers) High dilution (10 to 25 %) PF 17

18 Welding process comparison PROCESS GMAW DESCRIPTION Electrode : metal Shield gas : Ar DEPO- -SITION RATE 2 to 6 kg/h THICKNESS / LAYER 6 mm EFFI- CIENCY >90 % DILUTIO N RATE COATING MATERIALS Wire INVESTMENT MANU AUTO yes yes M TIG Electrode : W Shield gas : Ar 2 kg/h 3 mm <90 % 8-20 Wire or rod yes yes M ELECTRODE Encased rod or casting rod 2 to 4 Kg/h 5 mm <90 % Rod yes no S OXY-GAS TORCH PTA PTA-HE Brazing torch powder Electrode : W Plasma gas : Ar Shield gas : ArH2 Electrode : W Plasma gas : Ar Shield gas : ArH2 2 to 4 kg/h 2 to 6 (20) kg/h 1,5 to 3 kg/h 2 mm 4 mm 2 mm >95% yes no S FCAW Electrode : metal 7 to 15 6 mm >90 % Wire no yes L kg/h LASER CO2 laser power 1,5 2 mm 70 % <5 Powder no yes XXXXL source kg/hg 98 % 95 % < <5 Rod Powder Powder no no yes yes L L PF 18

19 PTA-PHE Coating features Chapter 5

20 PTA-PHE Benefits Low dilution = higher deposit hardness, = better corrosion resistance. Low Heat Affected Zone (HAZ). Residual stress reduced by 25 % to 100% compared GMAW, FCAW, TIG, electrode. Low dilution of the carbides, Finer crystallographic structure (higher hardness, higher abrasion resistance) PF 20

21 PTA-PHE Lower dilution GMAW-FCAW-TIG-ELECTRODE High dilution PTA-PHE Low dilution Coating as machined Coating as welded Dilution Heat affected zone Thermally Affected Zone PF 21

22 % of Iron PTA-PHE - Low dilution vs GMAW Fe PHE Fe PHE Fe PTA Fe PTA Fe GMAW ,4-0,2 0 0,2 0,4 0,6 0,8 1 1,2 1,4 1,6 1,8 Distance from interface (mm) Lower penetration of the substrate in the deposit material. Reduced Heat Affected Zone of the substrate (low HAZ), Limited diffusion of the substrate towards the deposit (up-to 5% dilution), Nominal hardness reached, even close to the interface, PF 22

23 Cobalt Gr6 microstructure vs Welding process GMAW Large dendritic structure PTA Medium dendritic structure PHE Fine dendritic structure PF 23

24 PTA-PHE - finer structure - higher hardness Hardness (Hv1) 700 Cobalt Gr 12 COATING PTA Hardfacing PHE Hardfacing Base metal 200 Grade 12 cobalt base coating 100-0,5-0,3-0,25-0,2-0,15-0,1-0,05 0 0,05 0,1 0,15 0,2 0,25 0,4 0,5 0,75 Bonding Distance to interface (mm) PF 24

25 Abrasion wear resistance ASTM G65 Cemented carbide PHE NiCrBSi+WCS SFL NiCrBSi+WCA PHE NiCrBSi+WCA PTA NiCrBSi+WCA Spray and fuse Ni+WC GMAW NI-WC Ni-Hard PTA NiCrBSi 60 HRC CrC D2 steel Hard Cr Hardox Steel PTA-PHE Co Gr 6 Hardox 400 GMAW Co Gr Volume loss mm PF 25

26 PTA-PHE benefits Chapter 6

27 PTA-PHE The precision of the Saint-Gobain torch and its high stability of arc during welding, makes possible to produce thin deposit having a controlled low dilution (low HAZ) and fine microstructure of deposit. This particular feature has the PHE TM * allowing to produce deposit without oscillation motion of the PTA torch, thus offering a fast cooling of the coating metal in fusion. * P.H.E. is a SG-CS patented PF 27

28 PTA-PHE Benefits PTA PHE cuts cost : Reduction of excessive build-up of coatings: PTA PHE allows to reduce coating thickness requirement from 3-4mm to 1,2 to 2 mm Uniformity and fine metallographic structure allowing higher machining speeds (the first pass of a Cobalt Gr 6 can be machined at 160 m/min), Low roughness of deposit minimizing the machining time (shape tolerance <0,4mm possible), PF 28

29 PTA-PHE Benefits Optimum build-up of coatings, Perfect geometry control of the deposit, close to the final geometry. Precision High deposit efficiency (> 95 %). Considerable gains in productivity (up to 100%) upto 65% time savings, upto 80% material saving, Reduction of the machining cost. Low cost of the powder compared to cored wires (-30%), Savings PF 29

30 Cost Benefit Analysis PTA / PHE / S&F 300 Relative cost of the coating solution 250 China Other Asia Emerg. Europe 200 Same cost vs PTA, but lower part distorsion Spray and fuse NiWC PTA NiWCA PHE NiWCA PHE NiWCS PF 30

31 PTA-PHE Applications Chapter 7

32 Engine Valve Application PHE Process Cadence : 320 p/h (+60%) Welded coating weight : 2g (-66%) Thickness : 0,8 to 2 mm PTA Process Cadence : 200 p/h Welded coating weight : 6g Thickness : 2 to 5 mm The automotive & heavy engines industry was the first to be interested in the PHE process for the hardfacing of exhaust valve seats using Cobalt F or Coablt PF 32

33 Mechanical Application Low thickness & wear resistant coatings hardfaced with PHE process. PHE process can be used as an alternative to hard chrome or thermal spraying (plasma or HVOF) for extreme cases of use. PHE is particularly suitable for parts that are subject to high amounts of stress or shocks, which are very often associated to problems relating to abrasion, wear, or corrosion. PHE Process Thickness : 1,5 to 2,5 mm COREC or NIREC materials PHE Process Thickness : 1,5 to 2,5 mm COREC or NIREC materials PF 33

34 Petro-Chem Application Valve obturator & valve seats can be hardfaced with PHE process. The PHE process significantly reduces coating costs by limiting the thickness of the coatings and by reducing machining costs by up to 50 %. This is due: to the perfectly uniform coating of surfaces, to an improved machining capability due to a thinner metallurgical structure. PHE Process Thickness : 2 to 2,5 mm COREC 6 or COREC 21 materials PF 34

35 Petro-Chem Application VALVE SEAT MATERIAL : COREC 6, EQUIPMENT : SN-PTA, SN-PHE, FEATURES : Corrosion resistance, wear resistance, HRc. BALL VALVE MATERIAL : COREC 6 or COREC 21, EQUIPMENT : SN-PTA, SN-PHE, FEATURES : Corrosion resistance, wear resistance, HRc (Corec 6) or HRc (Corec 21). Doc SNMI PF 35

36 Petro-Chem Application BUTTERFLY BALL VALVE MATERIAL : COREC 6, EQUIPMENT : SN-PTA, SN-PHE, FEATURES : Corrosion resistance, wear resistance, HRc. SEAT MATERIAL : COREC 6 or COREC 21, EQUIPMENT : SN-PTA, SN-PHE, FEATURES : Corrosion resistance, wear resistance, HRc (Corec 6) or HRc (Corec 21) PF 36

37 PTA-HE hardfacing with composite Tungsten Carbides PF 37

38 PTA-HE hardfacing with composite Tungsten Carbides 4% dilution 1,5mm thick coating 65% of Spherical WC PF 38

39 Typical microstructure of WC coatings PF 39

40 Oil drilling Application JOURNAL OF DRILLING BIT MATERIAL : COREC, EQUIPMENT : PTA, FEATURES : Wear resistance, >50 HRc. DRILL END / DRILLING TOOLS MATERIAL : WC composite, EQUIPMENT : PTA, FEATURES : abrasion and erosion resistance. Hardness :WC HV + Matrix >60 HRC. spherical WC PF 40

41 Mining Application WEAR PLATES, SCREENING, BUCKET WHEELS, TEETH MATERIAL : WC composite, EQUIPMENT : PTA, FEATURES : abrasion and erosion resistance WC >1800 HV + Matrix 60 HRC PF 41

42 Conclusion Chapter 8

43 Conclusion PTA PHE is a cost effective coating solution. High deposit efficiency (> 95 %) for saving materials. Perfect geometry control close to the final geometry. Nominal hardness and maximal abrasion resistance can be reached Alternative solution to spray & fuse technology when allowed by the part shape. Technology easy to set-up and for equipment maintenance PF 43

44 Thank you Danke Bedanke Merci Gracias 谢 谢 PF 44