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Down-selection and optimization of thermal-sprayed coatings for aluminum mould tool protection and upgrade
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Gibbons, Gregory John and Hansell, Robert George (2006) Down-selection and optimization of thermal-sprayed coatings for aluminum mould tool protection and upgrade. Journal of Thermal Spray Technology, Volume 15 (Number 3). pp. 340-347. doi:10.1361/105996306X124329
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Official URL: http://dx.doi.org/10.1361/105996306X124329
Abstract
This article details the down-selection procedure for thermally sprayed coatings for aluminum injection mould tooling. A down-selection metric was used to rank a wide range of coatings. A range of high-velocity oxyfuel (HVOF) and atmospheric plasma spray (APS) systems was used to identify the optimal coating-process-system combinations. Three coatings were identified as suitable for further study; two CrC NiCr materials and one Fe Ni Cr alloy. No APS-deposited coatings were suitable for the intended application due to poor substrate adhesion (SA) and very high surface roughness (SR). The DJ2700 deposited coating properties were inferior to the coatings deposited using other HVOF systems and thus a Taguchi L18 five parameter, three-level optimization was used to optimize SA of CRC-1 and FE-1. Significant mean increases in bond strength were achieved (147 +/- 30% for FE-1 [58 +/- 4 MPa] and 12 +/- 1% for CRC-1 [67 +/- 5 MPa]). An analysis of variance (ANOVA) indicated that the coating bond strengths were primarily dependent on powder flow rate and propane gas flow rate, and also secondarily dependent on spray distance. The optimal deposition parameters identified were: (CRC-1/FE-1) O-2 264/264 standard liters per minute (SLPM); C3H8 62/73 SLPM; air 332/311 SLPM; feed rate 30/28 g/min; and spray distance 150/206 mm.
| Item Type: | Journal Article | ||||
|---|---|---|---|---|---|
| Subjects: | T Technology > TA Engineering (General). Civil engineering (General) | ||||
| Divisions: | Faculty of Science, Engineering and Medicine > Engineering > WMG (Formerly the Warwick Manufacturing Group) | ||||
| Journal or Publication Title: | Journal of Thermal Spray Technology | ||||
| Publisher: | Springer Verlag | ||||
| ISSN: | 1059-9630 | ||||
| Official Date: | September 2006 | ||||
| Dates: |
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| Volume: | Volume 15 | ||||
| Number: | Number 3 | ||||
| Number of Pages: | 8 | ||||
| Page Range: | pp. 340-347 | ||||
| DOI: | 10.1361/105996306X124329 | ||||
| Status: | Peer Reviewed | ||||
| Publication Status: | Published | ||||
| Related URLs: |
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