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Functional Coatings: Overview High-Density-Infrared Transient Liquid CoatingsCraig A. Blue, Vinod K. Sikka, Evan K. Ohriner, P. Gregory Engleman, and David C. Harper |
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TABLE OF CONTENTS |
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A high-density-infrared, transient-liquid coating process has been developed to produce wear- and corrosion-resistant coatings on a variety of surfaces that are of commercial interest. The process combines infrared heating with power densities up to 3.5 kW/cm2 with a room-temperature spray process to quickly form wear- and/or corrosion-resistant coatings in seconds. This process has been demonstrated using Cr2C3 and WC-reinforced coatings with nickel-based binders. Coating densities as high as 98-100 percent of theoretical density have been achieved with coating thickness of 10 mm to 2 mm. The same processing techniques have also been shown to be capable of performing localized and selective heat treatment of surfaces.
RADIANT-ENERGY THEORY |
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High-density infrared (HDI) provides a fast, controllable method for metal-heating applications. All bodies radiate energy as a function of their absolute temperature, as defined by Stefan-Boltzmann Law |
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where Q is total emissive power (W/cm2), k is the Stefan-Boltzmann constant 5.56 × 10-12 (W/cm2-°K4), and T is absolute temperature (K). Infrared energy is the portion of the electromagnetic spectrum between 0.78 mm and 1,000 mm. The infrared electromagnetic spectrum can be divided into three divisions: short wave (0.78 mm to 2.0 mm), medium wave (2.0 mm to 5.0 mm), and long wave (5.0 mm to 1 mm). The actual emission spectrum of a given source is dependent upon its temperature; increasing the source temperature will result in shorter overall wavelengths of the energy. This also corresponds to an increase in the overall emissive power per Equation A.3 In order to understand which parameters are important in rapid-infrared heating, consider the general equation for heat transfer between the source and target |
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Where Q is heat transfer between
the source and target (W/cm2), FV is the
view factor between the source and target, ES is the emissivity factor of
the source, AT is the absorption factor of the target, k is the Stefan-Boltzmann
constant, TS is the absolute temperature of the source, and TT is the absolute
temperature of the target. The view-factor term is the fraction between 0 and 1 that quantifies the amount of radiant energy emitted from the source that falls incident upon the target. Control of the heating rate is accomplished by varying the source temperature. The absorbed heat transfer (Q) results in a temperature rise of the target as defined by |
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where T is the product temperature rise
(K), A is the target area (cm2), t is
the heating dwell time, M is the target mass (kg), and Cp is the target
specific heat (W-s/kg-K). |
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where Ml is the radiant power in W/mm2, corresponding to wavelength l; C1 is the constant 3.741 × 108 W × mm4/m2; C2 is the constant 14,388 mm × K; l is wavelength (mm); and T is the temperature of the filament (K). A depiction of Plank's Law is shown in Figure A. | |||||||||
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The emission of radiation, however, is not the emission of heat. It is only when a body absorbs radiation that it is converted into heat. The overall absorption capability, a, at a point is the ratio between the flux absorbed and the incident flux. For all known bodies, this ratio is less than one, since part of the radiation is reflected and, if the body is not opaque, part of the radiation is transmitted. If r is the reflection factor or reflectivity and t is the transmission factor or transmissivity, |
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This is schematically depicted in Figure B. |
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The Infrared Processing Center of the Materials Processing Group in the Metals and Ceramics Division at ORNL has a variety of HDI equipment with the capability of producing heat fluxes 10-3,500 W/cm2. In the HDI processing facility, the HDI lamp is mounted on a large, five-axis robotic manipulator arm. A state-of-the-art robotic controller defines arm movement; this controller is capable of using computer-aided drawing data files of large parts to generate instructions to manipulate the source over a complicated geometry in a predetermined, systematic way. The HDI processing facility is shown in Figure C. | |||||||||
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Test-sample processing is performed
in an environmentally controlled box, which has a quartz window cover to
permit processing of materials in a controlled atmosphere. The infrared
reflector has a focal length that extends through the quartz and onto the
material being processed. A lathe to rotate parts while heat treating or
fusing coatings is also included in the processing facility. Another feature of the plasma lamp for this facility is a water window (Figure D), which passes a thin film of water over the quartz glass covering the elliptical reflector to protect the lamp when operating in harsh environments. This window has a 3 mm water film that continuously cools the lamp quartz window. The water clings to the quartz window due to surface tension and stream momentum. Water is introduced on one side of the lamp across an air knife and removed on the opposite side through a vacuum orifice. This protects the lamp from liquid-metal splatter or hot-spalled material, which is necessary in many processing applications. |
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The lamp consists of a quartz tube 3.175 cm in diameter and 10.16 cm, 20.32
cm, or 38.1 cm long. The lamp is sealed at the ends where the cathode and anode
are located. Deionized water mixed with argon or nitrogen gas enters at the
cathode side through high-velocity jets impinging at a given angle. Due to the
high velocities and pressure, the deionized water is impelled to the wall of
the quartz tube and spirals down the length of the tube in a uniform 2-3 mm
thick film. This water film serves two purposes: to cool the quartz wall and
to remove any tungsten particulate that may be expelled from the electrodes.
The gas moves in a spiral fashion through the center of the tube, and a capacitative
circuit initiates the plasma. The plasma, which has a temperature in excess
of 10,000 K,6 is stable
and produces a radiant spectrum 0.2-1.4 mm (Figure
2). The spectrum is primarily in the infrared (0.78 mm
to 1.00 mm), although substantial energy is released
in the visible wavelength, similar to the appearance of natural sunlight in
energy distribution and color rendition.
The spectrum is absorbed with high efficiency by metal surfaces. In contrast,
the spectrum of a CO2 laser with wavelengths
near 10.6 mm is absorbed with much lower efficiency.
The powder coatings discussed here are highly absorbing, because the open areas
act like black bodies.
The lamp has a typical life of approximately 1,200 h, and failure occurs in
the anode and cathode, which are inexpensive and can be changed in approximately
15 minutes. Furthermore, the lamp has a consistent spectral output independent
of lamp life and power level. The lamp is typically configured with a reflector
to produce a line focus or an area of uniform irradiance (Figures 3a
and 3b).
A plasma-sprayed coating that has been HDI-processed is shown in Figures 4a and 4b. The HDI-processed thermal-sprayed coating has dramatically reduced coating porosity, as seen in Figure 4b. The coating has only microporosity, similar to the base 4340 steel, after the HDI processing. The mechanical interface between the coating and the base material has been transformed into a metallurgical bond.
Hardness profiling from the coating to the base material reveals
that approximately 200 mm of the base material is
slightly overtempered (Figure 5). The
HDI processing almost completely eliminates the porosity in the plasma coating.
Processing time is approximately 10 cm2/s
for the 20 cm lamp, and the resultant hardness of this coating is 982 HV. This
post-HDI processing of plasma-sprayed coatings is presently being evaluated
for the surfacing of rolling-mill rolls, for corrosion resistance in the chemical
industry, and for wear/corrosion applications in the heavy equipment industry.
Powder Spray and Fuse
Coupling HDI processing with powder spraying at ambient temperature is a second
coating method. Room-temperature spray processes are utilized to deposit WC
and Cr2C3
with an alloy matrix on the surfaces of wear- and corrosion-sensitive parts.
The ceramic particulate can have volume fractions as high as 70 vol.%, while
the matrix is chosen to provide sufficient coefficient of thermal expansion
to accommodate the differences in expansion and contraction between the coating
and matrix. The matrix is also chosen to resist thermal softening and chemical
effects. The process allows for selective deposition at room temperature of
a coating material only in the desired areas, and fusing has little effect on
the base material. Figures 6a and 6b
illustrate some results of ORNL's HDI-TLC process. Large chain parts utilized
in industries such as mining, where corrosion and wear can result in large down
time of equipment, are shown in the figure.
The scan speed and power density used to produce the tungsten carbide/nickel-chromium
coating shown in Figure 6b was 0.5 cm/s
and 1,000 W/cm2, respectively. These coatings
have a typical hardness on the order of 1,000 HV, which is similar to the as-plated
hardness of hard chromium (1,020 HV). Also, the HDI-TLC coatings are under compression
after coating, which suppresses crack formation.
A substantial amount of work has been accomplished in the area of depositing
an HDI coating of Cr2C3
on H-13 core pins, which are a serious problem for aluminum die-casting industries.
This process was also used to produce a coating to eliminate the reaction of
the molten aluminum with steel dies that form a low-temperature eutectic at
652°C. This reaction is also called soldering. Work accomplished by ORNL
in the HDI-TLC of die pins has increased the life of the pins by an order of
magnitude. Further refinement in fusing cycles and metal-matrix improvements
may extend the life of high-aspect ratio pins, which are most susceptible to
soldering due to the higher temperatures experienced, by two orders of magnitude
or more.
The key to the success of this work is the ability of the HDI-TLC process to
fuse the coating to the base material without excessive dissolution of the iron.
If iron is present at the coating surface, soldering will persist.
If thicker coatings are necessary, a third coating method may be utilized in
which a precursor carbide mat is first applied in the area to be coated, and
a metallic matrix is rapidly infiltrated into the ceramic precursor and wetted
to the substrate. This is almost identical to the described spray process, but
it allows for thicker coatings up to 3 mm. A typical thick coating of this type
is shown in Figure 7.
With this type of application technique, hard phase loading of 80 vol.% is possible.
These types of coatings can be utilized for a variety of applications, including
rollers, shafts, turbines, conveyors, drilling tooling, mining equipment, textile
guides, pipes, compressors, dies, paper rolls, pumps, tooling, cutters, metal-working equipment, and lawn equipment.
References
1. N.C. Cox
and D.E. McGee, "Use of High Density IR for the Rapid Heating of Metals," Industrial
Heating, 4 (1989), pp. 46-48.
2. H. Bischof,
"The Answer Is Electrical Infrared," J. Microwave Power and Electron. Energy,
25 (1) (1990), pp. 47-52.
3. R. Loison,
Chauffage industrial (France: Ecole nationale superieure des Mines de
Paris, 1956).
4. J. Gosse,
Rayonnement thermique (France: Editions Scientifiques Riber, 1975).
5. J. Scadura
et al., Initiation aux transferts thermiques (France: Technique et Documentation,
1978).
6. D.M. Camm
and B. Lojek, "High Power Arc Lamp RTP System for High Temperature Annealing
Applications" (Paper presented at 2nd International Rapid Thermal Conference,
1994).
Craig A. Blue, Vinod K. Sikka, Evan K. Ohriner, P.
Gregory Engleman, and David C. Harper are with the Infrared Processing Center
at Oak Ridge National Laboratory.
For more information, contact C.A. Blue, Oak Ridge National Laboratory, Metals
and Ceramics Division, One Bethel Valley Road, Oak Ridge, Tennessee 37831-6083;
(423) 574-4351; fax (423) 574-4357; e-mail blueca@ornl.gov.
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