Advances in the field of HVOF coatings by
GTV
Dr.-Ing. K. Nassenstein, Dr.-Ing. A. Schwenk
GTV Verschleißschutz GmbH, D-57629 Luckenbach, Germany
www.gtv-mbh.de;
[email protected],
Fon: +49 2662 9576 0; fax +492662 9576-30
Contents
1. Principle – HVOF fluid dynamics
2. Process optimisation
3. Analysis of the fluid dynamics
4. Coating quality
HVOF fluid dynamics
HVOF-Process Supersonic flow
non adjusted flow conditions („underexpanded jet“, ps > pa
or „overexpanded jet“, ps < pa),
(ps: static pressure of the supersonic flame at the nozzle exit, pa: ambient pressure)
shock diamonds in the expansion nozzle and the exiting supersonic flame
1. Shock diamond
1. Expansion
Supersonic flame „underexpanded“
Process optimisation
REQUIREMENTS of HVOF coatings:
ECOMOMY
HVOF Process Efficiency (DE)
1. Coating porosity < 1 %
2. Coating surface roughness Ra << 2 µm
3. Max. hardness, wear and corrosion resistance
PHYSICS
1. Supersonic flame temperature of the combustion
2. Supersonic flame velocity combustion chamber
pressure p0
3. Expansion of the supersonic flow nozzle geometry
Supersonic fluid dynamics Powder treatment and „in-flight“ behaviour
Process optimisation
Supersonic fluid dynamics Powder treatment and „in-flight“ behaviour
Kerosene Systems (K2) Fuel Gas Systems (TopGun)
Limit: supersonic flame temperature ( 1) supersonic flame velocity (p0)
< 1 is not adjustable because of carbon residues combustion chamber pressure p0 4 bar
Tparticle always lower compared to fuel gas vparticle always lower compared to kerosene
systems! systems
Advantage:
supersonic flame velocity (p0) supersonic flame temperature ()
combustion chamber pressure 13 bar < 1 is adjustable
very high particle velocities ! max. particle temperatures can be achieved
Process optimisation – K2
Supersonic fluid dynamics of the HVOF
K2 - System
Analysis of the fluid dynamics
Standard cylindrical nozzle 150/11, O2 900 l/min, kerosene 26 l/h, p0 = 8,5 bar
pa 1,0 bar
ps 1,9 bar ps 0,5 bar ps 1,9 bar ps 0,7 bar
ps,exit >> pa underexpanded supersonic flame at the nozzle exit
Analysis of the fluid dynamics
Comparison of axial velocity distribution in the supersonic flow (150/11)
vexit 1400 m/s vflame 1900 m/s v 1300 m/s
acceleration deceleration acceleration
„in-flight“ particles cool down heating cool down
1. Expansion 1. Shock 2. Expansion
Process optimisation – K2
New nozzle geometries for an improved
Solution
Solution
expansion of the supersonic flame:
Solution
1. Weakening of the shock nodes
Higher particle velocities !
Analysis of the fluid dynamics
Divergent expansion nozzle 150/14, O2 900 l/min, kerosene 26 l/h, p0 = 8,5 bar
pa 1,0 bar
ps 1,1 bar ps 0,92 bar ps 1,08 bar
ps > pa slightly underexpanded supersonic flame at the nozzle exit
Analysis of the fluid dynamics
Comparison of axial velocity distribution in the supersonic flow (150/14)
vexit 1650 m/s vexit 1700 m/s vexit 1600 m/s
Almost uniform „in-flight“ particle behaviour !
1. Expansion 1. Shock 2. Expansion
Coating Quality
Powder feedstock: GTV 80.76.1 – WC/Co-Cr 86/10-4 (-45 + 15 µm)
nozzle 150/11; vf = 1400 m/s nozzle 150/14; vf = 1700 m/s
vparticle = 600 m/s vparticle = 660 m/s
hardness: 1300 HV0,3 Tparticle 100 °C hardness: 1400 HV0,3
Coating Quality
Powder feedstock: GTV 80.15.1 - NiCrBSi (-53 + 20 µm)
nozzle 150/11; vf = 1400 m/s nozzle 150/14; vf = 1700 m/s
vparticle = 610 m/s vparticle = 670 m/s
Tparticle 100 °C
hardness: 800 HV0,3 hardness: 900 HV0,3
Coating quality
Powder feedstock: GTV 80.20.1 - NiCr 80/20 (-53 + 20 µm)
nozzle 150/11; vf = 1400 m/s nozzle 150/14; vf = 1700 m/s
vparticle = 580 m/s vparticle = 630 m/s
Tparticle 100 °C
hardness: 420 HV0,3 hardness: 440 HV0,3
Coating quality
Powder feedstock: GTV 80.71.0W20 - WC/Co 88/12 (-20 + 5 µm)
nozzle 100/11; vf = 1400 m/s nozzle 100/14; vf = 1700 m/s
vparticle = 780 m/s vparticle = 825 m/s
Tparticle 50 °C
hardness: 1150 HV0,3 hardness: 1250 HV0,3
Sum up
Fluid dynamics:
150/14
150/11
10 - 15 % higher
particle velocities
due to an optimisation
of supersonic flame
expansion !
Economical aspects:
Higher coating quality but less deposition efficiency (DE: - 5 %)
Spare part costs: + 60 % but 2 times higher life time cost reduction !
Process optimisation - TopGun
Supersonic fluid dynamics of the HVOF
TopGun - System
Analysis of the flow characteristica
Nozzle 22/8/135, O2 300 l/min, C2H4 100 l/min, p0 = 2,3 bar, = 1
pa 1 bar vsonic 980 m/s
M 1,09
ps > pa slightly underexpanded supersonic flame at the nozzle exit
Process optimisation – TopGun
New nozzle geometries for an improved
Solution
Solution
expansion of the supersonic flame:
Solution
1. Weakening of the shock nodes
Higher particle velocities !
Analysis of the flow characteristica
Laval- nozzle exit 22/8/135, O2 300 l/min, C2H4 100 l/min, p0 4,0 bar, = 1
vsonic 870 m/s pa 1 bar
1380 m/s
M 1,6
ps pa almost uniform supersonic flame expansion at the nozzle exit no shock diamonds !
Coating quality
ASTM G65 Rubber Wheel
10
GTV 80.76.1 WC/Co-Cr 86/10-4 (-45+20 µm) 7
wear [mg/min]
6
0
TopGun 8 mm TopGun Laval K2 150/14
Particle velocity - SprayWatch
700
600
500
velocity [m/s]
400
300
200
100
0
TopGun 8 mm TopGun Laval K2 150/14
Conclusions
based on the results of computional fluid dynamics, new expansion
nozzles geometrieshave been designed for the fuel gas
system TopGun and the kerosene system K2 system
the emanating supersonic flame changes its flow characteristic from
„underexpanded“ to „slightly underexpanded“ for both systems:
vflame, exit 300 - 400 m/s, weakening of the shock nodes
coating quality can be improved by less porosity (< 1%),
higher hardness and improved wear resistance
End
...And pay attention...
8 shock diamonds...
Are not equal to Mach 8 !!!
GTV Verschleißschutz GmbH, D-57629 Luckenbach, Germany
www.gtv-mbh.de;
[email protected],
Fon: +49 2662 9576 0; fax +492662 9576-30
