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Study on Unified Understanding of Fundamental Coating Steps in Reactive Thermal Sprayings

Research Project

Project/Area Number 14350404
Research Category

Grant-in-Aid for Scientific Research (B)

Allocation TypeSingle-year Grants
Section一般
Research Field Metal making engineering
Research InstitutionToyota Technological Institute

Principal Investigator

TSUNEKAWA Yoshiki  Toyota Technological Institute, School of Engineering, Professor, 工学部, 教授 (50148350)

Co-Investigator(Kenkyū-buntansha) OKUMIYA Masahiro  Toyota Technological Institut, e School of Engineering, Asso. Professor, 工学部, 助教授 (20177182)
FUKUMOTO Masahiro  Toyohashi Univ., of Technology College of Engineering, Professor, 工学部, 教授 (80173368)
Project Period (FY) 2002 – 2004
Project Status Completed (Fiscal Year 2004)
Budget Amount *help
¥14,700,000 (Direct Cost: ¥14,700,000)
Fiscal Year 2004: ¥2,200,000 (Direct Cost: ¥2,200,000)
Fiscal Year 2003: ¥4,000,000 (Direct Cost: ¥4,000,000)
Fiscal Year 2002: ¥8,500,000 (Direct Cost: ¥8,500,000)
KeywordsDC Plasma Spraying / HVOF Spraying / RF Plasma Spraying / InProcess Reaction / Wettability / InSitu Composite / Droplet Temperature / Droplet Velocity / 発熱反応 / プラズマ溶射
Research Abstract

If composite powders consisted of multi-constituents are sprayed, it is worried about the decomposition of thermodynamically unstable species may occur in their spraying process. However, reactive spraying is quite effective to form in-situ composite coatings, because the required and thermodynamically stable compounds can be synthesized by the in process reaction. Following results are obtained in this study :
(1) Cast iron coatings with solid lubricant of graphite were formed by DC plasma spraying for the surface modification of aluminum substrates. Specially designed cast iron powder, which were alloyed with high silicon and aluminum of strong graphitizer, were supplied as a spray material. In order to form cast iron coatings with graphite structure, (a) pre-annealing of cast iron powder, (b) post annealing of sprayed coatings and (c) mixing with additional solid lubricant of hBN. The cast iron coatings with graphite structure exhibits mood tribological properties.
(2) Alloyed powder of Al-40wt%Si-10wt%Mg were sprayed by DC and RF plasma spraying, and also HVOF spraying. HVOF spraying gives the highest hardness among them due to refined microstructure and work hardening. The evaporation of magnesium occurs during the RF plasma spraying process, which causes less reinforced phase of Mg_2Si. It is expected that the in process reaction of SiO_2 reduction give us in situ composite coating in the case of Al-Si Mg powder mixed with SiO_2. The coatings with DC plasma spraying show the highest hardness, that is, the highly proceeded in process reaction, because it causes the high amount of MgAl_2O_4 due to the optimum droplet temperature.

Report

(4 results)
  • 2004 Annual Research Report   Final Research Report Summary
  • 2003 Annual Research Report
  • 2002 Annual Research Report
  • Research Products

    (32 results)

All 2005 2004 2003 Other

All Journal Article (18 results) Book (1 results) Publications (13 results)

  • [Journal Article] In-situ Formation of of Al-Si-Mg Based Composite Coating by Different Reactive...2005

    • Author(s)
      I.Ozdemir, Y.Tsunekawa et al.
    • Journal Title

      Surface and Coating Technology (In press)

    • Description
      「研究成果報告書概要(和文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Surface Modification of Aluminum Using Ion Nitriding and Barrel Nitriding2005

    • Author(s)
      M.Okumiya, Y.Tsunekawa et al.
    • Journal Title

      Surface and Coating Technology (In press)

    • Description
      「研究成果報告書概要(和文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] In-situ Formation of AI-Si-Mg Based Composite Coating by Different Reactive...2005

    • Author(s)
      I.Ozdemir, Y.Tsunekawa et al.
    • Journal Title

      Surface and Coating Technology (in press)

    • Description
      「研究成果報告書概要(欧文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Surface Modification of Aluminum Using Ion Nitriding and Barrel Nitriding2005

    • Author(s)
      M.Okumiya, Y.Tsunekawa et al.
    • Journal Title

      Surface and Coating Technology (in press)

    • Description
      「研究成果報告書概要(欧文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Corrosion Behaviour of Plasma Sprayed Coatings2005

    • Author(s)
      E.Celik, I.Ozdemir, E.Avci, Y.Tsunekawa
    • Journal Title

      Surface & Coating Technol. Vol.193

      Pages: 297-302

    • Related Report
      2004 Annual Research Report
  • [Journal Article] Characterization and Properties of Splats Sprayed with Different Cast Iron Powders2004

    • Author(s)
      M.F.Morks, Y.Tsunekawa, M.Okumiya
    • Journal Title

      Materials Letters 58

      Pages: 2481-2485

    • Description
      「研究成果報告書概要(和文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Effect of Substrate Surface Change on Flattening Behaviour of Thermal Sprayed Particles.2004

    • Author(s)
      M.Fukumoto et al.
    • Journal Title

      Materials Transactions 45,No.6

      Pages: 1869-1873

    • NAID

      10013135957

    • Description
      「研究成果報告書概要(和文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Characterization and Properties of Splats Sprayed with Different Cast Iron Powders2004

    • Author(s)
      M.F.Morks, Y.Tsunekawa, M.Okumiya
    • Journal Title

      Materials letters vol.58

      Pages: 2481-2485

    • Description
      「研究成果報告書概要(欧文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Effect of Substrate Surface Change on Flattening Behaviour of Thermal Sprayed...2004

    • Author(s)
      M.Fukumoto et al.
    • Journal Title

      Materials Transactions vol.45

      Pages: 1869-1873

    • Description
      「研究成果報告書概要(欧文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Characterization and Properties of Splats Sprayed with Different Cast Iron Powders2004

    • Author(s)
      M.F.Morks, Y.Tsunekawa, M.Okumiya
    • Journal Title

      Mater.Letters Vol.58

      Pages: 2481-2485

    • Related Report
      2004 Annual Research Report
  • [Journal Article] 溶射粒子偏平形態遷移に及ぼす基材加熱の影響解明2004

    • Author(s)
      福本昌宏, 扇谷一慶, 外
    • Journal Title

      溶接学会論文集 22巻・3号

      Pages: 398-402

    • NAID

      110003422439

    • Related Report
      2004 Annual Research Report
  • [Journal Article] Effect of Substrate Surface Change on Flattening Behaviour of Thermal Sprayed Particles2004

    • Author(s)
      M.Fukumoto, I.Ohgitani, et al.
    • Journal Title

      Mater.Trans. Vol.45,No.6

      Pages: 1869-1873

    • NAID

      10013135957

    • Related Report
      2004 Annual Research Report
  • [Journal Article] Creation of High Strength Bonded Abrasive Wheel with Ultrasonic aided composite plating.2003

    • Author(s)
      M.Okumiya, Y.Tsunekawa et al.
    • Journal Title

      Surface and Coating Technology 169-170

      Pages: 112-115

    • Description
      「研究成果報告書概要(和文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Synthesis and Characterization of Nanocrystalline Iron Aluminide Intermetallic Compounds2003

    • Author(s)
      W.Hu, T.Kato, M.Fukumoto
    • Journal Title

      Materials Transactions 44. No12

      Pages: 2678-2687

    • NAID

      10011818172

    • Description
      「研究成果報告書概要(和文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Creation of High Strength Bonded Abrasive Wheel with Ultrasonic Aided...2003

    • Author(s)
      M.Okumiya, Y.Tsunekawa et al.
    • Journal Title

      Surface and Coating Technology vol.169-110

      Pages: 112-115

    • Description
      「研究成果報告書概要(欧文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] Synthesis and Characterization of Nanocrystalline Iron Aluminide Intermetallic...2003

    • Author(s)
      W.Hu, T.Kato, M.Fukumoto
    • Journal Title

      Materials Transactions vol.44

      Pages: 2678-2687

    • Description
      「研究成果報告書概要(欧文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Journal Article] In Situ Formation of Al-Si-Mg Based Composite Coating by Different Reactive Thermal Spray Processes

    • Author(s)
      I.Ozdemir, I.Hamanaka, M.Hirose, Y.Tsunekawa, et al.
    • Journal Title

      Surface & Coating Technol. (in press)

    • Related Report
      2004 Annual Research Report
  • [Journal Article] Surface Modification of Aluminum Using Ion Nitriding and Barrel Nitriding

    • Author(s)
      M.Okumiya, Y.Tsunekawa, et al.
    • Journal Title

      Surface & Coating Technol. (in press)

    • Related Report
      2004 Annual Research Report
  • [Book] Handbook of Aluminum, vol.2, Chapter 13 Surface Modification2003

    • Author(s)
      K.Funatani, M.Yoshida, Y.Tsunekawa
    • Total Pages
      81
    • Publisher
      Marcel Dekker, Inc.
    • Description
      「研究成果報告書概要(和文)」より
    • Related Report
      2004 Final Research Report Summary
  • [Publications] Y.Tsunekawa et al.: "Formation of Superhand Modified Surface by Reactive Electrical Discharge Machining"Materials Science Forum. 426-432. 2605-2610 (2003)

    • Related Report
      2003 Annual Research Report
  • [Publications] M.Okumiya, Y.Tsunekawa et al.: "Creation of High Strength Bonded Abrasive Wheel With Ultrasonic Aided Composite Plating"Surface and Coating Technology. 169-170. 112-115 (2003)

    • Related Report
      2003 Annual Research Report
  • [Publications] M.F.Morks, M.A.Shoeib, Y.Tsunekawa et al.: "Effect of Particle Size and Spray Distance on the Features of Plasma Sprayed Cast Iron"Proc.ITSC 2003. 1081-1085 (2003)

    • Related Report
      2003 Annual Research Report
  • [Publications] M.Fukumoto et al.: "Dependence of thermal Sprayed Particle/Substrate Interface Microstructure on Substrate Temperature"Proc.ITSC 2003. 1047-1052 (2003)

    • Related Report
      2003 Annual Research Report
  • [Publications] W.Hu, T.Kato, M.Fukumoto: "Synthesis and Characterizaion of Nanocrystalline Iron Aluminide Intermetallic Compounds"Matarials Transactions. 44-12. 2678-2687 (2003)

    • Related Report
      2003 Annual Research Report
  • [Publications] M.Fukumoto et al.: "3-Dimensional Transition Map of Flattening Behavior in thermal Spray Process"Proc.ISPC-16. 608 (2003)

    • Related Report
      2003 Annual Research Report
  • [Publications] K.Funatani, M.Yoshida, Y.Tsunekawa: "Handbook of Aluminum, Vol.2 Chapter 13"Marcel Dekker, Inc.. 81 (2003)

    • Related Report
      2003 Annual Research Report
  • [Publications] Y.Tsunekawa et al.: "Plasma sprayed coatings with Water and Gas Atomized Bearing Steel Powders"Surface Engineering. (in press).

    • Related Report
      2002 Annual Research Report
  • [Publications] M.F.Morks et al.: "Splat Microstructure of Plasma Sprayed Cast Irou with Different Chamber Pressures"J. Thermal Spray Technologies, ASM. (in press).

    • Related Report
      2002 Annual Research Report
  • [Publications] M.F.Morks et al.: "Microstructure of Plasma Sprayed Cast Iron Splats with Different Particle Sizes"Materials Transactions. (in press).

    • Related Report
      2002 Annual Research Report
  • [Publications] Y.Tsunakawa et al.: "Application of in-process Reaction to the Fabrication of MgAl_2O_4/Al-Si Composite Coating by HVOF Spraying"Proc. Surface Modification Technologies 15, ASM. 9-18 (2002)

    • Related Report
      2002 Annual Research Report
  • [Publications] M.F.Morks et al.: "Splat Morphology and Microstructure of Plasma Sprayed Cast Iron with Different Preheat Temperatures"J. Thermal Spray Technologies, ASM. 11,No.2. 226-232 (2002)

    • Related Report
      2002 Annual Research Report
  • [Publications] M.Fukumoto et al.: "New Criterion for Splashing in Flattening of Thermal Sprayed Particles outo Flat Substrate Surface"Surface Coating Technology. 161. 103-110 (2002)

    • Related Report
      2002 Annual Research Report

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Published: 2002-04-01   Modified: 2016-04-21  

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