NDLI: Down-selection and optimization of thermal-sprayed coatings for aluminum mould tool protection and upgrade

Content Provider	Springer Nature Link
Author	Gibbons, Gregory John Hansell, Robert George
Copyright Year	2006
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); C$_{3}$H$_{8}$ 62/73 SLPM; air 332/311 SLPM; feed rate 30/28 g/min; and spray distance 150/206 mm.
Starting Page	340
Ending Page	347
Page Count	8
File Format	PDF
ISSN	10599630
Journal	Journal of Thermal Spray Technology
Volume Number	15
Issue Number	3
e-ISSN	15441016
Language	English
Publisher	Springer-Verlag
Publisher Date	2006-01-01
Publisher Place	New York
Access Restriction	One Nation One Subscription (ONOS)
Subject Keyword	alloys ceramics and refractories injection mould tooling metals semimetals spray coating techniques Surfaces and Interfaces, Thin Films Tribology, Corrosion and Coatings Materials Science Characterization and Evaluation of Materials Operating Procedures, Materials Treatment Analytical Chemistry
Content Type	Text
Resource Type	Article
Subject	Surfaces, Coatings and Films Materials Chemistry Condensed Matter Physics

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