cst 2 thermal spraying thermal spraying.pdf · 2007. 7. 17. · amperit® / product portfolio for...
TRANSCRIPT
H.C. STARCKH.C. STARCKAMPERITAMPERIT®®
andAMPERWELDAMPERWELD®®
Powders forSurface Technologyand more… !
Hans Keller, May 2006, ITSC, Seattle
May 2006
Rhina plant of "Elektrochemische Werke Bitterfeld", around of 1913 - thevery beginnings of the industrial commitment of Hermann C. Starck
Hermann C. Starck (photographed in September 1967)
The History of H.C. Starck
May 2006
The modern world of H.C. Starck
Chemical and Fabricated Products
Ceramics and Surface Technology
Hard Metals
Electronics and Optics
May 2006
Facts about H.C. Starck
Founded by 1920 in Berlin by Hermann C. Starck
Legal form GmbH
Nominal Capital 42 million Euro
Sales 2005 920 million Euro (H.C. Starck Group)
Number of employees 3.437 worldwide
Parent Company since 1986 Bayer AG, Leverkusen
May 2006
The International Group
The international group of H.C. Starck
H.C. Starck Inc.Newton, MA., USA
H.C. Starck ThailandMap Ta Phut, Thailand
H.C. Starck CanadaSarnia / Ontario, Canada
H.C. Starck CeramicsSelb, Germany
H.C. Starck Liaison OfficeSheffield, UK
H.C. Starck - V TECH Ltd.Tokyo, Japan
H.C. Starck Liaison OfficeParis, France
H.C. Starck Liaison Office Mijdrecht, Netherlands
H.C. Starck Liaison Office Gothenburg, Sweden
H.C. Starck Liaison Office Singapore
H.C. Starck GmbH Goslar / Laufenburg / Leverkusen
Germany
H.C. Starck Hermsdorf Hermsdorf, Germany
H.C. Starck Liaison Office Milan, Italy
H.C. Starck UK Ltd. West Horndon / Calne, UK
Agents in more than 30 countries
H.C. Starck Liaison Office Shanghai, China
May 2006
The International Group
Production plants around the globe
Coldwater135
Cleveland108
Cleveland108
Cleveland108
Cleveland108
Calne72
Calne72
Calne72
Calne72
East Rutherford 137
East Rutherford 137
East Rutherford 137
East Rutherford 137
Latrobe38
Latrobe38
Latrobe38
Latrobe38
Newton320
Newton320
Newton320
Newton320
Map Ta Phut223
Map Ta Phut223
Sarnia60
Sarnia60
Goslar1.304
Goslar1.304
Goslar1.304
Goslar1.304
Laufenburg 471
Laufenburg 471
Laufenburg 471
Laufenburg 471
North America Europe Asia
Leverkusen 109
Leverkusen 109
Leverkusen 109
Leverkusen 109
Selb227
Hermsdorf113
Tokyo120
Total Worldwide:
3.437
May 2006
Organizational Chart
The organization of H.C. Starck
Corporate Staff Departments
MSÖ Marketing Services and Public Relations
RPV Law, Patents and Insurance
QM Quality Management
MSÖ Marketing Services and Public Relations
RPV Law, Patents and Insurance
QM Quality Management
BPRBattery Products
BPRBattery Products
HMCHardmetals,Mill Productsand Catalysts
HMCHardmetals,Mill Productsand Catalysts
EOP Electronic and Optic Products
EOP Electronic and Optic Products
CST Ceramic and Surface
Technology
CST Ceramic and Surface
Technology
Business Groups
FE Research and Development
FE Research and Development
Central Divisions
BW Business
Management
BW Business
Management
MWProcurement
MWProcurement
PT Production and
Engineering
PT Production and
Engineering
FPRFabricatedProducts
FPRFabricatedProducts
PS Human Resources
PS Human Resources
H.C. Starck GmbH Executive Board
H.C. Starck GmbH Executive Board
May 2006
Markets we serve
High Temperature Applications
Battery Industry
Mining Industry
Thermal Spraying
Chemical Industry
Aerospace Industry
Metal- working Industry
Electronics
Medical
Automotive Industry
May 2006
Quality management and ISO certifications
Our company has been certified accordingto DIN EN ISO 9001 and DIN EN ISO 14001 with all sites of H.C. Starck GmbH:
• In addition our Central Quality Control isaccredited in compliance with DIN EN ISO IEC 17025:2000.
• We have also introduced QM processeswhich go beyond the requirements of DIN EN ISO 9001:2000 in those productionfacilities in which particulary sophisticatedproducts are manufactured. Our QM system has been positively evaluated in audits conducted by customers that areOEMs or direct suplliers of the aircraft, automotive and aerospace industry re-quiring standards based on QS 9000/VDA 6.1/TS 16949 / AS 9001 etc.
May 2006
H.C. Starck Laboratory Accreditation
May 2006
Materials – Development – SolutionsOur concept to serve the market
Materials…Stands for H.C. Starck´smaterial competence whichis unique the world over and extends throughout thecompany both vertically and horizontally.
Development…Stands for the innovation po-tential and expertise thatmakes us a driving force behind new products, appli-cations and global markets.
Solutions…Stands for the ability to supportour customers with appropriateor even customized productsolutions across their entirevalue chain.
May 2006
Business Unit Surface Technology
INDUSTRIALSOLUTIONS
EVERYTHERE IN THE WORLD…!
May 2006
Our global sales networkBenelux served by Flame Spray Technologies b.v.
May 2006
Headquarter Germany
H.C. Starck GmbHHead of Global Marketing and Sales, Laufenburg
Marketing, Laufenburg
Sales, Goslar
Technical Support, Laufenburg
May 2006
H.C. Starck GmbHGermany, Goslar
UK and Ireland, Sheffield
Scandinavia,Gothenborg
Italy, Milano
Flame Spray Technologies (FST) b.v.Benelux, Duiven
Sales Offices Europe…
May 2006
Sales Offices North America
H.C. Starck Inc.Cincinnati Office, West Chester, OH
Newton Office, Newton, MA
Houston Office, Conroe, TX
Coldwater Office, Coldwater, MI
May 2006
Sales Offices Japan and Korea
H.C. Starck Ltd.Japan, Tokyo
Bayer Korea Ltd. / Division H.C. StarckSouth Korea, Seoul
May 2006
Bayer (SEA) Pte. Ltd. / H.C. StarckSingapore
In China (中国) also:SIGNAL HITEK, Shanghai
DENSE COAT, Beijing
Sales Offices Asia/Pacific
May 2006
Our Technical SupportProviding Technical Expertise and more
A modern thermal spray laboratory and highly special-ized metallographic laboratorycombined with outstandingexperience in many applicationsguarantee top-quality applicationengineering including:
⇒ Materials respectively coating
recommendations
⇒ Coating quality analysis
⇒ Spray parameters
⇒ Trouble shooting and advices
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AAAMMMPPPEEERRRIIITTT®®® 777000444 CCCrrr222 OOO333 fffuuussseee ddd
The listed spray parameters can be used for the equipments noted below. H.C. Starck GmbH recommend the following settings as good starting points. Although applications and equipments vary, modification / optimizat ion of the spray parameters may further enhance the coat ing quality.
SULZER METCO F4
Grain Sizes .0 (22/5 μm) / .053 (25/10 µm) / .065 (30/10 µm) Settings Baseline Alternative
Nozzle 6 mm 6 mm Powder Injector: Size 1,5 mm 1,5 mm Angle 90° 90° Gauge 6 mm 6 mm Gases Primary Ar 36,0 Nl/min Ar 42,0 Nl/min Secondary H2 13,0 Nl/min H2 12,0 Nl/min Carrier 1) Ar 2,5-4,0 Nl/min Ar 2,5-4,5 Nl/min Amperage 630 A 630 A Voltage 69 V 76 V Powder Feed Rate, max. 1 x 50 / 2 x 35 g/min 1 x 50 / 2 x 35 g/min Spreader / Suction Piece L / L (NL / NL) L / L (NL / NL) Spray Distance 110 mm 90 - 110 mm Grain Sizes .1 (45/22 μm) / .3 (45/5 µm) / .054 (45/10 µm) Settings Baseline Alternative
Nozzle 6 mm 6 mm Powder Injector: Size 1,5 mm 1,5 mm Angle 90° 90° Gauge 6 mm 6 mm Gases Primary Ar 33,0 Nl/min Ar 42,0 Nl/min Secondary H2 13,0 Nl/min H2 12,0 Nl/min Carrier 1) Ar 2,5-4,0 Nl/min Ar 2,5-4,5 Nl/min Amperage 630 A 630 A Voltage 69 V 76 V Powder Feed Rate, max. 1 x 50 / 2 x 35 g/min 1 x 50 / 2 x 35 g/min Spreader / Suction Piece L / L (NL / NL) L / L (NL / NL) Spray Distance 110 mm 90 - 110 mm 1) Car rier flow depends on gas supply pressure, hose length and local installation conditions Note: The condit ions of your use and application of our products , techni cal ass ist ance and informat ion (whether verbal, wri tten or by way of product ion eval uations), inc luding any sugges ted formulations and recommendati ons, are beyond our control. Therefore, it i s imperat ive t hat you t es t our producst , techni cal ass ist ence and informati on t o det ermine to your own sati sfact ion whet her they are suit able f or your intended uses and applicat ions . This applicat ion-specif ic analys is at leas t mus t inc lude tes ting to determine suit abilit y f rom a technical as well as health, safety, and env ironmental s tandpoint. Such test ing has not necessari ly been done by H. C. Starck. All informati on is given wit hout warranty or guarantee. It is express ly unders tood and agreed that t he cus tomer assumes and hereby express ly releases H.C. Starck from al l li abilit y, in t ort, contract or ot herwise, incurred in connec tion with the use of our produc ts, technical assis tance and informati on. Any s tatement or recommendation not contained herei n is unauthori zed and shall not bind H.C. St arck . Nothing herein shal l be const rued as a recommendat ion to use any produc t i n conf lic t w ith patent s covering any material or its use. No license is impli ed or in f ac t grant ed under the c laims of any pat ent. I n case of order please refer to issue number of this produc t data sheet. All deliveries are based on the las test issue of t he product dat a sheet and the latest version of our General conditions of Sal es and Delivery.
May 2006
Our Technical SupportApplication Spray and Metallographic Laboratory
Equipment includes:
⇒ Cold Spray
⇒ HVOF (DJ Hybrid, Top Gun)
⇒ Plasma (F4, 7/9 MB)
⇒ Wear Test
⇒ Corrosion Test
⇒ Cavitation Test
⇒ Bond Strength Test
⇒ Bending Test
⇒ Surface Roughness Test
⇒ Micro- and Macrohardness Test
May 2006
Our Global PartnerWorking close together
May 2006
Fundamental research
Support to industry
Evaluation of applications
Fluid dynamics
H.J. Richter
Equipment
P. Heinrich
Linde Gas
Gas technology
Powder
A. Eiling
Materials
P. Richter
Spray systems
H. Kreye
Material science
Cold Spray Competence GroupDriving force for the future
May 2006
UniqueinBreadthandDepth
Materials – Solutions - Development
May 2006
Inhouse production capabilities
Providing well-established andnew production methods for stateof the art materials:
• Atomization
• Agglomeration (Sintering)
• Sintering
• Fusing
• Cladding
• Blending
• Spheroidization
May 2006
Atomization
Vacuum
MCrAlYs
Inert gas
Ni-SF
Water
NiCr
May 2006
Agglomeration and/or Sintering
Agglomeration
ZrO2-Y2O3
A + S
WC-Co
Sintering
WC-Co-Cr
May 2006
Fusing and Crushing
Fusing
Cr2O3
May 2006
Cladding, Blending, Spheroidization
Cladding
Ni-Graphite
Blending
Mo-NiSF
Spheroidization
ZrO2-Y2O3
May 2006
Product PortfolioforAMPERIT®
andAMPERWELD®
Materials – Solutions - Development
May 2006
Materials – Solutions – DevelopmentAMPERIT® / Product Portfolio for Thermal Spraying
Carbides for wear resistance.
⇒ WC-Co
⇒ WC-Co-Cr
⇒ WC-Ni
⇒ WC-WB-Co (-Cr)
⇒ WC-CrC-Ni
⇒ WC-NiMoCrFeCo
⇒ Cr3C2-NiCr
⇒ Cr3C2-CoNiCrAlY
⇒ Mo2C
⇒ TiC
May 2006
Materials – Solutions – DevelopmentAMPERIT® / Product Portfolio for Thermal Spraying
Oxides for wear protection, chemical resistance and heatprotection.
⇒ Cr2O3
⇒ Cr2O3-TiO2
⇒ Al2O3
⇒ Al2O3-TiO2
⇒ TiO2
⇒ Al2O3-ZrO2
⇒ ZrO2-Y2O3
⇒ Y2O3
May 2006
Materials – Solutions – DevelopmentAMPERIT® / Product Portfolio for Thermal Spraying
MCrAlYs as bond coat and as corrosion protection for high temperature applications.
⇒ NiCoCrAlY
⇒ NiCrAlY
⇒ CoNiCrAlY
⇒ NiCoCrAlTaReY
⇒ SV 20, SL 20, SH20, SVP 20
⇒ SV 30, SL 30
⇒ SL 349, SVP 349
⇒ Sicoat 2231, 2453, 2464
May 2006
Materials – Solutions – DevelopmentAMPERIT® / Product Portfolio for Thermal Spraying
Molybdenum for automotiveapplications.
⇒ Mo (low carbon)
⇒ Mo (high carbon)
⇒ Mo-Mo2C
⇒ Mo2C
⇒ Mo-NiSF
⇒ Mo-NiSF + hard particles
May 2006
Materials – Solutions – DevelopmentAMPERIT® / Product Portfolio for Thermal Spraying ®
Other pure metals, alloysand blends.
⇒ W, Ta, Ti, Nb, Ni
⇒ Ni-Graphite
⇒ NiCr
⇒ NiAl
⇒ NiCrBSi
⇒ 316 L
⇒ Hastalloy
⇒ others on request
May 2006
Materials – Solutions – DevelopmentAMPERWELD® / Product Portfolio for Welding
AMPERWELD® powders.
⇒ Cast Tungsten Carbide
⇒ Macroline Tungsten Carbide
⇒ TiC
⇒ VC
⇒ Co-HFA NF 12
⇒ Ni-SA 625
⇒ Ni-SA 718
⇒ Co
⇒ W
⇒ Mo
May 2006
Examplesof AreasofApplications
Materials – Solutions - Development
May 2006
Materials – Solutions – DevelopmentExamples of Areas of Applications
Aircraft Turbines…Hot gas corrosion resistance forturbine blades through sprayedMCrAlYs alloy, thermal barriercoatings made of ZrO2-Y2O3 forturbine parts in the highesttemperature zones, wear resistancemade by WC-Co and mechanicalseals made of soft Ni-Graphite abradables for rotating parts.
May 2006
Materials – Solutions – DevelopmentExamples of Areas of Applications
Automotive…Mo + NiSF alloys on piston rings reduce wear in combustionengines. Wear resistant alloys formotor blocks made of light alloys.
May 2006
Materials – Solutions – DevelopmentExamples of Areas of Applications
Paper and Printing
Industry…Ceramic or carbide wear resistantcoatings for paper machinecylinders. Wear resistant and LASER engravable Cr2O3 coatingsfor printing rolls.
May 2006
Materials – Solutions – DevelopmentExamples of Areas of Applications
Hard chrome
replacement…WC-Co, WC-Co-Cr or Cr3C2-NiCr as replacements for galvanizedhard chrome coatings for hydrauliccylinders.
May 2006
Materials – Solutions – DevelopmentExamples of Areas of Applications
Energy…Ni- and Co-based alloys as high temperature corrosion resistanceand bond coat for thermal barriercoatings on stationary gas turbineblades.
May 2006
New productsforApplications
Materials – Solutions - Development
May 2006
Solutions – AMPERIT® 512WC-Co 88/12 (low carbon) for sink rolls in steel industry
Modified WC-Co powder to increase the resistance againstmolten metal attack for Zn bathrolls designed for kerosine basedHVOF systems.
May 2006
Solutions – AMPERIT® 519WC-Co 88/12 (fine carbide) for corrugating rolls
Fine carbides combined withfine grain sizes for smooth and thin as-sprayed coatings with high hardness to increase the lifetimeof corrugating rolls.
May 2006
Solutions – AMPERIT® 594Cr3C2-CoNiCrAlY 75/25 agglomerated sintered
Modified Cr3C2-based powderfor outstanding oxidation resist-ance and excellent wear and erosion protection.
May 2006
Solutions – AMPERIT® 703Chromium oxide H.P. sintered for printing rolls
High purity and metal freepowder especially for anilox rollsand other applications withoutstanding purity requirements.
May 2006
Solutions – AMPERIT® 235NiCrAl-Bentonite 20/80 for abradable coatings
Uniform cladded Bentonite forconsistant sprayability and reproducible coating properties.
May 2006
Solutions – AMPERIT® 832ZrO2-Y2O3 93/7 agglomerated sintered for TBC coatings
Hollow spheric particles in agglomerated sintered form to combine the advantages of HOSP® powders with the high quality consistency and excellentmelting behavior of agglomeratedsintered powders.
® Registered Trademark Sulzer Metco
May 2006
Solutions – AMPERIT® 151Tantalum Special Grade for Cold Spray
Cold Spray
Special designed Ta refractorymetal to spray very dense, high purity and oxygen-free coatingsfor petrochemical and electronicalapplications.
May 2006
Solutions – Macroline Tungsten CarbideFused Tungsten Carbide for PTA-Welding
Source: RWE Power AG, Frechen
Mining Industry
PTA Welding
May 2006
6561156
2189
0
500
1000
1500
2000
2500
WSC (mod.) + NiSF 60/40 WSC + NiSF 60/40 mWC + NiSF 60/40
Verschleißabtrag in mg (ASTM G 65-94)Verschleißabtrag in mg (ASTM G 65-94)
Solutions – Macroline Tungsten CarbideStandard WSC or Macroline Tungsten Carbide (MTC)
The comparisonOur standard
New MTC
May 2006
Approvalsfor theAircraft Industry
Materials – Solutions - Development
May 2006
H.C. Starck serving the aircraft industry
Our company serves globally theaircraft industry with state of theart materials on highest qualitylevels. With over 100 OEM approvals we are preferedsupplier to:
⇒ OEMS
⇒ OEM Subcontractor
⇒ Independent aircraft repair
shops
May 2006
GE Aircraft Engines (S-400)
May 2006
Rolls Royce Pratt & Whitney
May 2006
Snecma Moteus MTU Aero Engines
May 2006
⇒ Documentation of powder
analyses:
– all powder analyses results are
documentated (electronic media).
⇒ Powders:
– a powders sample of each pro-
duced lot is stored for a minimum of
5 years.
⇒ Specific test reports:
– reports are filed and send with all
materials
H.C. Starck powders for aircraft industry
All powders for the aircraftindustry are produced and documented according to DIN EN ISO 9001 and OEM specificationrequirements including:
⇒ Documenation of raw materials:
- a detailed describtion of raw
materials and sources is given.
⇒ Documentation of production
processes:
– a detailed describtion of produc-
tion equipment and production set-
tings / parameters is given.
May 2006
Examples of Specific Tests Reports
May 2006
R + D workfor
NextGeneration
Materials…
Materials – Solutions - Development
May 2006
Materials – Solutions – DevelopmentExpertise for New Markets
Powder development is produc-tion on a small scale. Standard powders are modified, orcompletely new powders aredeveloped. The ability to modifystandard powders ensures ourcustomers fast and economiccustomization, as well as testingon a small scale. Innovative materials closely geared to marketneeds are also developed here, to offer our customers uniquesolutions to meet the mostchallenging requirements.
May 2006
Materials – Solutions – DevelopmentR + D work for next generation materials
Ultrafine carbides for high hardness and very good wearresistance.
1000
1100
1200
1300
1400
1500
1600
6 1.8 1 0.8 0.4Average Carbide Size (µm)
Har
dnes
s VH
N 3
00 g
0
1
2
3
4
5
6
Abr
asio
n W
ear
(mg)
May 2006
Materials – Solutions – DevelopmentR + D work for next generation materials
Special matrix materials forexcellent corrosion resistance.
0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
I corr (µ
A/c
m²)
0
10
20
30
40
50
60
70
80
Rp
(kΩ
cm
²)
Polarization Curve in 5%-NaCl Solution
WC-Co WC-Co-Cr WC-NiMoCrFeCo Cr3C2-NiCr
May 2006
Materials – Solutions – DevelopmentR + D work for next generation materials
Special composites for high temperature applications in steelindustry….
Al2O3-MCrAlY
TiB2-MCrAlY
May 2006
Materials – Solutions – DevelopmentR + D work for next generation materials
New binder alloys for envi-ronmental and human protectionusing:
Co and Ni are classified:harmful to healthcarcinogenicallergenicPollutant
Development of less harmful binder alloys
⇒ (Partial) replacement of standard powders
AMPERSINT® S.T.A.R.:high energy milled materials
AMPERSINT® COM:chemically precipitated
May 2006
Our CompetenceProviding Materials, Solutions and Developments
YouYou areare wellcomewellcome to to joinjoin usus !!