Wire-like spray material, functional layer which can be produced therewith and process for coating a substrate with a spray material

Patent metadata

Field	Value
Publication number	US-9487660-B2
Application number	US-201113697081-A
Country	US
Kind code	B2
Filing date	May 3, 2011
Priority date	May 22, 2010
Publication date	Nov 8, 2016
Grant date	Nov 8, 2016

Abstract

A wire-like spray material ( 4 ) based on an iron for electric arc wire spraying and also a functional layer ( 2 ) which can be produced therewith on a substrate ( 1 ). The functional layer ( 2 ) has good corrosion resistance towards diesel fuel having a high sulphur content.

First claim

The invention claimed is:

1. An arc sprayed functional layer ( 2 ) of reduced friction, wherein said functional layer is formed by arc wire spraying of a wire-form spraying material ( 4 ) formed at least with carbon as microalloy such that upon solidification of the spraying material a functional layer ( 2 ) having a hardness in the range of 400 to 850 HV 0.1 is produced, the following alloying constituents being provided in the wire-form spraying material:
carbon 0.7% by weight to 1.2% by weight,
chromium 12% by weight to 20% by weight,
manganese 0.8% by weight to 2% by weight,
molybdenum 0.4 to 1.3% by weight,
nickel 0.01% by weight to 1% by weight,
sulfur 0.01% by weight to 0.035% by weight,
copper 0.01% by weight to 0.4% by weight,

and optionally:
silicon 0.01% by weight to 1% by weight,
vanadium 0.01% by weight to 0.3% by weight,
phosphorus 0.01% by weight to 0.045% by weight,
aluminum at most 0.01% by weight,

and the remainder iron and unavoidable impurities in each case relative to a total weight.

2. An arc sprayed functional layer ( 2 ) of reduced friction, produced from a spraying material, the functional layer ( 2 ) having a hardness in the range of 400 to 850 HV 0.1 and comprising the following alloying constituents:
carbon 0.45% by weight to 0.8% by weight,
manganese 0.8 to 2% by weight,
molybdenum 0.4 to 1.3% by weight,
chromium ≧10% by weight,
nickel 0.01% by weight to 1% by weight,
sulfur 0.01% by weight to 0.035% by weight,
copper 0.01% by weight to 0.35% by weight,

and optionally:
silicon 0.01% by weight to 1% by weight,
vanadium 0.01% by weight to 0.3% by weight,
phosphorus 0.01% by weight to 0.045% by weight,
aluminum at most 0.01% by weight,

and the remainder iron and unavoidable impurities in each case relative to a total weight.

3. The functional layer ( 2 ) as claimed in claim 2 , wherein the functional layer ( 2 ) has interstitially dissolved iron nitrides and chromium nitrides, the nitrogen portion of the alloy being a proportion of 0.01 to 2% by weight relative to a total weight.

4. The functional layer ( 2 ) as claimed in claim 2 , produced by melting a wire-form spraying material ( 4 ) formed at least with carbon as microalloy such that upon solidification of the spraying material a functional layer ( 2 ) having a hardness in the range of 400 to 850 HV 0.1 is produced, the following alloying constituents being provided in the wire-form spraying material ( 4 ):
carbon 0.7% by weight to 1.2% by weight,
chromium 12% by weight to 20% by weight,
manganese 0.8% by weight to 2% by weight,
molybdenum 0.4 to 1.3% by weight,
nickel 0.01% by weight to 1% by weight,
sulfur 0.01% by weight to 0.035% by weight,
copper 0.01% by weight to 0.4% by weight,

and optionally:
silicon 0.01% by weight to 1% by weight,
vanadium 0.01% by weight to 0.3% by weight,
phosphorus 0.01% by weight to 0.045% by weight,
aluminum at most 0.01% by weight,

and the remainder iron and unavoidable impurities in each case relative to a total weight in an arc ( 5 ) and depositing the melt as a functional layer ( 2 ) on a substrate ( 1 ), with nitrogen being used as process gas.

5. The functional layer ( 2 ) as claimed in claim 4 , wherein the wire-form spraying material ( 4 ) is melted in the arc at a melting power of at least 9000 W.

6. The functional layer ( 2 ) as claimed in claim 4 , wherein the wire-form spraying material ( 4 ) is conveyed at a speed of at most 12 m/s and sprayed to form a jet of melted particles, wherein the jet of melted particles is sprayed at a speed of at most 20 m/s.

7. The functional layer ( 2 ) as claimed in claim 4 , wherein residual compressive stresses are generated in the functional layer ( 2 ) by temperature control in a heating oven or by local inductive heating.

8. The functional layer ( 2 ) as claimed in claim 4 , wherein the wire-form spraying material ( 4 ) is melted in the arc at a melting power of at least 9000 W with a current intensity of at least 250 A and/or a voltage of at least 36 V.

Assignees

• Izquierdo Patrick
• Joos Rainer
• Lux Tobias
• Oezdeniz Eyuep Akin
• Daimler Ag

Inventors

• Izquierdo Patrick
• Joos Rainer
• Lux Tobias
• Oezdeniz Eyuep Akin

Classifications

• C22C38/44

  with molybdenum or tungsten · CPC title

• C22C38/52

  with cobalt · CPC title

• C23C4/08

  containing only metal elements (C23C4/073 takes precedence) · CPC title

• C22C38/42

  with copper · CPC title

• C23C4/131

  Wire arc spraying · CPC title