Method for coating a substrate with a spray material and functional layer achievable with this method

Patent metadata

Field	Value
Publication number	US-9988701-B2
Application number	US-201314405867-A
Country	US
Kind code	B2
Filing date	May 28, 2013
Priority date	Jun 29, 2012
Publication date	Jun 5, 2018
Grant date	Jun 5, 2018

Abstract

A method for coating a substrate, in which a wire-shaped spray material is melted in an electric arc and is deposited as a functional layer on the substrate. The invention also relates to a functional layer which can be produced on the substrate by this method. The functional layer has a high hardness value and good corrosion resistance on exposure to diesel fuel with a high sulphur proportion.

First claim

The invention claimed is:

1. A functional layer reduced in terms of frictional power and faulted as a dense coating on a substrate, the functional layer comprising an iron-based alloy having:
a martensitic structure, and
the following alloy components specified with the indicators of nickel equivalent (NiÄ) and chrome equivalent (CrÄ) of the Schäffler diagram:
CrÄ>10;
NiÄ>CrÄ−9; and
NiÄ<19-0.8*CrÄ

each with regard to a total weight,
wherein
manganese with a proportion of 0.3% by weight to 2% by weight, and/or
silicon with a proportion of 0.01% by weight to 1% by weight, and/or
molybdenum with a proportion of 0.01% by weight to 1% by weight, and/or
niobium with a proportion of 0.1% by weight to 1% by weight, and/or
titanium with a proportion of 0.001% by weight to 0.02% by weight,

are included, each with regard to a total weight,
wherein the functional layer is deposited on the substrate from a wire-shaped spray material melted in an electric arc at at least 9000 W and at a voltage of at least 36 volts.

2. A method for coating a substrate comprising:
melting a wire shaped spray material in an electric arc at at least 9000 W and at a voltage of at least 36 volts; and
depositing the melted wire shaped spray material as a dense functional layer on the substrate,
wherein a spray wire based on iron is used, having the following alloy components specified with the indicators of nickel equivalent (NiÄ) and chrome equivalent (CrÄ) of the Schäffler diagram:
CrÄ>10.5 and
NiÄ>CrÄ−8 and
NiÄ<21-0.8*CrÄ
each with regard to a total weight,
wherein the wire-shaped spray material additionally comprises the following alloy components:
manganese with a proportion of 0.3% by weight to 2% by weight, and/or
silicon with a proportion of 0.1% by weight to 1% by weight, and/or
molybdenum with a proportion of 0.01% by weight to 1% by weight, and/or
niobium with a proportion of 0.01% by weight to 1% by weight, and/or
titanium with a proportion of 0.001% by weight to 0.02% by weight,

each with regard to a total weight.

3. The functional layer according to claim 1 , wherein
manganese with a proportion of from 0.3 to 0.8% by weight, and/or
silicon with a proportion of from 0.2 to 0.6% by weight, and/or
molybdenum with a proportion of from 0.2 to 0.6% by weight and/or
niobium with a proportion of from 0.2 to 0.6% by weight, wherein the sum of the niobium and nickel proportion <1% by weight and/or
titanium with a proportion of from 0.005 to 0.1% by weight,

are included, each with regard to a total weight.

4. The method according to claim 2 , wherein the wire-shaped spray material additionally comprises the following alloy components:
manganese with a proportion of from 0.3 to 0.8% by weight, and/or
silicon with a proportion of from 0.2 to 0.6% by weight and/or
molybdenum with a proportion of from 0.2 to 0.6% by weight, and/or
niobium with a proportion of from 0.2 to 0.6% by weight, wherein the sum of niobium and nickel proportion <1% by weight and/or
titanium with a proportion of from 0.005 to 0.01% by weight,

each with regard to a total weight.

5. The functional layer according to claim 1 , wherein hardness of the functional layer is greater than 350 HV 0.1.

6. The functional layer according to claim 1 , wherein hardness of the functional layer is in the range of 400 to 650 HV 0.1.

7. The method according to claim 2 , wherein the wire-shaped spray material is melted in the electric arc with a current of at least 250 amps.

8. The method according to claim 2 , wherein the wire-shaped spray material is deposited as a beam of melted particles comprising a high airspeed particle beam.

9. The method according to claim 8 , wherein the wire-shaped spray material is deposited using a Laval nozzle.

10. The method according to claim 8 , wherein the beam of melted particles is suctioned at a speed of a maximum of 20 m/s.

11. The method according to claim 2 , wherein the wire-shaped spray material is supplied at a speed of a maximum of 12 m/s.

12. The method according to claim 2 , wherein hardness of the functional layer deposited on the substrate is greater than 350 HV 0.1.

13. The method according to claim 2 , wherein hardness of the functional layer deposited on the substrate is in the range of 400 to 650 HV 0.1.

14. The method according to claim 2 , further comprising improving adhesion of the functional layer sprayed on the substrate by generating compressive stresses of the functional layer by tempering the functional layer in a heating oven by local inductive heating of the functional layer.

15. The functional layer according to claim 1 , wherein the wire-shaped spray material is melted in the electric arc with a current of at least 250 amps.

16. The functional layer according to claim 1 , wherein the wire-shaped spray material is deposited as the functional layer on the substrate as a beam of melted particles comprising a high airspeed particle beam.

17. The functional layer according to claim 16 , wherein the wire-shaped spray material is deposited as the functional layer on the substrate using a Laval nozzle, wherein the beam of melted particles is suctioned at a speed of a maximum of 20 m/s and supplied at a speed of a maximum of 12 m/s.

Assignees

• Daimler Ag

Inventors

• Oezdeniz Eyuep Akin
• Joos Rainer
• Hansen Wolfgang
• Walker Michael
• Akay Uemit

Classifications

• C22C38/58

  with more than 1.5% by weight of manganese · CPC title

• B23K35/0261

  Rods, electrodes or wires · CPC title

• C22C38/02

  containing silicon · CPC title

• C22C38/44

  with molybdenum or tungsten · CPC title

• C23C4/08 Primary

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