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Deliverables
The aim of this project is to develop a new tungsten carbide coating which will be applied thanks to H.V.O.F. (High Velocity Oxy Fuel) thermal spraying process on the cutting edge of belt saw blades.
This coating should allow:
-Economic gains by the reduction of the number of blades used, the decrease of the intervention frequency and a better valorisation of the sawn-up items.
-Industrial gains by an optimisation of the sawing parameters and an increase of the cutting capacity.
-Environmental gains by the reduction of waste and therefore the wood consumption,
-Improvement in working conditions by the reduction of the number of workers interventions and noise reduction due to the optimisation of the sawing parameters.Results :
The industrial requirements, needs and expectations have been translated in terms of material technical specifications which have led to a list of ten materials to be tested validated by the partnership.
The ten selected materials have been sprayed on plane samples. Their morphologies have been observed and they have been characterised in terms of hardness, sand erosion and mechanical shocks on a bench specially developed. Then they have been compared to the nominal Stellite coating. Six of the ten materials have been selected on the sawing bench.
Important difficulties have been encountered to realise coatings on 6 mm thick two teeth circular saw blades, mainly to obtain the set of the saw and to have no cracks after the sharpening. Only two materials could be realised on these circular saw blades. When possible comparative cutting trials with the Stellite coating have been realised, and, macroscopic and microscopic analysis of the blades after the wear tests have been done.
After these wear tests it has been decided by the partnership to realise a H.V.O.F. coating with the selected material on an industrial belt saw blade and to test it in a sawmill.
This tested blade presented blunted edges which have not allowed to carry on, but with the correct teeth, the coating behaviour was better than with the Stellited teeth. The deposited material would be able to improve the service life of the belt saw blade. Nevertheless, this application requires very thick coatings that could not be realised in an industrial way by the HVOF process.
After these first results, the partnership has decided to realise an other trial using a new material with characteristics closed to H.V.O.F coated material.
The choice of this last material has been done because it is one of the few compositions with a high level of carbide and which could be find in wire and this conditioning allows to use various spraying process.
Following the trials realised in sawmills and in comparison with the Stellite coated belt saw blades used for many years, the belt saw blades coated with the new material showed a good behaviour (higher feed speed, dimensional precision and surface quality of sawing).
Indeed, even if the number of trials is still limited, the first results have showed :
-A higher feet speed,
-An increase of the service life, in spite of the cutting conditions (manual coatings, blunted and micro-jagged edges, higher saw kerf, non ideal teeth profile, hardwood sawed).
Even if the material needs to be optimised, the industrial results are hopeful and the process will be able to be industrialised.
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