Cel
Major success has been achieved with two of the four objectives which relate to liquid fuel spraying (HVOLF) of three coating types Inconel (IN625), Stellite 6 (STE6) and NiCoCrAlY. With this new liquid fuel process the conditions for spraying good quality coatings has been determined. It has been shown that the proportion of each powder particle melted in the spray gun is less than 10% nevertheless a dense pore-free coating results. When compared with gas fuel sprayed (HVOGF) coating there is less oxide present in the coating. At normal cooling rates Stellite 6 contains a eutectic phase with a distribution of carbides but after HVOLF spraying the coating contains very little evidence of the carbide being present even when examined by transmission electron microscopy (TEM).
The microstructure of HVOLF coatings depend on the fine dendritic structure, which exists in gas atomised powder feedstock. The corrosion performance of the HVOLF IN625 coatings was improved by at least an order of magnitude over HVOGF coatings when tested by salt spray and potentiodynamic methods. HVOLF STE6 coatings also showed considerable improvement in corrosion resistance over gas sprayed coatings. Spraying of IN625 and STE6 by gas and liquid fuel increased the hardness of these materials to 450HV and 580HV respectively. Erosion tests have demonstrated the ability of STE6 and Co-WC coatings to exhibit major improvements over cast iron substrate materials.
Opportunities to promote further improvement in HVOLF spray guns (as produced by Metallisation) has been highlighted by using a computer based model of the thermal spray process. Modifications to the gun design have been carried out and these have shown a reduction in waste heat whilst maintaining coating quality.
Developments in powder production by Cogne has led to controlled particle size ranges which suit the HVOLF gun. Such powders (IN625 and STE6) have been coated with alumina to promote their use in HVOGF gun whereby coatings with reduced chromium oxide contents can be produced. These coatings have not demonstrated corrosion resistance equivalent to that of the above HVOLF coatings. Use of this form of coating may exists in applications where wear resistance is needed but aggressive corrosion conditions do not exist.
Evaluation of the four coated components, i.e. Caprari cast iron pump impeller, Pompe Garbarino brass pump impeller, a Yorkshire Water sludge conveyor system and a mild steel pump casing supplied by Chemiquip will continue and these will be evaluate after service testing and the results will be supplied to all partners..
Opportunity to exploit the positive results obtained from the project are being discussed by the partners. Besides the technical evaluation of the coating in these applications an assessment of the costs of using coated components is being considered in the light of the whole life costs of running plant, which is currently being introduced into water industry operations.
Coatings are often required to protect the surfaces of valves, pumps, pipes and other components experiencing combinations of corrosion, erosion and cavitation arising from exposure to contaminants, such as solids, sea water, etc in the water treatment industry. This may be achieved by the application of a high performance protective layers on the surface of the part to protect the less expensive substrate. Protective surface layer for this application are usually deposited by weld surfacing, but in this project it is proposed that the weld facing should be replaced in appropriate applications by a thermal spray coating capable of an enhanced performance with the added possibility of economic and process advantages. This will overcome particular disadvantages associated with weld surfacing, such as the dilution of the surface layer by the base metal, the high heat input that can degrade the properties of the base material and the rough or uneven surface that often requires extensive and expensive final machining. Thermal spraying offers many advantages such as zero surface dilution, low heat input and the production of a very uniform coatings of excellent surface finish, which requires little final machining. Its use to date has been limited by the relatively low bond strength to the substrate and the significant porosity in the coated layer which are produced by the more traditional thermal spray processes. High Velocity Oxy Fuel (HVOF) spraying is a recently developed thermal spray process that provides a metallic or cermet coating with a high bond strength and a very low porosity. Therefore, HVOF spraying could provide a basis for the application of a wider range of coatings to components used for water treatment. It is more efficient than weld surfacing and offers a greater flexibility of alloy selection as a larger choice of feedstock powders exists for the spray process, compared with the welding rods or wires used in the surfacing process. It has been reported in some initial trials that the corrosion resistance of certain sprayed alloy coatings containing Cr are not as high as that of the same weld deposited alloy and there can also be a problem with relatively low shear strength in the coatings, leading to local delamination or flaking of the surface. This degradation in the alloy properties has been attributed to the presence of thin chromium oxide layers in the sprayed coatings. This project aims to overcome these limitations by developing a liquid fuelled form of spraying equipment (HVOLF) in which the velocity and temperature of the sprayed particles are better controlled thus reducing the potential of the gaseous environment to promote Cr oxidation. In a parallel activity a new and novel powder with an inert oxide (alumina) coating surrounding an alloy core will be developed which when sprayed will provide a dispersion hardened coating with enhanced erosion/cavitation properties. The influence of spray equipment (HVOF and HVOLF) on the dispersion will also be assessed. Thus the main aim of the project is to develop a spraying process which produces coating with both corrosion and erosion/cavitation resistance which are increased to at least 25% above that of current systems. The newly developed coatings will then be applied, by commercial sprayers, onto specific components supplied by pump and valve makers. After short term in house tests the successful parts will be performance tested in water treatment and supply systems. The results of the research have the potential to widen the application of thermal spray coatings and increase market penetration by spray equipment and powder producers. The use of specific components complete with the new coatings in the water treatment and supply industry has the potential to reduce equipment and operational costs and provide customers of the industry with cheaper and more consistent supplies together with enhanced water quality.
Dziedzina nauki (EuroSciVoc)
Klasyfikacja projektów w serwisie CORDIS opiera się na wielojęzycznej taksonomii EuroSciVoc, obejmującej wszystkie dziedziny nauki, w oparciu o półautomatyczny proces bazujący na technikach przetwarzania języka naturalnego. Więcej informacji: Europejski Słownik Naukowy.
Klasyfikacja projektów w serwisie CORDIS opiera się na wielojęzycznej taksonomii EuroSciVoc, obejmującej wszystkie dziedziny nauki, w oparciu o półautomatyczny proces bazujący na technikach przetwarzania języka naturalnego. Więcej informacji: Europejski Słownik Naukowy.
- inżynieria i technologia inżynieria śodowiska energetyka i paliwa paliwa ciekłe
- nauki przyrodnicze nauki chemiczne chemia nieorganiczna związki nieorganiczne
- nauki przyrodnicze nauki chemiczne chemia nieorganiczna metale przejściowe
- inżynieria i technologia przemysł maszynowy inżynieria produkcji obróbka skrawaniem
- inżynieria i technologia inżynieria materiałowa powłoki
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Program(-y)
Wieloletnie programy finansowania, które określają priorytety Unii Europejskiej w obszarach badań naukowych i innowacji.
Wieloletnie programy finansowania, które określają priorytety Unii Europejskiej w obszarach badań naukowych i innowacji.
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Zaproszenia do składania wniosków dzielą się na tematy. Każdy temat określa wybrany obszar lub wybrane zagadnienie, których powinny dotyczyć wnioski składane przez wnioskodawców. Opis tematu obejmuje jego szczegółowy zakres i oczekiwane oddziaływanie finansowanego projektu.
Zaproszenie do składania wniosków
Procedura zapraszania wnioskodawców do składania wniosków projektowych w celu uzyskania finansowania ze środków Unii Europejskiej.
Brak dostępnych danych
Procedura zapraszania wnioskodawców do składania wniosków projektowych w celu uzyskania finansowania ze środków Unii Europejskiej.
System finansowania
Program finansowania (lub „rodzaj działania”) realizowany w ramach programu o wspólnych cechach. Określa zakres finansowania, stawkę zwrotu kosztów, szczegółowe kryteria oceny kwalifikowalności kosztów w celu ich finansowania oraz stosowanie uproszczonych form rozliczania kosztów, takich jak rozliczanie ryczałtowe.
Program finansowania (lub „rodzaj działania”) realizowany w ramach programu o wspólnych cechach. Określa zakres finansowania, stawkę zwrotu kosztów, szczegółowe kryteria oceny kwalifikowalności kosztów w celu ich finansowania oraz stosowanie uproszczonych form rozliczania kosztów, takich jak rozliczanie ryczałtowe.
Koordynator
DUDLEY
Zjednoczone Królestwo
Ogół kosztów poniesionych przez organizację w związku z uczestnictwem w projekcie. Obejmuje koszty bezpośrednie i pośrednie. Kwota stanowi część całkowitego budżetu projektu.