Risultati finali
The main role of the KUL in the nanospraying project is to evaluate the thermal sprayed nano-structured coatings. For that questionnaires were sent out to the partners companies to know the actual filed condition and the contact geometry. On the based of those questionnaires, lab test conditions were determined to simulate the field condition as soon as possible. AFM, TEM, XRD, SEM and tribological experiments were carried out on the plasma sprayed samples as well as on reference materials.
On the basis of the abrasion rate of the materials a preliminary ranking of the materials were made and the best performing materials were subjected to further in depth investigation. It has been found that wear rate of nano-structured coatings are much lower then the conventional coatings and bulk materials. Beside that, electrochemical noise measurement and EIS technique were used to evaluate the wear and corrosion-wear behavior of the coatings.
The corrosion and corrosion-wear behaviour of the nanostructured coatings are compareable with their conventional counterpart. Based on both mechanical and electrochemical investigation, optimized coatings were selected for the industrial bench tests. The outcome from the industrial bench test suggested that the optimization of the coatings according to the laboratory simulation is relevant and appropriate since the coatings provide positive performance in the industrial bench test.
Result Description (commercial, social or scientific):
Concepts of nanomaterials suitable for thermal spraying has been established from initial guesses (based on physico-chemical principles) and extensive experimental trials of powders deposition by thermal spraying and feedback from wear testing results. A very tight experimental plan and well based loop of experiments has allowed the establishing of important principles for successfully conceive thermal spraying powders made up of agglomerated nanocrystals. Coatings with excellent characteristics and behaviour have been processed: the selection of best coatings has been made thanks to the characterization of microstructure properties (XRD and SEM investigations) together the tribological characterization. The achieved goal has been the keeping the initial nanostructure after deposition by optimised thermal spraying.
Key principles are reactivity, particles sizes and shape. The result has scientific relevance, but then most of the project results (commercial, social) are bonded to the feasible process and the availability of a suitable powder.
Key innovative features of the result:
Metallurgical principles for nanophased powders to be used in thermal spraying.
Dissemination and use potential:
The use potential of the results, associated with others projects results (in particular the availability of optimised thermal spraying processing) is extremely strong, since it opens the generation of new classes of coatings with outstanding wear properties.
Current status and use of the result and its expected benefits:
The research has confirmed that the nanostructured coatings show an improved behaviour respect to the conventional coating materials; so breakthroughs are expected into new applications of thermal spraying of nanopowders.
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