低成本电弧喷涂替代堆焊案例分析研究

A Case Study of the Potential of Wire Arc Spraying As a Cost Effective Alternative to Established Weld Overlay Processes

堆焊是一种常规的涂层制备方法,并且制备的涂层可以满足各种性能要求的需要。堆焊在工业中普遍应用,然而,他们有一个共同点,由于涂层制备速度的限制,导致成本相对较高。本文主要关注采用电弧喷涂替代MAG堆焊用于农业装备制造生产线的可行性,例如,耕作设备。与堆焊相比,采用电弧喷涂可以优化五种以上的生产工艺,减少多项生产工艺流程。本文主要目标是应用电弧喷涂工艺获得一个类似或更好的涂层质量。本文中制备的涂层材料重点是降低成本,提高生产效率,其目标是实现耕作设备在复杂耕作条件下具备更高的耐磨性。将涂覆有耐磨涂层的犁头在田间的测试是主要的评定方法。此外,该涂层将采用金相光学显微镜(LOM)和扫描电子显微镜(SEM)观察来解释和支持的现场试验研究结果。

In general, the well established and numerous weld overlay processes are effective and produce coatings,which meet the requirements of their intended usage. Problems and requests within the industries using weld overlay processes are wide spread, however, they have one thing in common. The limiting factors of process speed as well as the relatively high process cost. This paper focuses on the possibilities of using wire arc spraying as an alternative to MAG overlay welding in an established production line of devices used for agricultural purposes, i.e. ploughing. This will optimise the production of components with a factor 5 or more and reduce the number of process steps when using weld overlay. The primary objective is to obtain a similar or better coating quality, when applying wire arc spraying. A minor material study, where the focal point is cost efficiency, is implemented targeting high wear resistance, as well a high tolerance of intense and random impact by various sized hard and abrasive objects during ploughing. The coated ploughshares exposed to fields test as the primary ranking method in fields with well defined compositions. Furthermore, the coatings will be metallurgically examined using light optical microscopy （LOM） and scanning electron microscopy （SEM） to interpret and support the field tests.