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USE OF GAS DETONATION FORCOATING DEPOSITION:

DETONATION SPRAYING

V. Yu. Ulianitsky, A.A. Shtertser*, S.B. ZlobinLavrentyev Institute of Hydrodynamics SB RAS

Lavrentyev avenue, 15, Novosibirsk, 630090, Russia

asterzer@mail.ru

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Detonation Spraying

Detonation Spraying (DS) is one of explosive technologies and can be attributed to

Explosive Working of Materials. It is based on gas detonation phenomenon. DS is used

for deposition of powder coatings (metal, ceramic, composite and etc.) onto different

substrates, mainly on metallic surfaces.

At first DS was employed in 1950s in USA [1, 2], and later on in 1960s in USSR [3].

Comprehensive review of technological application of gas detonation is done in [4]. DS

is particularly effective in deposition of WC-based hard alloy coatings [5]

1) R. M. Poorman, H. B. Sargent, and H. Lamprey. Method and Apparatus Utilizing Detonation Waves for Spraying and

other Purposes. US Patent No. 2714563, Aug. 2, 1955.

2) John F. Pelton. Flame Plating Using Detonation Reactants. US Patent No. 2972550, May 28, 1958.

3) Bartenev S.S., Fedko Yu.P., Grigorov A.I. Detonation Coatings in Machinery Building. Leningrad: Mashinostroenie,

Leningrad section, 1982.

4) Yu.A. Nikolaev, A.A. Vasiliev, V.Yu. Ulianitsky. Gas Detonation and its Application in Engineering and Technologies

(Review) // Combustion, Explosion, and Shock Waves. 2003, vol 39, No. 4. P. 382-410.5) S.B. Zlobin, V.Yu. Ulianitsky, A.A. Shtertser. Comparative Analysis of Nanostructured and Microstructured Cermet

Detonation Coatings // Uprochnayushie Technologii I Pokrytia. 2009, No. 3. P. 3-11.

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Gaseous and Liquefied Fuels

H2 - hydrogenCH4 methane

C2H2 acetylene

C2H4 ethylene

C2H6 ethane

C3H6 propylene

C3H8 propaneC4H10 butane

Liquefied hydrocarbons -propane + butane (70/30, 60/40, 50/50)

MAPP liquefied petroleum gas mixed with methylacetylene (propyne)-

propadiene (allene) system. For example 30% propane (propylene,

butane, etc.) + 70% C3H4. MAPP is more safe than acetylene and it is

more and more used in gas welding and cutting in recent years.Research by European space concerns into using light hydrocarbons with

liquid oxygen as a relatively high performing propellant combination which

would also be less toxic than the commonly used MMH/NTO

(monomethylhydrazine/nitrogen tetroxide) systems, showed that propyne

(C3H4) would be highly advantageous as a rocket fuel for craft intended

for low Earth orbital operations.

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Detonation Parameters of Some Gaseous

MixturesCombustible mixture 0, kg/m3

at 250

/

0

/

0, D, m/s Mass velocity

u, /Dynamicpressure,

Hu2/2, bar

22

+ 2

0,4909 1,84 18,79 3682 2837 1294 7,56

CH4

+ 2O2

1,090 1,85 29,33 3726 2391 1102 12,24

2C2H2+ 5O2 1,238 1,84 33,84 4215 2424 1108 13,98MAPP + 1,51

2

MAPP + 32

1,4931,424

1,791,83

49,10

42,69

35294097

27032539

11921153

18,9517,35

3

8+ 3

2

3

8+ 4,5

2

1,4311,398

1,841,85

44,53

38,25

37693854

25802409

11791106

18,3615,84

4

10+ 3,5

2

4

10+ 5

2

1,5451,486

1,831,85

48,27

42,76

36763882

25932474

11801136

19,7717,75

50/50

+ 3,52

50/50

+ 52

1,4811,438

1,851,85

45,80

39,68

37923867

25702421

11771111

18,8916,46

3

6+ 1,51

2

3

6+ 3

2

1,4721,411

1,781,85

43,01

42,89

29583972

25532546

11181166

16,3617,66

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Detonation Spraying

Investigation of spraying process and development of DS equipment wascarried out in a number of organizations all over the world including

Lavrentyev Institute of Hydrodynamics SB RAS (LIH SB RAS). In recent

years the new technology and equipment for detonation spraying was

developed in LIH SB RAS - Computer Controlled Detonation Spraying

(CCDS). In CCDS transverse injection of powder into the barrel is made

using a powder feeder fixed on the said barrel. The System can work withany detonating gaseous mixture, but acetylene (or MAPP) + oxygen mixture

is preferable for spraying of refractory composites such as WC/Co. CCDS

permits to vary spraying parameters in a wide diapason, and to deposit

coatings from refractory alloys, high-temperature ceramic, and fusible

metals onto different substrates including plastic.

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Detonation Spray equipment: CCDS 2000

Control unit Chiller

Gun with 3-D

manipulator

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CCDS Gun

1- barrel (length 800)

2- powder feeder (shuttle

design)

3- mixing and ignition chamber

4- ignition plug5- stand

Mass of gun is about 15 kg. It

can be mounted on industrial

robot.

1

2

3

4

5

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Gun control program(view of computer monitor)

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CCDS in operationEPNM-2010

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CCDS Technical Characteristics

Computer Control Power consumption - not more than 1 kW Fuel Inert gas for barrel purging - nitrogen, air Barrel length - up to 1 m Barrel diameter - up to 30 mm Coating thickness per shot - up to 10 m

Coating maximal thickness - not limited Rate of shots - up to 15 shots per second Productivity Efficiency of powder deposition - up to 70% Coating strength - up to 300 Mpa Coating porosity Microhardness of WC/Co coatings - up to 1300 Hv Cooling System (closed cycle): Mass

Volume of cooling water - less than 5 litre Heat Exchange Power Manipulator Drive Gear: provides rotation and linear move along two coordinates. Parts with mass up to 300 kg and surface area 500 x 500 mm

can be treated by CCDS

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Heating and Acceleration of Powder Particle

in the Barrel

The theoretical procedure and computer software were elaborated in LIH forcalculation of velocity and temperature of powder particles accelerated in CCDS

barrel*.

*Gavrilenko T.P., Nikolaev Yu.A., Ulianitsky V.Yu., Kim, M.Ch., Hong J.W.,

Computational

Code for Detonation Spraying Process, Proc. of the 15th Intern. Thermal Spray Conf.,

25-29 May, 1998. Nice, France. 1998, p. 1475-1483.

0

500

1000

1500

2000

2500

3000

3500

050100150200250300350400

Position, mm

Particletemperature,K

20m

30m

50m

0

50

100

150

200

250

300350

400

450

500

050100150200250300350400

Position, m

Particlevelocity,m

/s

20m30m50m

Example of calculation for WC/Co (88/12 wt%) particles: The data on acceleration and heating

of the particles is displayed on computer monitor in the form of diagram. On pictures calculation

results are presented for WC/Co (88/12 wt%) particles sprayed using 50% explosive charge.

Particles can be heated up to melting point and accelerated up to 500 m/s.

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Heating and acceleration of WC/Co particle

in the barrel

velocity

temperature

Co binder melting

Particle composition WC/Co-88/12, particle diameter d=30, barrel length

800 mm, barrel diameter 20 mm, explosive mixture C2H2 + O2, explosivemixture length 440 mm (barrel filling), powder injection point 300 mm from

barrel end. Particle velocity is 317 m/s, particle temperature 2266 K.

Cobalt melting point TmCo = 1765 K, vaporization temperature TvCo = 3373 K;

WC melting point TmWC = 3248 K, vaporization temperature TvWC = 6273 K.

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Experimental measurements of particle

velocity

Last time in collaboration with researches from Ecole Nationale dIngenieurs de Saint-Etienne (France)measurements of particle velocities were performed using CCD-camera-based diagnostic*. In this

method tracks of particles are registered in a form of digital images. A CCD camera converts optical

brightness into electrical amplitude signals using charge coupled device (CCD) image sensor.

*I. Smurov, D. Pervushin , Yu. Chivel , B. Laget , V. Ulianitsky, S. Zlobin. Presentationat

ITSC-2010, Singapure, May 3-5

Typical CCD-camera image with 10

s time exposition. Tracks of 30m

WC/Co particles are registered in a

window of 30x22 mm.

Powder flux cross-section is 20 mm.

Depth of resolution is about 5 mm.

Measurement results are in good

agreement with calculated values

of velocity.

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Applications of DS(aircraft motor-building)

Wear resistant hard-alloy coating on anti

-vibration ledges of gas turbine compressor

blade.

Hard alloy WC/Co 75/25 is sprayed on a

ledge butt-end (shown by arrows).

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Applications of DS(wear resistant and electro-insulating coatings)

Parts of hydraulic devices

(plunger) hardened by

aluminum oxide coating.Microhardness HV

3001600

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Ceramic coating on work surface of rocket nozzle made of aluminum.

Layer thickness of 500 m increases manyfold nozzle service life

Applications of DS(heat-proofing coating)

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High-voltage insulation for extreme conditions (radiation)

Applications of DS

Elements of electro-physical apparatus coated with aluminum oxide (insulation up to 5 kV)

Hydrogen energy and ecology

Catalyst supporter for conversion reactor transforming

liquid fuel into synthesis gas (H2+CO)

Catalytic system for neutralization of

automobile exhaust

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Applications of DS(wear resistant coatings)

WC/Co-75/25 coating between teeth on a boring bit

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Applications of DSplastic metallization (delicate modes of spraying)

Correctly chosen mode of spraying provides adhesion up to 8 MPa for zinc

or aluminum coating on polystyrene or fluoroplastic (teflon) substrate

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CCDS with two powder feeders

At present investigations on deposition of composite

and gradient coatings with use of two powder feeders

are under performing. Two feeders provide possibility

to alternate shots with different powders in defined

order.

Gradient coatings permit, for example, to adjust

properties of metal substrate and ceramic layer by

introducing of interlayer gradient coating.

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Gradient coating Al2O3 + Ti on Ti substrateEPNM-2010

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CONCLUSION

CCDS provides wide opportunities for deposition of metal, ceramic andcomposite coatings on components of machines and mechanisms

Thank you for your attention

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