Investigation of an innovative method for the production of diamond reinforced coatings by HVOF and Warm Spraying for highly wear loaded surfaces (re-submission)

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Diamond metal composite layers with small diamond grain sizes can be used as super wear-resistant protective layers for tools and structural components (hardfacing). Especially the high abrasive, erosive and impact loads in the field of stone processing, for example during deep drilling, lead to increased tool wear, which is beyond the capabilities of conventional wear-resistant coatings.The aim of this research project is to develop a detailed understanding of the processes and mechanisms during the thermal spraying of metallic coated diamonds as well as diamond metal powders by High Velocity Oxygen Fuel Spraying (HVOF) and Warm Spraying (WS). The methods offer, due to the combination of high kinetic and moderate thermal energy as well as the wide adjustable parameters, outstanding features for the production of diamond impregnated metal matrix composite layers. The potential of diamond metal composite layers sprayed by HVOF and WS is investigated fundamentally in model tests under realistic wear conditions. For this purpose, abrasive, erosive and impact wear conditions are considered extensive. The aim is to elucidate the wear and failure mechanisms of diamond impregnated metal matrix composite layers and to identify the influence of thermal spraying parameters. Due to the comprehensive understanding of the coating process and the wear mechanisms, it will be possible to formulate an optimal solution (coating) as a function of all parameters.