Optimized surface roughening by pulsed water jet for stronger thermal barrier coating

通过脉冲水射流优化表面粗糙化，以获得更强的热障涂层

• 批准号: 524178-2018
• 负责人: Kabir, AbuSyedHumaun
• 金额: $ 1.82万
• 依托单位: Carleton University
• 依托单位国家: 加拿大
• 项目类别: Engage Grants Program
• 财政年份: 2018
• 资助国家: 加拿大
• 起止时间: 2018-01-01 至 2019-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=654956
• 关键词: Optimized; surface; roughening; pulsed; water

Cast-iron has been widely used to manufacture automotive engines. When car engines fail, they are typically replaced because**traditional engine remanufacturing techniques are quite expensive. A new remanufacturing technique has been adopted by major**automakers, known as Plasma Transferred Wire Arc (PTWA) coating technology, aims to give a new life to old engines that would**otherwise be scrapped. A coating is applied through PTWA process to the inner-wall of a worn-out engine block that helps restore**it to its original condition. This innovative remanufacturing process requires very little raw materials as well as saves more than**50% CO2 emission associated with the production of a new engine.**Generally, during cast-iron engine remanufacturing process, an expensive nickel-aluminum (Ni-Al) chemical coating is formed**prior to final PTWA coating of carbon steel to increase the overall bond strength. This expensive Ni-Al pre-coating step can be**avoided by using an optimized surface roughness of the substrate and has been reported extensively for aluminum based**engines. Cast-iron is brittle compared to aluminum alloys and difficult to create a significant surface roughness by conventional**roughening processes.**The idea behind this project is to significantly roughen the cast-iron substrate by an inexpensive and environment friendly highpressure**pulsed water jet technology that is expected to create bond strength as high as Ni-Al coating. An optimized surface**roughness on the substrate will not only provide a metallic diffusion bonding during the PTWA coating but also will create**mechanical interlocks between coating and the substrate, increasing the overall bond strength.

铸铁已被广泛用于制造汽车发动机。当汽车发动机发生故障时，它们通常会被更换，因为**传统的发动机再制造技术相当昂贵。主要汽车制造商已经采用了一种新的再制造技术，即等离子转移焊丝电弧(PTWA)涂层技术，旨在赋予原本将被报废的旧发动机新的生命。通过PTWA工艺在磨损的发动机机体内壁上涂覆一层涂层，有助于将其恢复到原来的状态。这种创新的再制造工艺需要非常少的原材料，并可节省**50%以上与生产新发动机相关的二氧化碳排放。**通常，在铸铁发动机再制造过程中，在碳钢的最终PTWA涂层之前**会形成昂贵的镍铝(Ni-Al)化学涂层，以提高整体结合强度。这种昂贵的Ni-Al预涂覆步骤可以通过使用优化的基材表面粗糙度来**避免，并已被广泛报道用于铝基发动机**。与铝合金相比，铸铁很脆，很难通过传统的**粗化工艺**产生显著的表面粗糙度。**该项目背后的想法是通过廉价且环保的高压**脉冲水射流技术显著粗化铸铁基材**该技术有望产生与镍铝涂层一样高的结合强度。优化的衬底表面**粗糙度不仅将在PTWA涂层过程中提供金属扩散连接，还将在涂层和衬底之间产生**机械互锁，从而提高整体结合强度。