I found this on the web. It's from Thermico and describes what we did there.

1. A D V A N C E D C O A T I N G S O L U T I O N S

2. nanoHVOF - for the most demanding
OD and ID Applications with
®
OD and ID Applications with
WC-CoCr 86 10 4
nanoHVOF powder – System Technology
and Application Know-How
®
Götz Matthäus – General Manager Thermico GmbH & Co. KG, Germany
Michael Molnar – President Thermico USA , Inc.

3. Outline
1. Thermico performance profile
2. NANO HVOF R&D Project - advantages of spraying fine powders2. NANO HVOF R&D Project - advantages of spraying fine powders
3. Problematic of spraying fine powder materials
4. nanoHVOF powder
5. nanoHVOF is a system
®
®
6. Applications

4. Thermico
Research and Development
All scientific processes which lead to innovative products are realized in our shop
located in Dortmund - Germany
Performance profile
located in Dortmund - Germany
Spherodized Powder material, Coating and Technology development
System manufacturing
A reliable Spare Part and component production to build up Turnkey Systems for
HVOF and Plasma is done in our shop located in Dortmund - Germany.
ID and OD torches, Powder Feeder, Monitored and computer based Visualization and
Controller Units
International Spray ShopInternational Spray Shop
Located in Dortmund – Germany and Greensboro, NC – USA* we have
nanoHVOF coating Shops for the most demanding OD and ID Applications
Aerospace, Landing Gear, Oil & Gas, Paper Rolls * under construction

5. EU R&D Project NANO HVOF (4/2000 – 10/2003)
The NANO HVOF EU project shows the idea and the high potential of HVOF
coatings sprayed with fine, 5 - 15 µm powders.
The research and development work of the NANO HVOF EU project only
Micrograph of a dense WC-CoCr 86 10 4 coatingSEM of a 5-15µm agglomerated,
sintered and crushed WC-CoCr powder
The research and development work of the NANO HVOF EU project only
focused an improvement of coating quality concerning high density and
submicron splat-thickness.
All coatings of this R&D Project where produced with conventional
agglomerated, sintered and crushed powders.

6. What are the advantages of spraying powders with particle
?
sizes less than 15 µm?

7. Advantages of spraying fine powders
Diagram shows that particle velocity depends on particle size

8. Advantages of spraying fine powders
Kinetic energy depends on particle velocity
30µm
5 µm
Ek (30µm) ½ m v2 1
------------------- = ------------ = ------------
Ek (5µm) ½ m v2 6,25
400 m/s
1000 m/s
Under constant mass flow conditions a comparison between 5 µm and 30 µm particles shows,
the smaller the particle size, the higher the particle velocity.
Due to high particle velocity the kinetic energy increases exponentially (EK = ½ mv
2
).

9. Advantages of spraying fine powders
HVOF standard powder
Agglomerated, sintered
and crushed powder
WC-CoCr 86 10 4
For melting a small particle less thermal energy is needed
Particle size Particle sizeParticle size
-45 +20 µm
HVOF Process energy
100 – 250 kW
Particle size
-15 +5 µm
HVOF Process energy
30 – 80 kW

10. Advantages of spraying fine powders
- Higher residual compressive stress
A summary of the advantages shows that the EU R&D NANO
HVOF Project already is a further development of standard HVOF :
- Higher residual compressive stress
due to higher particle velocity
- Improved wear properties, improved
corrosion barrier due to a dense coating
structure with submicron splatthickness
- Reduced amount of heat to work piece,- Reduced amount of heat to work piece,
because to melt a small particle
less energy is needed.

11. ?
Concerning the advantages of spraying with particles less
than 15 µm, there is still one question left:
Why is spraying with fine particles not common with HVOF
technology yet?

12. Fine and crushed powder materials do not allow Near-net shape
sprayed coating applications and ductile ID WC-CoCr coatings
Challenges of spraying fine agglomerated,
sintered and crushed powder materials
• Crushed particle shape causes insufficient
flow characteristics
- an irregular pulsing powder flow does
not allow Near-net shape Spraying
• Crushed particles have a large surface
SEM of a 5-15µm agglomerated, sintered and
crushed WC-CoCr powder
• Crushed particles have a large surface
which is sensitive to be oxidized
- Oxides reduce the ductility of the coating
- With decreasing DE oxides will appear as
dust Inclusions, especially in an ID coating
structure.Internal cracks after ductility test

13. Fine agglomerated, sintered and crushed powder materials can not
deliver good Seawater Resistance and lower the Wear Resistance
Challenges of spraying fine agglomerated,
sintered and crushed powder materials
• agglomerated and sintered powders only
provide a sintered Co, Cr metal matrix
- an inhomogeneous phase distribution with
free Co can not deliver a good Seawater
Resistance
• To provide metallurgical bonded Carbides
in the matrix, agglomerated and sintered
powders require high temperature andpowders require high temperature and
stand-off in the spray process
- High stand-off do not allow coating of small
Inside Diameter Areas (ID must be > 14”)
- Not metallurgical bonded carbides lower the
Wear Resistance of the coating.
SEM of a 5-15µm agglomerated, sintered and
crushed WC-CoCr powder

14. Demand for WC-CoCr powder material with
optimized characteristics
The use of fine agglomerated, sintered and crushed powder materials
is lowering performance characteristics and coating quality
Problem
Fine agglomerated, sintered and crushed powders:
Solution
Fine powder material with:
do not allow Near-net shape spraying spheroid particle shape
do not allow ductile Internal Diameter coatings dense, spheroid particle shape
increase the amount of oxides in the coating dense, spheroid particle shape
produce coatings with poor Seawater Resistance matrix providing a melted alloy
do not allow coating of small Inside Diameter Areas metallurgical bonded carbidesdo not allow coating of small Inside Diameter Areas metallurgical bonded carbides
have lower Wear Resistance, limited by process temperature metallurgical bonded carbides
Thermico has coped with this challenge…

15. To achieve more performance characteristics and a higher coating quality further
Research and Development of powder materials and System Technology was done by
Thermico from 2006 up to 2010.Thermico from 2006 up to 2010.

16. Controlled Plasma Spherodization to achieve ultrafine and highly
optimized nanoHVOF powder
nanoHVOF Powder
®
Feedstock Material
WC-CoCr 86 10 4
Controlled Process nanoHVOF Powder
WC-CoCr 86 10 4
®
®
Spherodized particle shape provides a matrix consisting
of a 14 wt% CoCr28 melted alloy in which the
submicron carbides are metallurgical bonded
Feedstock material < 10 µm
and a primary carbide size
of 400 – 900 nm
Plasma Spherodization

17. Quality Control and parameter adjustment to ensure a reliable
powder production
nanoHVOF Powder
®
Bulk density
by hall flowmeter funnel
Element detection by EDX-AnalysisParticle shape by SEM
Feedback of Powder Quality
The Controlled Plasma Spherodization Process is based on
a measurement and adjustment of:
• Inert gas flow• Plasma gas composition
• Plasma gas flow
• Plasma Power • Powder feed rate
•Powder gas flow
Process Input

18. Controlled Plasma spherodization means to get the right quality of the
metallurgical structure with only a very low amount of W2C phases
nanoHVOF Powder
®
X-Ray Diffraction of a WC-CoCr particle shows the structure after
controlled Plasma Spherodization

19. nanoHVOF Powder
Tailored nanoHVOF Powder cuts enable maximal Deposit Efficiency and
an as-sprayed surface roughness less than 1.5 µm Ra
®
®
Really smooth HVOF
Ultra fine powders
-5+2 µm or -10+5 µm
produce ultra fine splats
Ultra fine splats
produce ultra fine surfaces
Really smooth HVOF
-5+2 µm or -10+5 µm
ultra fine nanoHVOF Powder cuts®
+ Save on grinding + Save on finishing + Save powder + Reduce overall costs

20. Hard
Inside and outside diameter coatings with
Hardness > 1200 HV 0.3 (Standard deviation of ± 30 HV 0.3)
More than smooth – nanoHVOF performance characteristics
nanoHVOF Coating quality
®
®
Hardness > 1200 HV 0.3 (Standard deviation of ± 30 HV 0.3)
Ductile
Performs well in
tests such as a Guided Bend Test
Vickers-indent with1Kg at the
interface (Substrate / coating),
without any formation of cracks

21. Dense
Coating structure with virtually Zero Porosity,
to survive more than 1000 hours in a Salt
Fog Test by 50 µm coating thickness
More than smooth – nanoHVOF performance characteristics
nanoHVOF Coating quality
®
®
Fog Test by 50 µm coating thickness
Near-net
Allows for coating thickness
accuracy of ±15 µm as-sprayed
Corrosion resistant
Nanostructured Coating with homogeneous
phase distribution providing a melted CoCr28
melted alloy matrix for high Seawater Resistance
accuracy of ±15 µm as-sprayed

22. To achieve superior coating quality for the most demanding OD and ID
Applications
nanoHVOF is a System
®
nanoHVOF Powder®
nanoHVOF System Technology
Ultra fine, spherodized and nano structured powder
Powder feeder, torch and system technologies optimized for spraying
ultra fine nanoHVOF powder
®
®
nanoHVOF Application Know-How
Thermico experience and training means successful coating developments
for the most demanding applications
®

23. Feeding ultra fine powders with particle sizes less than 10 µm is a challenge
nanoHVOF is a System
Powder feeder
®

24. CPF-2 Powder feeder for standard, micro and nanoHVOF Powders®
nanoHVOF is a System
Powder feeder
®

25. Precise dosage of fluidized Powder by gravimetric feeding principle
with controlled rotation of the feeding wheel
nanoHVOF is a System
Powder feeder
®
Feeding wheel BalancerFeeding principal

26. 3rd Generation of the CPF Powder Feeder Software and visualization to
control the feeding Process and get a constant powder flow
nanoHVOF is a System
Powder feeder
®
In Control
Customizable start and feeding parameter, trend
data storage and on-line visualization

27. Torch technology for outside and inside diameter coatings
nanoHVOF is a System
OD and ID Torches
®
CJS K5.2-N
OD-Applications
ID CoolFlow-N
ID-Applications

28. Dual chamber, hydrogen stabilized kerosene combustion reduces thermal
load to substrate and powder materials
nanoHVOF is a System
OD and ID Torches
®
Principal of Thermico CJS K5.2-N HVOF torchPrincipal of Thermico CJS K5.2-N HVOF torch
Increased volume of
2. combustion chamber
Mach 1 – 2.5
Super sonic area
• Low turbulence level for
the supersonic jet
• High pressure Area
N2 ,
• Main part of combustion
• Hydrogen stabilized
Kerosene/O2-Combustion
• Cold ignition point for powderN2 ,
1. combustion chamber
Optimized for spraying fine powders
with high affinity to oxygen
• Main part of combustion

29. nanoHVOF is a System
OD and ID Torches
To achieve a high quality coating structure with a very low amount of
oxides it is recommended to choose a spray parameter with λ ≤ 1
®
Required Amount of Oxygen for 100% combustion of combustibles
λ =
Provided amount of Oxygen, due to process parameter
A: Combustibles
Hydrogen stabilized O2 / Kerosene combustion, due to vaporization of Kerosene jet
by entering in the second combustion chamber
A
B
B
Required Amount of Oxygen for 100% combustion of combustibles
Combustion chamber principle of CJS K5.2-N and ID CoolFlow-N
B: Nitrogen + Oxygen
If λ = 1, than nitrogen is used as an inert cooling gas which increases the jet velocity by its
controllable mass flow.
The C-CJS Nitrogen Technology allows for achieving a high amount of
kinetic energy in the spray process without adding further thermal energy.

30. Control, visualization and analysis of the process
nanoHVOF is a System
System technology
®
NANO HVOF
State of the Art Soft- and Hardware for HVOF and Plasma

31. On-line Process monitoring and analysis
nanoHVOF is a System
System technology
®
On-line spray-jet visualization via USB-CameraOn-line Spray-jet-geometry monitoring system.
Observation of spray-spot and jet.
Trend data storage of all mass flows

32. nanoHVOF Applications
CJS K5.2-N
®
Outside diameter coatings
Turbine Blades
Near-net, nano structuredNear-net, nano structured
droplet erosion coatings
Landing Gear
Smooth surfaces and
close control of coating
thickness lead to reduced
grinding and finishinggrinding and finishing
costs on outside diameter
surfaces

33. nanoHVOF Applications
CJS K5.2-N
®
Outside diameter coatings
Gas Turbines
Low oxide HVOF sprayedLow oxide HVOF sprayed
metal coatings, for example,
MCrAlY and T-800
Hard Chrome replacement
Hydraulic Actuators, Rolls,
Mud Rotors and other general
applications

34. nanoHVOF Applications
CJS K5.2-N
®
CJS K5.2-N for cost-effective applications with brilliant results

35. nanoHVOF Applications
®
Critical pumps in crude oil and FCC process are an example for a single
application which demands for OD and ID Spraying
pump case pump cover pump impeller

36. nanoHVOF Applications
ID CoolFlow-N
®
Inside diameter coatings
Landing Gear
Coating inside diameters forCoating inside diameters for
hard chrome replacement even
on temperature sensitive
substrate materials without
extra cooling
Automotive
Inside diameter Al-SiC-Cu-Mg
coating

37. nanoHVOF Applications
ID CoolFlow-N
®
Pumps
Non Line-of-Side spraying
Inside diameter coatings
Non Line-of-Side spraying
improves erosion and
corrosion protection inside
casings, bushings and
sleeves
Pipes and Risers
Inconel and Tungsten Carbide
coatings of Pipes and Risers
reduce maintenance costs

38. nanoHVOF Applications
ID CoolFlow-N
®
ID CoolFlow-N applications beginning from 4“ inside diameter
107.0°C Trough hole internal exhaustion

39. nanoHVOF Applications
ID CoolFlow-N
®
Pump case and Non-Line-of sight spraying
Critical pumps in crude oil and fluid catalytic cracking
FCC processes

40. nanoHVOF Applications
ID CoolFlow-N
®
Pump case and Non-Line-of sight spraying

41. nanoHVOF Application
Facing sophisticating Applications
®
Rotational Media Transfer Unit (RMTU)
ID CoolFlow-N torch with Extension and RMTU

42. nanoHVOF Application
Facing sophisticating Applications
®
Rotational Media Transfer Unit (RMTU)
RMTU equipped for spraying Control box

43. Thank you very much for your attention!Thank you very much for your attention!