INSTITUTE OF TECHNOLOGY OF METALS
  
 



LANGUAGE
  • Russian

  • INSTITUTE
  • Institute
  • Main directions of scientific research work
  • Structure
  • Contacts
  • Cooperation

  • DEVELOPMENTS OF THE INSTITUTE
  • Continuous casting
  • Freezing-up casting
  • Bimetals
  • Silumins
  • Simulation of casting processes
  • Water analog simulation of die casting
  • Electroslag casting

  • CORROSION
  • Development of diagnosis system of the metal surface damage
  • Development of prognosis system of the steel surface damage by the Light Section Profiling System (LSP system) in high-speed production process
  • Development of prognosis system of the steel bulk property claim by the magnetic detection method in continuous production process
  • Diagnosis system of quality control and process control by digital image analysis
  • Universal magnetic thickness gage
  • Development of anti-corrosive active polymer film for steel packing

  • COATINGS
  • Magnetic Impulse Hardening
  • Cladding
  • IMM (Induction Metallurgical Method) Surface Hardening
  • Thermal Spray Coating Process
  • Flame Spray
  • Detonation Flame Spraying
  • Nontransferred Plasma Arc Spraying
  • Electric Arc Spraying
  • Activated arc spray- Hypersonic metallization
  • High-Frequency Pulse Hardening of Surfaces
  • Wire Arc Coatings
  • Metallization Of Ferrites And Creation Of Fixed Compositions Ferrite-metal

  • TECHNOLOGIES AND EQUIPMENT
  • Equipment For Surface Metallization And Blazing Of Oxide Materials
  • for continuous casting of cast iron and nonferrous metals
  • for battery grid casting
  • for continuous casting of CuCl belt
  • Plant for continuous casting of copper, aluminum, gold, silver, solder wires
  • DEVEOPMENT OF THE INSTITUTE :: Activated arc spray - Hypersonic metallization

            New concept of arc spray coating technology and equipment was developed by Belarus in the world for the first time.

            As compared to the standard scheme TAS (Traditional arc spray), the spray of liquid metal in AAS (Activated arc spray) of new technology, arising as a result of thermal effect of electric arc on the ends of the two wire electrodes, is performed by a jet of combustion products of propane-air mixture. The speed of the jet, coming from the nozzle reaches1500 m/sec at the temperature of 2200K.

            The scheme of traditional arc spray process TAS (Traditional arc spray).


            Scheme of the process of źHypersonic metallization╗ by AAS



            Developed AAS equipment by Belarus
     

            The coating is formed by spraying wires with diameter of 1.5-2.2 mm. The speed of the spraying jet is ~ 3M (1000 m/sec). Maximal working current ~380 A; air consumption ~60 m3/h; propane-butane consumption ~0.011 kg/hr. Productivity (wire; diameter-2 mm) at performing steel coatings ~18 kg/hr.

            Steel coatings, obtained by AAS method have porosity 2~4%, the density of aluminum alloys = 100%. This is especially important at corrosion-proof plating because it allows gaining serious savings of the plated material due to decreasing the thickness of the coating, necessary for protection from through porosity and increases the work life of the coatings. Bond resistance of the coatings 35~60 MPa.


    Microstructure of steel coatings: а, b ľ steel 40Х13; c, d ľ steel Свľ08;
    а, c ľ AAS (Activated arc spray); b, d ľ TAS (Traditional arc spray)

     


    a) Traditional arc spray coating b) Activated arc spray coating (Metallographic analysis)

    Compact equipment for realization of the process of źHypersonic metallization╗

            Advantages

            AAS combine the advantages of arc spraying and high-velocity metal spraying. The main distinctive feature of AAS is the presence of compact high efficiency propane-air mix combustion chamber. Supersonic jet of the mix has at the output the speed of 1500 m/sec and the temperature of 2200 K.

            That causes the particles are speeded up to 500 m/s. As a result, coating adhesion strength is twice improved in comparison with traditional metal spraying (MS). This is enough to work in the most extreme conditions and in cases of shock-abrasive wear. The oxide reduction and the alloying elements burning lowering are allowed by that feature also.

            For example, EAM coating carbon content was 2~3 times less then initial U10A and 40X13 wires one. In comparison, the AAS coating carbon content was not varied at reduction parameters of propane-air mixture.

            The conditions of particles formation and transportation and forming of coating are different from other thermal gas metal spraying methods and cause formation of other structures in the coating material. The use of AAS results in small quantity of fragile oxides, large quantity of intermetaloids, formation of tempering structures and high enough plasticity of the sprayed layer. This allows to use AAS in new fields and to significantly widen the range of parts that can be treated using this method.

            Second, as thickness of the coating necessary to cover through-out porosity can be decreased considerable material economy is achieved.

            High productivity is a traditional advantage of arc spraying. The productivity of a manual AAS-10 unit on steel is 18 kg/hour. Ionization of inter-electrode space reduces the arc current by 10-15 % and the productivity is the same as with traditional arc spraying.
     

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