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USE OF GAS DETONATION FOR
COATING DEPOSITION:
DETONATION SPRAYING
V. Yu. Ulianitsky, A.A. Shtertser*, S.B. Zlobin
Lavrentyev 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 - hydrogen
CH4 – methane
C2H2 – acetylene
C2H4 – ethylene
C2H6 – ethane
C3H6 – propylene
C3H8 – propane
C4H10 – 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
Mixtures
Combustible mixture
ρ0, kg/m3
at 250 С
ρН / ρ0
РН / Р0
Т, К
D, m/s
Mass
velocity
u, м/с
Dynamic
pressure,
ρH u2/2, bar
2Н2 + О2
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
13,98
MAPP + 1,51О2
MAPP + 3О2
1,493
1,424
1,79
1,83
49,10
42,69
3529
4097
2703
2539
1192
1153
18,95
17,35
С3Н8 + 3О2
С3Н8 + 4,5О2
1,431
1,398
1,84
1,85
44,53
38,25
3769
3854
2580
2409
1179
1106
18,36
15,84
С4Н10 + 3,5О2
С4Н10 + 5О2
1,545
1,486
1,83
1,85
48,27
42,76
3676
3882
2593
2474
1180
1136
19,77
17,75
СУГ50/50 + 3,5О2
СУГ50/50 + 5О2
1,481
1,438
1,85
1,85
45,80
39,68
3792
3867
2570
2421
1177
1111
18,89
16,46
С3Н6 + 1,51О2
С3Н6 + 3О2
1,472
1,411
1,78
1,85
43,01
42,89
2958
3972
2553
2546
1118
1166
16,36
17,66
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Detonation Spraying
Investigation of spraying process and development of DS equipment was
carried 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 with
any 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
Gun with 3-D
manipulator
Chiller
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CCDS Gun
4
3
1
2
5
1- barrel (length 800мм)
2- powder feeder (shuttle
design)
3- mixing and ignition chamber
4- ignition plug
5- stand
Mass of gun is about 15 kg. It
can be mounted on industrial
robot.
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Gun control program
(view of computer monitor)
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CCDS in operation
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CCDS Technical Characteristics
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Computer Control
- based on computer IC610H
Power consumption
- not more than 1 kW
Fuel
- acetylene, propane, propylene, etc.
Окислитель
- oxygen
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 μm
Coating maximal thickness
- not limited
Rate of shots
- up to 15 shots per second
Productivity
- up to 2 kg powder per hour
Efficiency of powder deposition
- up to 70%
Coating strength
- up to 300 Mpa
Coating porosity
- possible to achieve less than 1 %
Microhardness of WC/Co coatings
- up to 1300 Hv
Cooling System (closed cycle):
Mass
- less than 20 кг
Volume of cooling water
- less than 5 litre
Heat Exchange Power
- up to 6 kW
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 for
calculation of velocity and temperature of powder particles accelerated in CCDS
barrel*.
500
3500
2000
1500
20μm
30μm
50μm
1000
500
400
350
300
250
200
150
20μm
30μm
50μm
100
50
0
0
400
350
300
250
200
150
Position, mm
100
50
0
Particle velocity, m/s
2500
450
Particle temperature, K
3000
400
350
300
250
200
150
100
50
0
Position, mm
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.
*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.
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Heating and acceleration of WC/Co particle
in the barrel
350
3000
velocity
2500
250
2000
200
temperature
150
1500
Co binder melting
1000
100
temperature, K
velocity, m/s
300
500
50
0
0
0
50
100
150
200
250
300
350
distance from injection point, mm
Particle composition WC/Co-88/12, particle diameter d=30мкм, barrel length
800 mm, barrel diameter 20 mm, explosive mixture C2H2 + O2, explosive
mixture 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 d’Ingenieurs 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.
Typical CCD-camera image with 10
µs time exposition. Tracks of 30µm
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.
*I. Smurov, D. Pervushin , Yu. Chivel , B. Laget , V. Ulianitsky, S. Zlobin. Presentation at
ITSC-2010, Singapure, May 3-5
Applications of DS
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(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).
Applications of DS
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(wear resistant and electro-insulating coatings)
Parts of hydraulic devices
(plunger) hardened by
aluminum oxide coating.
Microhardness HV300 1600
Applications of DS
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(heat-proofing coating)
Ceramic coating on work surface of rocket nozzle made of aluminum.
Layer thickness of 500 μm increases manyfold nozzle service life
Applications of DS
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High-voltage insulation for extreme conditions (radiation)
Elements of electro-physical apparatus coated with aluminum oxide (insulation up to 5 kV)
Hydrogen energy and ecology
Catalytic system for neutralization of
automobile exhaust
Catalyst supporter for conversion reactor transforming
liquid fuel into synthesis gas (H2+CO)
Applications of DS
(wear resistant coatings)
WC/Co-75/25 coating between teeth on a boring bit
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Applications of DS
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plastic 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 substrate
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CONCLUSION
CCDS provides wide opportunities for deposition of metal, ceramic and
composite coatings on components of machines and mechanisms
Thank you for your attention