The algorithm of arc spraying process simulation was created, which allow to make prognosis of arc spraying jet configuration and flying particles parameters. This scientific research shows the dependence between the arc spraying technological parameters and mechanical and physical properties of the obtained coatings. It was established, how by change of the spraying parameters the coatings with the best exploiting parameters can by received. The performed research shows the influence of the kind of the sprayed material on morphology of the formed jet particles and on technical and structural characteristics of the formed coatings. On basis of obtained results made suggestions how to improve the creation of thermal spraying coatings making new products or making restoration.

The algorithm of arc spraying process simulation was created, which allow to make prognosis of arc spraying jet configuration and flying particles parameters. This scientific research shows the dependence between the arc spraying technological parameters and mechanical and physical properties of the obtained coatings. It was established, how by change of the spraying parameters the coatings with the best exploiting parameters can by received. The performed research shows the influence of the kind of the sprayed material on morphology of the formed jet particles and on technical and structural characteristics of the formed coatings. On basis of obtained results made suggestions how to improve the creation of thermal spraying coatings making new products or making restoration.

Le contexte du marché automobile actuel est conditionné par deux facteurs principaux : la prise de conscience del'impact sur l'écologie de ce mode de transport et une concurrence mondiale exacerbée. Ainsi, de nombreusesétudes soulignent l'intérêt de concevoir des moteurs dont le ratio puissance sur masse soit maximisé (Down Sizing).Ainsi les carters-cylindres traditionnellement réalisés en fonte pour des raisons de comportement tribologique sontreconçus pour être fabriqués à partir d'alliages d'aluminium. Ces derniers apportent un gain de masse au groupemotopropulseur mais présentent de piètres propriétés tribologiques. Pour pallier ce défaut, des chemises en fontesont généralement insérées dans les blocs lors de leur coulée. Toutefois cette solution n'est pas optimale et lesprocédés de projection thermique sont de plus en plus mis en oeuvre pour remplacer ces chemises par une mincecouche protectrice qui sera en contact avec les segments.Dans ce contexte ce travail se focalise sur l'application du procédé de projection thermique arc-fil rotatif pour ledépôt de revêtements en acier sur la paroi interne des fûts de carters-cylindres. L'objectif principal est de contribuerà cerner les mécanismes physiques reliant les paramètres de projection et les propriétés des revêtements. Desinvestigations ont été menées sur les différentes étapes de la vie des particules : les mécanismes d'atomisation ontété observés et quantifiés, les comportements à l'étalement des particules et les modes de refroidissement deslamelles ont été déterminés au moyen d'analyses des phases cristallines et les effets des paramètres opératoiressur la structure des dépôts ont été évalués. L'ensemble apporte ainsi de nouveaux éléments pour la maîtrise del'application de la projection thermique à l'arc-fil en milieu confiné et des pistes sont proposées pour optimiser lespropriétés des dépôts. / The current automotive market's context is conditioned by two main factors : the rising awareness of theenvironmental impact of this transportation mode and a strong competition between automakers at the world level.Thus, many studies already underlined the relevance of the « down sizing » of the engine blocks.Thus, cylinders-blocks, traditionally made from cast iron given its excellent tribological behavior and low cost, arenow designed with hypoeutectic aluminium-silicon cast alloys. However, the weight reduction brought by thesealloys is counteracted by their poor tribological properties. Therefore, Thermal spray processes are more and moresolicited to address this issue with the application of thin protective coatings on the working surfaces of thecylinders-blocks.In this frame, the present work was focused on the application of steel coatings on the bores' inner walls of cylinderblocks using the rotative twin-wire arc spray process. The main objective was to contribute to the understanding ofphysical mechanisms linking the spray parameters and the coating properties. Every stages of particles' life werethus investigated : the atomization mechanisms were observed and quantified, particles' spreading and coolingbehaviours were determined by mean of crystallographic examinations and process parameters' effects on coatingstructure were estimated. Globally, this document provides new elements contributing to the understanding and thecontrol of the process and solutions are proposed to raise the coatings properties.

Uma alternativa à utilização de tubos de alto custo, resistentes a erosão por partículas sólidas, nos trocadores de calor ar/gases de usinas termelétricas a carvão, é o revestimento por aspersão térmica com ligas especiais de média a alta dureza. Dentre os processos de aspersão térmica, os mais usualmente empregados para a deposição de revestimentos contra desgaste são por HVOF (High-Velocity Oxyfuel), PS (Plasma Spraying) e AS (Arc Spraying). O processo aspersão térmica a arco (AS) propicia alta produtividade devido a uma maior taxa de deposição quando comparado com os outros processos, além do custo operacional significantemente mais baixo para a fabricação de revestimentos. Neste trabalho, foram depositadas por AS quatro ligas metálicas contra o desgaste erosivo a base de carboneto de tungstênio, superligas de níquel, ligadas ao boro e aço inoxidável martensítico em comparação ao aço ASTM 178 grau A, o qual é atualmente empregado nos tubos do trocador de calor. A avaliação foi feita a partir de ensaios de erosão acelerada (norma ASTM G76), metalografia e MEV. Verificou-se que o comportamento dos revestimentos contendo grande quantidade de defeitos, principalmente porosidade, quando expostos ao desgaste acelerado numa temperatura de 370°C, apresentaram uma maior taxa de desgaste em relação ao aço ASTM A178, e que o melhor comportamento dentre as ligas analisadas foi do aço inoxidável AISI 420 aspergido, o qual apresentou aproximadamente 2% de porosidade e um mecanismo de remoção de material predominantemente dúctil. / An alternative to using tubes of expensive materials, resistant to erosion by solid particles in air-gases heat exchangers of coal power plants, is the thermal spray coatings with special alloys of medium to high hardness. Among the thermal spray processes, the most commonly employed for coatings against wear are HVOF (High-Velocity Oxyfuel), PS (Plasma Spraying) and AS (Arc Spraying). The arc thermal spray process (AS) provides high productivity, due to a higher deposition rate compared to other processes, in addition to the significantly lower operational cost. In this study four different alloys were deposited to evaluate the erosive wear resistance in comparison to the ASTM 178 Grade A steel (currently employed in the tubes of the heat exchanger): 1) with basis of tungsten carbide, 2) nickel superalloys 3) alloyed to Boron, and 4) martensitic stainless steel. The evaluation was made from accelerated erosion tests (ASTM G76), OM, SEM and Vickers micro hardness tests. It was found that the behavior of coatings containing large amounts of defects, mainly porosity, when exposed to accelerated wearing in a temperature of 370 °C showed a higher wear rate than the ASTM A178 and that the best performance among the alloys sprayed was the stainless steel AISI 420, which showed about 2% of porosity and a material removal mechanism predominantly ductile.

Uma alternativa à utilização de tubos de alto custo, resistentes a erosão por partículas sólidas, nos trocadores de calor ar/gases de usinas termelétricas a carvão, é o revestimento por aspersão térmica com ligas especiais de média a alta dureza. Dentre os processos de aspersão térmica, os mais usualmente empregados para a deposição de revestimentos contra desgaste são por HVOF (High-Velocity Oxyfuel), PS (Plasma Spraying) e AS (Arc Spraying). O processo aspersão térmica a arco (AS) propicia alta produtividade devido a uma maior taxa de deposição quando comparado com os outros processos, além do custo operacional significantemente mais baixo para a fabricação de revestimentos. Neste trabalho, foram depositadas por AS quatro ligas metálicas contra o desgaste erosivo a base de carboneto de tungstênio, superligas de níquel, ligadas ao boro e aço inoxidável martensítico em comparação ao aço ASTM 178 grau A, o qual é atualmente empregado nos tubos do trocador de calor. A avaliação foi feita a partir de ensaios de erosão acelerada (norma ASTM G76), metalografia e MEV. Verificou-se que o comportamento dos revestimentos contendo grande quantidade de defeitos, principalmente porosidade, quando expostos ao desgaste acelerado numa temperatura de 370°C, apresentaram uma maior taxa de desgaste em relação ao aço ASTM A178, e que o melhor comportamento dentre as ligas analisadas foi do aço inoxidável AISI 420 aspergido, o qual apresentou aproximadamente 2% de porosidade e um mecanismo de remoção de material predominantemente dúctil. / An alternative to using tubes of expensive materials, resistant to erosion by solid particles in air-gases heat exchangers of coal power plants, is the thermal spray coatings with special alloys of medium to high hardness. Among the thermal spray processes, the most commonly employed for coatings against wear are HVOF (High-Velocity Oxyfuel), PS (Plasma Spraying) and AS (Arc Spraying). The arc thermal spray process (AS) provides high productivity, due to a higher deposition rate compared to other processes, in addition to the significantly lower operational cost. In this study four different alloys were deposited to evaluate the erosive wear resistance in comparison to the ASTM 178 Grade A steel (currently employed in the tubes of the heat exchanger): 1) with basis of tungsten carbide, 2) nickel superalloys 3) alloyed to Boron, and 4) martensitic stainless steel. The evaluation was made from accelerated erosion tests (ASTM G76), OM, SEM and Vickers micro hardness tests. It was found that the behavior of coatings containing large amounts of defects, mainly porosity, when exposed to accelerated wearing in a temperature of 370 °C showed a higher wear rate than the ASTM A178 and that the best performance among the alloys sprayed was the stainless steel AISI 420, which showed about 2% of porosity and a material removal mechanism predominantly ductile.

Uma alternativa à utilização de tubos de alto custo, resistentes a erosão por partículas sólidas, nos trocadores de calor ar/gases de usinas termelétricas a carvão, é o revestimento por aspersão térmica com ligas especiais de média a alta dureza. Dentre os processos de aspersão térmica, os mais usualmente empregados para a deposição de revestimentos contra desgaste são por HVOF (High-Velocity Oxyfuel), PS (Plasma Spraying) e AS (Arc Spraying). O processo aspersão térmica a arco (AS) propicia alta produtividade devido a uma maior taxa de deposição quando comparado com os outros processos, além do custo operacional significantemente mais baixo para a fabricação de revestimentos. Neste trabalho, foram depositadas por AS quatro ligas metálicas contra o desgaste erosivo a base de carboneto de tungstênio, superligas de níquel, ligadas ao boro e aço inoxidável martensítico em comparação ao aço ASTM 178 grau A, o qual é atualmente empregado nos tubos do trocador de calor. A avaliação foi feita a partir de ensaios de erosão acelerada (norma ASTM G76), metalografia e MEV. Verificou-se que o comportamento dos revestimentos contendo grande quantidade de defeitos, principalmente porosidade, quando expostos ao desgaste acelerado numa temperatura de 370°C, apresentaram uma maior taxa de desgaste em relação ao aço ASTM A178, e que o melhor comportamento dentre as ligas analisadas foi do aço inoxidável AISI 420 aspergido, o qual apresentou aproximadamente 2% de porosidade e um mecanismo de remoção de material predominantemente dúctil. / An alternative to using tubes of expensive materials, resistant to erosion by solid particles in air-gases heat exchangers of coal power plants, is the thermal spray coatings with special alloys of medium to high hardness. Among the thermal spray processes, the most commonly employed for coatings against wear are HVOF (High-Velocity Oxyfuel), PS (Plasma Spraying) and AS (Arc Spraying). The arc thermal spray process (AS) provides high productivity, due to a higher deposition rate compared to other processes, in addition to the significantly lower operational cost. In this study four different alloys were deposited to evaluate the erosive wear resistance in comparison to the ASTM 178 Grade A steel (currently employed in the tubes of the heat exchanger): 1) with basis of tungsten carbide, 2) nickel superalloys 3) alloyed to Boron, and 4) martensitic stainless steel. The evaluation was made from accelerated erosion tests (ASTM G76), OM, SEM and Vickers micro hardness tests. It was found that the behavior of coatings containing large amounts of defects, mainly porosity, when exposed to accelerated wearing in a temperature of 370 °C showed a higher wear rate than the ASTM A178 and that the best performance among the alloys sprayed was the stainless steel AISI 420, which showed about 2% of porosity and a material removal mechanism predominantly ductile.

Die vorliegende Arbeit befasst sich mit dem Einfluss der Porosität lichtbogendrahtgespritzter Zylinderlaufbahnen auf das Reibungsverhalten. Hierzu wird das fokussierte System aus Kolbenring, Schmierstoff und Lauffläche zunächst für einen repräsentativen Betriebspunkt per numerischer Abschätzung der Kolbenringzwischendrücke sowie der Schmierfilmdicke analysiert und eine Einteilung der Reibungszustände vorgenommen. Unter anderem auf Basis der strömungsmechanischen Ähnlichkeitstheorie erfolgt im Anschluss eine Ableitung von Betriebspunkten für experimentelle Untersuchungen an einem Mittelhub-Tribometer im Bereich der Grenzreibung sowie Mischreibung und Hydrodynamik. An diesem Modellprüfstand werden daraufhin zum einen Laufbahnsegmente differenter Porosität gegen einen nitrierten Kompressionsring bewertet. Neben skalaren Größen dienen wegaufgelöste Signale über dem Hub zur Analyse des Reibungsverhaltens. In Ergänzung zu den nitrierten Oberflächen wird das Potenzial einer ta-C Beschichtung zur Reibungsreduzierung bewertet. Die Übertragbarkeit der erarbeiteten Erkenntnisse auf den verbrennungsmotorischen Betrieb wird über eine Messreihe an einem Einzylinderprüfstand untersucht. Auch hier werden Oberflächendaten verwendet, um eine Korrelation zwischen den ermittelten Reibmitteldrücken respektive den wegaufgelösten Signalen und der Porosität herstellen zu können. Über diese experimentellen Untersuchungen hinaus wird das Verhalten des Schmierfilms zwischen dem Kolbenring und einzelner Poren der Lauffläche mit Hilfe der dreidimensionalen numerischen Strömungssimulation analysiert. Hierzu werden Laufbahnsegmente per Computertomographie vermessen, einzelne Porenobjekte isoliert und für die Simulation aufbereitet. Im Rahmen von stationären Berechnungen wird zunächst eine Vielzahl einzelner Objekte in einem abstrahierten System strömungsmechanisch untersucht. Die Analyse ausgewählter Poren in transienten Strömungssimulationen und die Bewertung der Übertragbarkeit der Erkenntnisse schließen diese Arbeit ab.:1. Einleitung und wissenschaftliche Zielsetzung 1.1. Einführung 1.2. Zielsetzung und Aufbau der Arbeit 2. Grundlagen 2.1. Grundlagen der Tribologie 2.1.1. Reibung 2.1.2. Verschleiß 2.1.3. Schmierung und Schmierstoffe 2.2. Geometrische Charakterisierung von Oberflächen 2.3. Amorphe Kohlenstoffschichten 2.4. Kolbengruppe und Zylinderlaufbahn 2.5. Strömungsmechanik 2.5.1. Strömungsmechanische Grundlagen 2.5.2. Grundgleichungen der Strömungsmechanik 3. Methoden 3.1. Topographie von Oberflächen 3.1.1. Konfokalmikroskopie 3.1.2. Computertomographie 3.2. Untersuchung tribologischer Eigenschaften 3.2.1. Mittelhub-Tribometer 3.2.2. Einzylinderprüfstand 3.3. Numerische Strömungssimulation 3.3.1. Vernetzungsmethoden 3.3.2. Finite-Differenzen-Methode 3.3.3. Finite-Volumen-Methode 3.3.4. Instationäre Strömungen 3.3.5. Turbulente Strömungen 3.3.6. Kompressible Strömungen 4. Analyse des Systems aus Kolbenring, Schmierstoff und Zylinderlaufbahn 4.1. Bewertung der Kolbenringzwischendrücke 4.2. Numerische Berechnung der Schmierfilmdicke 4.3. Analyse der Reibzustände 5. Experimentelle Analyse 5.1. Untersuchungen am Mittelhub-Tribometer 5.1.1. Ableitung der Betriebspunkte, des Prüfablaufs und der Versuchsmatrix 5.1.2. Analyse der Oberflächen der Versuchsteile 5.1.3. Signalaufbereitung und -bewertung 5.1.4. Ergebnisse im Bereich der Grenzreibung 5.1.5. Ergebnisse im Bereich der Mischreibung und Hydrodynamik 5.2. Untersuchungen am befeuerten Einzylinderprüfstand 5.2.1. Prüfablauf und Versuchsmatrix 5.2.2. Analyse der Oberflächen der Versuchsteile 5.2.3. Ergebnisse der Messungen am Einzylinderprüfstand 5.3. Übertragbarkeit der Messergebnisse für den repräsentativen Betriebspunkt 6. Strömungssimulation des Schmierfilms 6.1. Extraktion und Aufbereitung der Poren aus der Zylinderlaufbahn 6.1.1. Vermessung und Aufbereitung der Laufbahnsegmente 6.1.2. Extraktion und Aufbereitung der Poren 6.2. Stationäre Strömungssimulation 6.2.1. Modellierung des Systems und Automatisierung der Berechnung 6.2.2. Ergebnisse 6.3. Transiente Strömungssimulation 6.3.1. Modellierung des Systems 6.3.2. Ergebnisse 7. Zusammenfassung und Ausblick 7.1. Zusammenfassung 7.2. Ausblick Literatur Abbildungsverzeichnis Tabellenverzeichnis Nomenklatur A. Anhang A.1. Anhang zu Kapitel 5 A.2. Anhang zu Kapitel 6 / This work deals with the influence of the porosity of twin wire arc sprayed cylinder liner on the friction behavior. For this purpose, the focused system of piston ring, lubricant and liner is first analyzed for a representative operating point by numerical estimation of the piston ring intermediate pressures as well as the lubricant film thickness and a classification of the friction states is carried out. Among other things, based on the mechanics of flow similarities, a calculation of operating points for experimental investigations on a medium stroke tribometer in the field of boundary friction as well as mixed and hydrodynamic friction is done subsequently. After that, on this model test bench, cylinder segments of different porosity are evaluated against a nitrided piston ring. Beside scalar values, signals above the stroke are used to analyze friction behavior. In addition to the nitrided surfaces, the potential of a ta-C coating for friction reduction is investigated. The transferability of the developed findings to the combustion-engined operation is evaluated via a series of measurements on a single cylinder test bench. Here, too, surface data is used to establish a correlation between the mean effective pressure of frictional forces determined or the signals above the stroke and the porosity. In addition to these experimental investigations, the behaviour of the lubricant film between the piston ring and single pores of the cylinder surface is evaluated using the three-dimensional numerical flow simulation. For this purpose, liner segments are measured by computed tomography, individual pore objects are isolated and processed for simulation. In the context of stationary calculations, a large number of individual objects are first examined in an abstracted system. The analysis of selected pores in transient flow simulations and the evaluation of the transferability of the findings complete this work.:1. Einleitung und wissenschaftliche Zielsetzung 1.1. Einführung 1.2. Zielsetzung und Aufbau der Arbeit 2. Grundlagen 2.1. Grundlagen der Tribologie 2.1.1. Reibung 2.1.2. Verschleiß 2.1.3. Schmierung und Schmierstoffe 2.2. Geometrische Charakterisierung von Oberflächen 2.3. Amorphe Kohlenstoffschichten 2.4. Kolbengruppe und Zylinderlaufbahn 2.5. Strömungsmechanik 2.5.1. Strömungsmechanische Grundlagen 2.5.2. Grundgleichungen der Strömungsmechanik 3. Methoden 3.1. Topographie von Oberflächen 3.1.1. Konfokalmikroskopie 3.1.2. Computertomographie 3.2. Untersuchung tribologischer Eigenschaften 3.2.1. Mittelhub-Tribometer 3.2.2. Einzylinderprüfstand 3.3. Numerische Strömungssimulation 3.3.1. Vernetzungsmethoden 3.3.2. Finite-Differenzen-Methode 3.3.3. Finite-Volumen-Methode 3.3.4. Instationäre Strömungen 3.3.5. Turbulente Strömungen 3.3.6. Kompressible Strömungen 4. Analyse des Systems aus Kolbenring, Schmierstoff und Zylinderlaufbahn 4.1. Bewertung der Kolbenringzwischendrücke 4.2. Numerische Berechnung der Schmierfilmdicke 4.3. Analyse der Reibzustände 5. Experimentelle Analyse 5.1. Untersuchungen am Mittelhub-Tribometer 5.1.1. Ableitung der Betriebspunkte, des Prüfablaufs und der Versuchsmatrix 5.1.2. Analyse der Oberflächen der Versuchsteile 5.1.3. Signalaufbereitung und -bewertung 5.1.4. Ergebnisse im Bereich der Grenzreibung 5.1.5. Ergebnisse im Bereich der Mischreibung und Hydrodynamik 5.2. Untersuchungen am befeuerten Einzylinderprüfstand 5.2.1. Prüfablauf und Versuchsmatrix 5.2.2. Analyse der Oberflächen der Versuchsteile 5.2.3. Ergebnisse der Messungen am Einzylinderprüfstand 5.3. Übertragbarkeit der Messergebnisse für den repräsentativen Betriebspunkt 6. Strömungssimulation des Schmierfilms 6.1. Extraktion und Aufbereitung der Poren aus der Zylinderlaufbahn 6.1.1. Vermessung und Aufbereitung der Laufbahnsegmente 6.1.2. Extraktion und Aufbereitung der Poren 6.2. Stationäre Strömungssimulation 6.2.1. Modellierung des Systems und Automatisierung der Berechnung 6.2.2. Ergebnisse 6.3. Transiente Strömungssimulation 6.3.1. Modellierung des Systems 6.3.2. Ergebnisse 7. Zusammenfassung und Ausblick 7.1. Zusammenfassung 7.2. Ausblick Literatur Abbildungsverzeichnis Tabellenverzeichnis Nomenklatur A. Anhang A.1. Anhang zu Kapitel 5 A.2. Anhang zu Kapitel 6

The effect of substrate surface treatment (substrate sputter cleaning) in a cathodic arc plasma prior to unbalanced magnetron deposition of transition metal nitride coatings on the performance of the coated components has been investigated. In particular the influence of parameters such as ion species, ion energy and exposure time on the changes in substrate surface topography, microstructure and micro-chemistry were studied employing transmission electron microscopy, energy dispersive X-ray analysis, electron energy loss spectroscopy, X-ray diffraction, atomic force microscopy and optical microscopy. The consequences for both the microstructure of subsequently grown transition metal nitride coatings and their adhesion were elucidated. The relevance for practical applications was demonstrated using the example of dry high-speed milling tests, which showed that an appropriate choice of substrate surface pre-treatment parameters can double the life time of the coated tools. This was found to be due to an improved adhesion as a result of a combina-tion of reduced oxygen incorporation at the interface between coating and substrate and local epitaxial growth of the coating. The latter is promoted by certain sub-strate surface pre-treatment procedures, which provide clean surfaces with preserved crystallographic order.