Method to produce high corrosion and wear resistant cast iron components by water jet surface activation, nitrocarburization and thermal spray coating

Abstract

The invention relates to a method of producing a corrosion resistant coating system on a cast iron substrate preferably in the shape of a brake disc, the coating system being completed by a thermally sprayed top layer, characterised in that the cast iron substrate is first subjected to activation by means of a pulsed water jet after completion of machining which increases the surface roughness of the surface thus treated, whereupon the surface is nitrocarburized so that a corresponding diffusion layer is formed on it, whereupon the surface is subjected to an oxidation process in a next step and only then the top layer is applied by thermal spraying.

Claims

1. A method of producing a corrosion resistant coating system on a cast iron substrate in the shape of a brake disc, comprising: first subjecting the cast iron substrate to activation with a pulsed water jet after completion of machining which increases a surface roughness of a surface of the cast iron substrate thus treated, nitrocarburizing the surface so that a corresponding diffusion layer is formed on the surface, subjecting the surface to an oxidation process in a next step, and then applying a top layer to the surface by thermal spraying.

2. The method according to claim 1, wherein the pulsed water jet is exposed to ultrasound in such a way that cavitation beads are formed in the water jet, wherein the water jet is tuned such that the beads are thrown against the surface to be treated and implode against the surface, thereby increasing the surface roughness.

3. The method according to claim 2, wherein the ultrasound is tuned in that way such that at least a part of the cavitation beads are small enough to increase a sub-surface roughness.

4. The method according to claim 1, wherein the water jet is blasted at an angle of about 90 against the surface to be treated.

5. The method according to claim 1, wherein the water jet is adjusted and guided over the surface to be treated with such a dwell time that the water jet creates localized depressions in the surface at intervals, which have an undercut.

Description

(1) Optionally, prior applying the thermally sprayed top coating, applying an additional intermediate layer (bond coat) by thermal spraying in order to improve the adhesion of the top coating to the component, wherein the intermediate layer comprises a metal-based material.

(2) FIG. 1a) shows a thermally sprayed coating system comprising a bond coat and top coat and the nitrocarburizing+oxide layer over a state-of-the-art mechanically activated surface having a typical dovetail structure which is known to improve the adhesion of thermally sprayed coating.

(3) FIG. 1b) shows the corresponding cross-section of a real component with one of the state-of-the art surface activation and coating system.

(4) FIG. 2a) shows the thermally sprayed coating system and nitrocarburizing+oxide layer over a pulsed water jet activated surface which reveals the specific microstructure having undercuts and sub-surface roughness which allow reducing the waviness of the top layer and at the same time increasing the adhesion of the thermally sprayed layer on the substrate.

(5) As can be seen the black line separating the cast iron substrate from the bond coat is not shown as smooth line but in itself comprise small ripples which represent said sub-surface roughness. Same can be seen on FIG. 2b)

(6) FIG. 2b) shows the corresponding cross-section of a real component with the inventive solution.

(7) As can be seen in FIG. 2a) the black line separating the cast iron substrate from the bond coat is not shown as smooth line but in itself comprise small ripples which represent said sub-surface roughness. Same can be seen on FIG. 2b)

(8) FIG. 3 shows adhesion measurements results which are conducted on standardized sized samples using the ASTM C 633 Adhesion or Cohesive Strength of Flame-Sprayed Coatings. The adhesion of the coating system using state of the art mechanical activation and the GNC OX+thermal spray coating increases from 28-32 MPa to 30-42 MPa when the standard mechanical activation is replaced by the inventive pulsed water jet surface activation (see second row in the table of FIG. 3)

(9) Note that in the sense of this description, pulsed fluid jet does not include grit blasting using sand or other powder as medium because this has its disadvantages that some undercuts can be produced, but then particles get trapped in the undercuts, which have negative effects on the wear and corrosion resistant coating.

DESCRIPTION OF THE PREFERRED EMBODIMENT

(10) In the preferred embodiment the iron-based component is a cast iron brake disc which has a thermally sprayed coating on at least a part of the main exposed surfaces of the disc, including the outer edges of the said surfaces.

(11) The brake disc is initially finely mechanically turned in order to reach the adequate Disc Thickness Variation (DTV) and Lateral Runout (LRO) as known from the state-of-the-art. These primary mechanical finishing methods allow to reduce the chatter and judder of the brake disc during operation which are the main cause of brake disc failures. Additionally, the mechanical finish allows reducing the thickness of material to be grinded afterwards, improves the homogeneity and precision of the coating thickness distribution, which consequently will have a positive influence on the mechanical properties of the coating, such as hardness, tensile strength, porosity, among others.

(12) Afterwards the surfaces of the brake disc that are thermally coated undergo a mechanical activation by a pulsed water jet process. The water jet activation method, described elsewhere (EP2741862B1), consists mainly of a high frequency pulsed high pressure water jet process, which allows controlling of the surface roughness and microstructure produced on the surface of the brake disc. The main parameters include the frequency of the pulse, which ranges from 10 kHz to 50 kHz, preferably at about 20 kHz, pressure of the water jet, between 550 and 800 bar, preferably between 600 and 700 bar. During the surface activation, the nozzle of the water jet system is set at a distance to the substrate between 25 and 60 mm, preferably 30 to 40 mm.

(13) In case of treating a brake disc's friction surface and also often in case of treating the whole brake disc, too, the movement of the spot where the water jet impacts the surface is set in such a way that it advances in radial direction seen in regard to the axis around which the brake disc rotates at the same time. It is quite important to choose a proper relative movement and movement speed of the impact zone with respect to the surface of the brake disc. It is hard to give absolute values at this stage. However, what should be kept in mind is that the relative movement speed determines how often a surface area will be hit by the water jet during the treatment. Therefore, relative movement of the water jet and relative movement speed of the water jet with respect to the surface and relative to the rotation speed of the brake disc is of high importance to achieve the desired surface roughness and surface roughness distribution. An important lighthouse parameter to characterize the surface are the roughness Rz (peak to peak) and Ra (average roughness). The relative movement speed should, in general, be chosen in such a way that the surface test indicates that the roughness Rz is around 100 m. Some tolerance is admitted. In simplest case we talk about a tolerance of about +/20%, more preferably the tolerance is about +/10%. In other cases, it can be sufficient that Rz is not too small and below 85 to 90 m. The value of Ra should be approximately identical or ideally be within the same ranges defined above for Rz.

(14) The averaged roughness depth Ra is the average of the individual roughness depths of five consecutive individual measurement sections in the roughness profile. In each measuring section the extreme values are added to a span and divided by the number of measuring sections.

(15) The measurement of Rz and Ra are standardized values. The measurement undertaken here has to comply with the DIN-ISO Standard applicable at the filing day. At this point please see DIN-ISO 25178,

(16) The above process results in producing compression residual stress on the surface, which densifies the surface of the brake disc, allows eliminating of the superficial carbon lamellae that are present from the cast process and produces of a predefined wanted surface roughness, which is characterized by a Rz value in the range of 90 to 150 m, preferably at about 125 m and a corresponding Ra value characterized by the ratio Rz/Ra of preferably at least 5 or above.

(17) After the mechanical surface activation, the brake disc is going through a heat treatment process at temperatures of approximately 500 C. to 590 C., preferably between 570 C. to 580 C. and is subsequently subjected to a nitrocarburization process in a controlled atmosphere, usually at a pressure close to the atmospheric pressure of about 1030 mbar), and exposed to gases such as ammonia, nitrogen and carbon dioxide. The respective gas flows are adapted depending on the cast iron base material and weight of the brake disc component. The nitrocarburization process is favorable for iron-based material as it forms a harder material of FeNC over the whole exposed surfaces of the component. The component afterwards is cooled down at a lower temperature of about 500 C. where it can optionally go through a plasma activation process at work pressures below 2 mbar, preferably between 1 to 2 mbar or directly through the additional optional oxidation process. The optional plasma activation process is described more in detail elsewhere (U.S. Pat. No. 5,679,411A), whereas the whole process including the latter process of additional oxidation is better known as gas nitrocarburization and oxidation or GNC OX. The optional plasma activation allows an additional cleaning of the surface by sputtering and also sputter-ions produced during this process create lattice defects on the surface which contribute to a final denser oxide layer after the oxidation process. The resulting nitrocarburizing layer or diffusion zone are at least 15 m thick and the oxide layer at least 2 m. The additional optional thin oxide layer of magnetite (Fe.sub.3O.sub.4) is a continuous and a closed layer which is produced over the whole component surface, allowing an improved corrosion resistant of the component.

(18) Since the nitrocarburization process does not change the microstructure produced by the pulsed water jet surface activation process, the iron cast brake disc can be coated by the thermal spray process directly afterwards without any necessary additional pre-treatment.

Application of the Thermal Spray Coating

(19) Bond Coat, for example by High Velocity Oxi-Fuel (HVOF):

(20) An intermediate layer is applied between the top coat and the lonit OX layer consisting of a nickel-based alloy, preferably of a nickel-chromium alloy, or of the Fe-based alloy by HVOF and or APS process. The range of gases in HVOF process could be oxygen: 100-400 NLPM and secondary gas: 300-800 NLPM (Normal Lister per Minute). The spray distance is the range of 55 to 450 mm, depending if HVOF or APS process.

(21) The Bond coat may have a thickness in the range of 30 to 120 microns. The intermediate layer serves to compensate the different thermal expansion coefficient of cast iron substrate and top coat, quasi as an elastic compensating. Porosity <3%

Top Coat for Example by APS

(22) A top coat is applied on top of the BC by APS process or by other thermal spray process. It consists of an oxide ceramic and a Fe-based material. The fraction of oxide ceramic (for example one of the elements or a combination hereof Component B of the table) could be between 30-70 wt %. The range of gases in APS process could be Argon: 20-150 NLPM and secondary gas: 1-20 NLPM. The spray distance is in the range of 55 to 270 mm.

(23) The thickness of the cermet coating layer is in a range of 100 to 500 microns. Porosity: <5%

(24) The following table shows another bond coat herein called Component A.

(25) Component B is the ceramic part of the cermet composition for the top coat.

(26) TABLE-US-00001 A chemical analysis of a representative sample of the blend components shall show the following limits: Specification Required [wt. %] Element min max Component A) Iron (Fe) Balance Chromium (Cr) 26 31 Molybdenum (Mo) 3 5 Niobium (Nb) 0.2 1.0 Nickel (Ni) 0.2 TAO 3 Component B) Al2O3 Balance TiO2 1 5 SiO2 3.0 Fe2O3 2.0 TAO 1.0

(27) According to a preferred embodiment, a final step of grinding is performed in order to achieve a finish with the required end geometrical tolerance of the brake disc, such as the DTV, LRO and planarity. Since the brake disc surface will be subjected to friction with the braking pads, the surface has to have a low roughness, ideally below Rz<10 m.

Miscellaneous

(28) Beside to what has been claimed by now protection is also sought for the following:

(29) A method to produce a corrosion resistant coating system onto a cast iron substrate, wherein the coating system comprises at least a thermally sprayed top layer, wherein prior to applying the top layer the substrate is treated to produce at least a nitrocarburizing diffusion layer into the substrate, characterized in that prior to to establishing the nitrocarburizing diffusion layer, the surface of the substrate is mechanically activated by a pulsed fluid jet process in order to produce an equally distributed surface roughness comprising undercuts and within the undercuts a sub-surface roughness which favors the mechanical adhesion of the thermally sprayed coating.