eGun Technology Presentation ITSC-16 (2)
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Transcript of eGun Technology Presentation ITSC-16 (2)
ADDED VALUE THROUGH KNOW -HOW Systems Consumables Services www.fst.n lADDED VALUE THROUGH KNOW -HOW Systems Consumables Services www.fst.n l
May 2016M.P. Zwetsloot
Ethanol-fueled HVOFITSC, Shanghai China, May 2016
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Ethanol Fuel of the Future
“The fuel of the future is going to come from fruit or from
apples, weeds, sawdust – almost anything,”
– Henry Ford, Ford Motor Company, 1925
2015 United Nations Climate Change Conference, Paris
• set a goal of limiting global warming to less than 2
degrees Celsius (°C)
• calls for zero net anthropogenic greenhouse gas
emissions to be reached during the second half of the
21st century
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Ethanol as a fuel choice
Cost:
Ethanol and Kerosene costs
are comparable. Less oxygen required. Less cooling required. Overalloperating costs are lower.
Widely Available:
Ethanol is produced around the world and easily available
Consistency:
Ethanol is a very consistent fuel providing repeatable & reproducible coating (C2H5OH)
No Ash Formation:
There is no contamination of a coating by carbon, even if fuel rich mixtures are used
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Environmentally friendly:
Sustainable fuel life-cycle
100% natural product
Carbon neutral
30% less toxic emissions than a petroleum based fuel.
The cleaner HVOF liquid fuel alternative
Ethanol as a fuel choice
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Safety:
Ethanol is a relatively safe fuel
Ethanol is approved as an indoor table burner, heating or cooking stove fuel
Less toxic fumes and particulate matter
Legislation
Local Laws do apply since ethanol is alcohol.
Ethanol as a fuel choice
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eGun – fuel power variation
*The power is estimated based on the full and ideal, stoichiometric combustion process. Conditions in the combustion chamber are not taken into account anyhow. The enthalpy of combustion if calculated for liquid organic compound(s) and gaseous products of reaction.
Mixture Energy / liter Power of flame (20L/h)
Unit MJ/L kW
CDA (UK,) 19.91 110
Cargill at (95%et.) 20.09 111
Pure ethanol (100%) 20.38 113
E95 (95%, 5%gasoline) 20.89 116
E85 (85%, 15%gasoline) 21.96 122
Ethanol + 5%wt. of water 19.36 107
Kerosene - C12H26 - C18H38 35.57 197
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More efficient combustion - smaller chamber - less cooling power required
Optimized Combustion
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Typical parameters
WC-Co-Cr 86/10/4 Cr3C2-NiCr 75/25
Kerosene Ethanol Kerosene Ethanol
Oxygen 1050 l/min 530 l/min 800 l/min 480 l/min
Fuel 24 l/h 28 l/h 21 l/h 23 l/h
Combustion chamber pressure 8 bar 11 bar 7 bar 11 bar
Cooling capacity 80-90 kW 25-30 kW 80-90 kW 25-30 kW
Average particle velocity 650-750 m/sec 750-850 m/sec 630-720 m/sec 810-860 m/sec
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eGun™ results
Cr2C3-NiCr 75/25 Alloy 625 NiCrBSi 60HRc
WC-NiMoCrFeCo Tribaloy 400 Alloy 6
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Operating Window:
Ethanol allows combustion mixtures
that are oxygen rich or neutral as
well as fuel rich, this significantly
increasing the operating window in
comparison with kerosene, creating
new advanced coatings opportunities.
Oxygen Flow Rate
Fuel rich
Oxygen rich
Ethanol as a fuel choice
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The eGun™ torch design operates a high combustion
chamber pressures resulting in higher particle velocities.
Ethanol HVOF
9 bar = 150kw 27kw to water
11 bar = 184kw 33kw to water
13 bar = 216kw 39kw to water
Kerosene HVOF
8 bar = 280kw 70/90kw to water
(Depending on Barrel Length)
Chamber Pressure
Fla
me V
elo
cit
yHigher Pressure
=
Higher Velocity
Operating window ethanol vs. kerosene
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eGun™ flame studies
Higher combustion chamber pressures, higher particle
velocities
At 13 bar combustion chamber pressure, average particle
velocity for WC/CoCr -45+15µm of >800m/s
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Positioning the eGun™
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Process Characterisation
Design of Experiment:
- Injection optimisation (6 – 12 NLPM)
- Spray distance optimisation (200 – 500mm)
- Spray parameters optimisation:- λ – stoichiometry
- (1.2 - oxy rich, 1 - stoichiometric, 0.8 fuel rich)
- Mass flow fuel + oxygen mixture- 16 g/sec, 17.5 g/sec (nozzle optimum), 19 g/sec
- Deposition Efficiency Test
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eGun™: WC-CoCr (-30/+5µ) spray distance
200mm 250mm 300mm
350mm 400mm 450mm
Spray distance optimisation (λ = 1, Mass flow – 17.5 g/s), magnification x100
D=245μm
Porosity=<0.5%
HV0.3=1398
HV0.3std.dev.=62
D=260μm
Porosity=<0.5%
HV0.3=1412
HV0.3std.dev.=47
D=290μm
Porosity=<0.5%
HV0.3=1332
HV0.3std.dev.=97
D=319μm
Porosity=<0.5%
HV0.3=1177
HV0.3std.dev.=80
D=357μm
Porosity=0.8%
HV0.3=1073
HV0.3std.dev.=116
D=369μm
Porosity=4.5%
HV0.3=913
HV0.3std.dev.=160
Po
wd
er
Fe
ed
ra
te: 7
5 g
r/m
in
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eGun™: Scan Window
400
420
440
460
480
500
520
540
560
580
600
20 22 24 26 28 30 32 34 36 38 40
Oxyg
en
flo
w (
st.
L/m
in)
Ethanol flow (L/h)
Design nozzle parameters
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400
420
440
460
480
500
520
540
560
580
600
20 22 24 26 28 30 32 34 36 38 40
Oxyg
en
flo
w (
st.
L/m
in)
Ethanol flow (L/h)
Design nozzle parameters
eGun™: Scan Window
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400
420
440
460
480
500
520
540
560
580
600
20 22 24 26 28 30 32 34 36 38 40
Oxyg
en
flo
w (
st.
L/m
in)
Ethanol flow (L/h)
Design nozzle parameters
eGun™: Scan Window
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400
420
440
460
480
500
520
540
560
580
600
20 22 24 26 28 30 32 34 36 38 40
Oxyg
en
flo
w (
st.
L/m
in)
Ethanol flow (L/h)
eGun™: Scan Window
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eGun™: WC-CoCr (-30/+5µ)
Mass Flow
Oxy
rich
Fuel
rich
Fuel-Oxy
Stoichiom
etry
D=432μm
Porosity=0.45%
HV0.3=1035
HV0.3std.dev.=86
D=400μm
Porosity=0.53%
HV0.3=1075
HV0.3std.dev.=96
D=344μm
Porosity=0.18%
HV0.3=1194
HV0.3std.dev.=94
D=331μm
Porosity=0.25%
HV0.3=1134
HV0.3std.dev.=61
D=323μm
Porosity=0.15%
HV0.3=1261
HV0.3std.dev.=106
D=304μm
Porosity=0.09%
HV0.3=1193
HV0.3std.dev.=125
D=293μm
Porosity=0.10%
HV0.3=1261
HV0.3std.dev.=89
D=291μm
Porosity=0.07%
HV0.3=1368
HV0.3std.dev.=53
Po
wd
er
Fe
ed
ra
te: 7
5 g
r/m
in
D=316μm
Porosity=0.15%
HV0.3=1201
HV0.3std.dev.=149
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Mass flow (g/s)
La
mb
da
(-)
19.018.518.017.517.016.516.0
1.2
1.1
1.0
0.9
0.8
>
–
–
–
–
–
–
–
–
<
1360
1040
1040 1080
1080 1120
1120 1160
1160 1200
1200 1240
1240 1280
1280 1320
1320 1360
HV
Harness HV0.3 vs lambda, mass flow
Mass flow (g/s)
La
mb
da
(-)
19.017.516.0
1.2
1.0
0.8
>
–
–
–
–
–
–
–
–
<
0.50
0.10
0.10 0.15
0.15 0.20
0.20 0.25
0.25 0.30
0.30 0.35
0.35 0.40
0.40 0.45
0.45 0.50
Porosity
Porosity vs lambda, mass flow
Mass flow (g/s)
La
mb
da
(-)
19.017.516.0
1.2
1.0
0.8
>
–
–
–
–
< 10
10 11
11 12
12 13
13 14
14
thick-pass
Thickness per pass vs lambda, mass flowFeature Value Unit
2D-Porosity <0.5 %
Hardness 1100-1350 HV0.3
Hard. STDDEV 34 - 50 HV0.3
Tensile strength >85 MPa
Ra 3.1 μm
DE 48 % (weight)
eGun™: WC-CoCr (-30/+5µ)
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eGun™: WC-CoCr (-30/+5µ)
SAMPLE# GUNWEIGHT
LOSS
AVERAGE
LOSS
STANDARD
DEVIATION
STANDARD
DEVIATION
- - g g g %
16-032-1-1 eGun 0.216
16-032-1-2 eGun 0.233
16-032-1-3 eGun 0.213
16-032-2-1 eGun 0.245
16-032-2-2 eGun 0.236
16-032-2-3 eGun 0.237
16-032-3-1 eGun 0.164
16-032-3-2 eGun 0.327
16-032-3-3 eGun 0.316
16-033-1-0 JP5000 0.467
16-033-2-0 JP5000 0.461
16-033-3-0 JP5000 0.497
4.9
2.1
2.4
4.1
0.221
0.239
0.322
0.475
0.011
0.005
0.008
0.019
Rubber Wheel Test (ASTM G65)For comparison only – Abrasive material used Al2O3
JP-5000® is a trademark of Praxair
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Feature Value Unit
2D-Porosity <1 %
Hardness 1050-1200 HV0.3
Hard. STDDEV 95 - 130 HV0.3
Tensile strength - MPa
Ra 5.9 μm
DE 52 % (weight)
Feed Rate 75 Gr/min
eGun™: WC-CoCr (-45/+15µ)
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eGun™: Cr3C2-NiCr 75/25, -30/+5µ
Feature Value Unit
Trade name Amperit 588.059 -
Chemistry Cr3C2-NiCr -
Grain size 30/5 μm
2D-Porosity <1 %
Hardness 1000-1200 HV0.3
Tensile strength >85 Mpa
Ra 3.1 μm
DE 44 % (weight)
Powder Feed rate 75 Gr/min
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Feature Value Unit
Trade name Amperit 588.074 -
Chemistry Cr3C2-NiCr -
Grain size 45/15 μm
2D-Porosity <2 %
Hardness 800-900 HV0.3
Tensile strength >88 MPa
Ra 5-6 μm
DE 33 % (weight)
Powder feed rate 75 Gr/min
eGun™: Cr3C2-NiCr 75/25, -45/+15µ
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Feature Value Unit
Trade name Amperit 413.001 -
Chemistry NiCrAlY -
Grain size 45/22 μm
2D-Porosity <0.5% %
Hardness 300-500 HV0.3
Ra 6.9 μm
DE 55 % (weight)
Powder Feed Rate 75 Gr/min
eGun™: NiCrAlY, -45+22µ
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200mm 250mm 300mm 350mm
400mm 450mm
D=650μm
Porosity<0.1%
HV0.3=572
HV0.3std.dev.=48
D=588μm
Porosity<0.1%
HV0.3=504
HV0.3std.dev.=46
D=621μm
Porosity<0.1%
HV0.3=495
HV0.3std.dev.=25
D=658μm
Porosity<0.1%
HV0.3=487
HV0.3std.dev.=24
D=670μm
Porosity<0.1%
HV0.3=437
HV0.3std.dev.=38
D=661μm
Porosity=0.1%
HV0.3=405
HV0.3std.dev.=49
eGun™: NiCoCrAlReY, -45+22µ
Powder Feed rate: 75 gr/min
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16 17.5 19
08
1.0
1.2
D=574μm
Porosity=0.2%
HV0.3=649
HV0.3std.dev.=33
D=597μm
Porosity<0.1%
HV0.3=637
HV0.3std.dev.=39
D=515μm
Porosity<0.1%
HV0.3=677
HV0.3std.dev.=64
D=622μm
Porosity=0.3%
HV0.3=537
HV0.3std.dev.=38
D=661μm
Porosity=0.1%
HV0.3=405
HV0.3std.dev.=49
D=523μm
Porosity<0.1%
HV0.3=582
HV0.3std.dev.=34
D=671μm
Porosity=0.1%
HV0.3=491
HV0.3std.dev.=24
D=601μm
Porosity=0.1%
HV0.3=510
HV0.3std.dev.=40
D=559μm
Porosity=0.1%
HV0.3=534
HV0.3std.dev.=27
eGun™: NiCoCrAlReY, -45+22µ
Po
wd
er
Fe
ed
ra
te: 7
5 g
r/m
in
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eGun™: NiCoCrAlReY, -45+22µ
Feature Value Unit
Trade name Amperit 429 -
Chemistry NiCoCrAlReY -
Grain size 45/22 μm
2D-Porosity <0,5 %
Hardness 500-700 HV0.3
Tensile strength >85 MPa
Ra 7.0 μm
DE 52 % (weight)
Mass flow rate (g/s)
La
mb
da
(-)
19.017.516.0
1.2
1.0
0.8
>
–
–
–
–
–
< 17
17 18
18 19
19 20
20 21
21 22
22
Thick-pass
Thickness per pass vs lambda and mass flow
Mass flow rate (g/s)
La
mb
da
(-)
19.017.516.0
1.2
1.0
0.8
>
–
–
–
–
< 0.05
0.05 0.10
0.10 0.15
0.15 0.20
0.20 0.25
0.25
Porosity
Porosity vs lambda and mass flow
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eGun™: Triballoy 400, -45+10µ
Feature Value Unit
Trade name T400 -
Chemistry CoCrMo -
Grain size -45/10 μm
2D-Porosity <1 %
Hardness 700 HV0.3
Ra 6 Μm
Powder feed rate 75 Gr/min
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eGun™: Triballoy 800, -45/10µ
Feature Value Unit
Trade name T800 -
Chemistry CoMoCr -
Grain size 45/10 μm
2D-Porosity <1 %
Hardness 700-850 HV0.3
Ra 5.8 μm
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eGun™: Stellite 6, -45/+20µ
Feature Value Unit
Trade name M484.24 -
Chemistry CoCrWSi -
Grain size 45/20 μm
2D-Porosity <0.5 %
Hardness 600 HV0.3
Tensile strength >89 MPa
Ra ~7.7 μm
DE 66 % (weight)
Powder Feed Rate 75 Gr/min
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eGun™ : WC-Co 83/17, -45+15µ
Feature Value Unit
Trade name Amperit 526 -
Chemistry WC-Co -
Grain size 45/15 μm
2D-Porosity ~1% %
Hardness 1000-1200 HV0.3
Ra 4.6 Μm
Powder Feed Rate 75 g/min
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eGun™: Alloy625, 53/+20µ
Feature Value Unit
Trade name M-325.33 -
Chemistry NiCrMoNbFe -
Grain size 53/20 μm
2D-Porosity 0.5 %
Hardness 500 HV0.3
Ra 8.9 μm
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eGun™ - Life of hardware
Requires long term spray testing
Dependent on sprayed materials (metals, carbides etc)
Requires correlation of wear with deterioration of coating
properties to establish replacement criteria
So far it’s has been only performed as qualitative analysis,
but lifetime of parts such as barrel and combustion chamber
appear to similar to parts of the JP-5000 Torch
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eGun™: Conclusions
• Excellent microstructure achievable from wide process operation
window (Tolerant process)
• Consistent coating quality (Low Standard Deviation)
• Coating properties can be customised according to customer need
(hardness & porosity)
• For carbides we see results similar to the HVAF process when
using finer grades of powder. Thus coating quality ranging from
HVOF to HVAF.
• Flexible process – allows for more oxy - fuel variation for further
process development possibilities
• Promising DE results
• Excellent bond strength of
coatings, especially for metallics
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Already over 25 systems sold
Some first feedback
Operators love to work with the eGun™
Softer, more consistent starts
Easy to maintain
Cleaner gun parts
No smelly kerosene spills
Smaller and lighter torch
Less heat impact on parts
Excellent target efficiency
Lower extraction requirements than other LF systems
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&
In addition to controlling the eGun™,
the system is also capable of operating
kerosene HVOF torches.
Ethanol HVOF technology will be introduced as the
eGun™ and will operate on the HV-50 or MP-50.
The HV-50 System
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eGun™ example application
M-484.24 Alloy 6 CoCrWSi - Coating thickness 1,2 mm
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May 2016M.P. Zwetsloot
Thank you for your attention
Please visit us at our booth for more information