TY - JOUR

T1 - Development and Analysis of Microstructures for the Transplantation of Thermally Sprayed Coatings

AU - Freiburg, D.

AU - Biermann, D.

AU - Peuker, A.

AU - Kersting, P.

AU - Maier, H. J.

AU - Möhwald, K.

AU - Knödler, P.

AU - Otten, M.

N1 - Funding information: The results in this paper were achieved in the course of a research project supported by the Deutsche Forschungs-gemeinschaft (DFG) under the reference numbers Mo 881/9-1 and Bi 498/6-1. The authors of this paper gratefully acknowledge this support.

PY - 2014/6/11

Y1 - 2014/6/11

N2 - Thermally sprayed coatings and tribological surfaces are a point of interest in many industrial sectors. They are used for better wear resistance of lightweight materials or for oil retention on surfaces. Lightweight materials are often used in the automotive industry as a weight-saving solution in the production of engine blocks. For this, it is necessary to coat the cylinder liners to ensure wear resistance. In most cases, the coating is sprayed directly onto the surface. Previous research has shown that it is possible to transfer these coatings inversely onto other surfaces [1]. This was achieved with plasma sprayed coatings which were transplanted onto pressure-casted surfaces. These transplanted surfaces exhibited better adhesive strength, smoother surfaces, and lower form deviation compared to directly coated surfaces. Additionally, it was shown that even microstructures of a surface coated by plasma spraying can be transferred to pressure-casted surfaces. This paper presents the development and micromilling of different microstructures for transferring thermally sprayed coatings onto pressure-casted surfaces. In the development process, microstructures with different shapes and aspect ratios as well as thin tribological surfaces are designed in order to evaluate the advantages and limitations of the transplantation process. In subsequent experiments, the micromilling process and a simulation of the coating transplantation are presented and analyzed.

AB - Thermally sprayed coatings and tribological surfaces are a point of interest in many industrial sectors. They are used for better wear resistance of lightweight materials or for oil retention on surfaces. Lightweight materials are often used in the automotive industry as a weight-saving solution in the production of engine blocks. For this, it is necessary to coat the cylinder liners to ensure wear resistance. In most cases, the coating is sprayed directly onto the surface. Previous research has shown that it is possible to transfer these coatings inversely onto other surfaces [1]. This was achieved with plasma sprayed coatings which were transplanted onto pressure-casted surfaces. These transplanted surfaces exhibited better adhesive strength, smoother surfaces, and lower form deviation compared to directly coated surfaces. Additionally, it was shown that even microstructures of a surface coated by plasma spraying can be transferred to pressure-casted surfaces. This paper presents the development and micromilling of different microstructures for transferring thermally sprayed coatings onto pressure-casted surfaces. In the development process, microstructures with different shapes and aspect ratios as well as thin tribological surfaces are designed in order to evaluate the advantages and limitations of the transplantation process. In subsequent experiments, the micromilling process and a simulation of the coating transplantation are presented and analyzed.

KW - Coating

KW - Microstructure

KW - Milling

UR - http://www.scopus.com/inward/record.url?scp=84902489682&partnerID=8YFLogxK

U2 - 10.1016/j.procir.2014.03.054

DO - 10.1016/j.procir.2014.03.054

M3 - Article

AN - SCOPUS:84902489682

VL - 14

SP - 245

EP - 250

JO - Procedia CIRP

JF - Procedia CIRP

SN - 2212-8271

ER -