Innovations from Venti Oelde Hardfacing on High Strength Steel for Lightweight Wear Protected Structural Materials

Prof. Dr.-Ing. Volker Wesling, ISAF, Technische Universitat Clausthal, Clausthal-Zellerfeld; Dr.-Ing. Rolf Reiter, ISAF, Technische Universitat Clausthal, Clausthal-Zellerfeld; Dipl.-Ing. Lukas Lau, ISAF, Technische Universitat Clausthal Clausthal-Zellerfeld; Marvin Hecht, M. Sc., ISAF, Technische Universitat Clausthal, Clausthal-Zellerfeld; Dr.-Ing. Frank Schreiber, DURUM VerschleiRschutz GmbH, Willich; Dipl.-Ing., Dipl.-Wirtsch.-Ing. Ivo Kupka, Ventilatorenfabrik Oelde GmbH, Oelde; Dipl.-Ing. Thomas Gandt, Ventilatorenfabrik Oelde GmbH, Oelde Wear and tear on machines and plants results in billions...

1 Introduction Wear and corrosion are significant factors in the failure and breakdown of components in the industrial sector. In Germany, downtime and repair work cause losses amounting to 2 - 4 % of the Gross Domestic Product (GDP), averaging about 85 billion Euros [1]. In view of these enormous costs, researchers are continuously in search of new materials capable of withstanding the loads better and longer and, thereby, reducing costs. Industrial fans, also, are affected by wear during their service life, necessitating regular maintenance and repair work. One way to reduce the occurring wear,...

2.2 Conventional Wear Protection Welded protective coatings are preferred as an answer to wear in fan construction, because of the required wear reserve, or rather, layer thickness, and the dynamic wear and tear to the hardfac-ing deposition. The wear-resistant materials consist of a relatively hard and tough mixed crystalline matrix, in which the wear-resistant, hard materials are embedded. High-alloy ferrous and nickel base alloys are used as wear-resistant alloys. Table 2. These are normally applied to the substrate materials grade S235, S355, and in exceptional cases, S690 and S960, by metal-cored...

Table 4 Selected controlled dip transfer (short arc) welding processes acc. to manufacturer [10] Fig. 4 Structural component coating Fe-base + Cr-Boride + VC applied by controlled dip transfer (short arc) welding process controlled dip transfer (short arc) welding processes, without the original base material properties being unacceptably impaired. This means that the hardfaced base materials can be used as high-stress structural materials, i.e. both lightweight structural aims are realized (retention of the base material properties) as well as considerable extension of the useful life being...

density was measured using a pycnometer, Table 5. The generated composite layers were metallographi-cally examined and, as well as determination of the coating hardness (Rockwell hardness test, Scale C), low-load hardness measurements were taken in the area of the heat-affected zone. The newly developed wear-resistant material type FeCrNbVBC also possesses additional hard phases of vanadium carbide, which are deposited in the matrix between the boride hard phases and thus further reduce the size of the gaps between the hard phases, Fig. 6. Fig. 7 Schematic diagram of the blast wear test setup...

6 7 compressed air supply, an injector and the sampling, see Fig. 7. Via the dosing system, a set amount of the abrasives, non-varying for the complete test run, flows out of the container and is led to the injector. The free-travelling particles in the gas-bearing blast cause impact and/or abrasive material damage, depending on the load angle. For the tests, a blast angle of 10° (inclined blast wear) on the weld transition was selected, because practical experience has shown this to be a particularly weak point. The test was carried out in the direction of the weld using cement dust as abrasives....

5 Lightweight Construction Potential So as to achieve the goal of a lightweight construction, coating thicknesses of between 2 and 2.5 mm were aimed at. The extent of the heat-affected zones was about 3 mm for all welds and, therefore, in comparison with conventional composite layers, had a stable width of considerably < 5 mm, whereby the stress bearing residual cross-section was clearly increased. In conjunction with a dilution zone of < 1.5 mm, a preservation of the base material properties can, therefore, be assumed for all coatings. In addition, low-load hardness measurements (HV 1) were...

8 9 7 Our thanks to the following The work was funded by the Federal Ministry of Economics within the framework of a ZIM (Central Innovation Program – Medium-sized Business Sector) cooperation project. The authors express their sincere thanks for this support. 8 Literature [1] Theisen, W.: „Metal Matrix Composites“ widerstehen dem Verschleiß: Walzen aus Pulver. In: Klein, S. (Hrsg.), RUBIN (2004), Bochum, Sonderheft, S. 90-95. [2] Fa. Ventilatorenfabrik Oelde GmbH [3] Schnick, T.; Schreiber, F.; Wenz, T.: Verschleißschutz durch Fülldraht- und Plasma-Pulver-Auftragschweißen. In: Wielage, B. (Hrsg.),...

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