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WO2025003180A1 - Procédé et dispositif de revêtement d'une surface de pièce à usiner - Google Patents

Procédé et dispositif de revêtement d'une surface de pièce à usiner Download PDF

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Publication number
WO2025003180A1
WO2025003180A1 PCT/EP2024/067888 EP2024067888W WO2025003180A1 WO 2025003180 A1 WO2025003180 A1 WO 2025003180A1 EP 2024067888 W EP2024067888 W EP 2024067888W WO 2025003180 A1 WO2025003180 A1 WO 2025003180A1
Authority
WO
WIPO (PCT)
Prior art keywords
filament
plasma
nozzle
plasma jet
coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Pending
Application number
PCT/EP2024/067888
Other languages
German (de)
English (en)
Inventor
Magnus Buske
Raphael GEHRA
Philipp Hermann
Hassan Orle Ahmad SCHLEE
Dhia Ben Salem
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Plasmatreat GmbH
Original Assignee
Plasmatreat GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from DE102023121696.1A external-priority patent/DE102023121696A1/de
Application filed by Plasmatreat GmbH filed Critical Plasmatreat GmbH
Publication of WO2025003180A1 publication Critical patent/WO2025003180A1/fr
Anticipated expiration legal-status Critical
Pending legal-status Critical Current

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Classifications

    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/26—Plasma torches
    • H05H1/32—Plasma torches using an arc
    • H05H1/42—Plasma torches using an arc with provisions for introducing materials into the plasma, e.g. powder or liquid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/08—Arrangements for controlling delivery; Arrangements for controlling the spray area responsive to condition of liquid or other fluent material to be discharged, of ambient medium or of target ; responsive to condition of spray devices or of supply means, e.g. pipes, pumps or their drive means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/20—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion
    • B05B7/201—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion downstream of the nozzle
    • B05B7/203—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion downstream of the nozzle the material to be sprayed having originally the shape of a wire, rod or the like
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
    • B05B7/224—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material having originally the shape of a wire, rod or the like
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/131—Wire arc spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/18—After-treatment
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H2245/00—Applications of plasma devices
    • H05H2245/40—Surface treatments
    • H05H2245/42—Coating or etching of large items

Definitions

  • the present invention relates to a method for coating a workpiece surface, in which an atmospheric plasma jet is generated by means of a plasma nozzle, in which a coating material is supplied to the generated plasma jet and in which the plasma jet with the coating material is directed onto the workpiece surface to be coated.
  • the present invention further relates to a device for coating a workpiece surface and the use of the device.
  • coating material in powder form is applied to the workpiece surface to be coated at very high speed.
  • the powders used here have very small particle sizes, some of which are respirable, and therefore require a high level of safety.
  • the gases (such as helium) used for the supersonic gas jets used in these processes are quite expensive.
  • this process requires a certain ductility of the powder particles and the workpiece surface to be coated, which results in material limitations.
  • WO 2011/042459 A1 discloses an atmospheric pressure plasma process in which a precursor in a gaseous, liquid or solid, powdery state is introduced into an atmospheric plasma jet and a coating is deposited on a workpiece surface in this way. Such precursors may require very high safety precautions.
  • a sputter electrode is used as the inner electrode of the plasma nozzle, from which particles are released by the high-frequency discharges between the sputter electrode and a counter electrode, which are embedded in the coating.
  • the present invention is based on the object of providing a method and a device for coating a workpiece surface, which reduce or overcome one or more of the aforementioned disadvantages of the methods from the prior art.
  • the invention is based on the object of providing a method and a device for coating a workpiece surface, which is also suitable for temperature-sensitive workpiece surfaces are suitable, lower
  • the above-mentioned object is achieved according to the invention by a method for coating a workpiece surface, in which an atmospheric plasma jet is generated by means of a plasma nozzle, in which a coating material is fed to the generated plasma jet and in which the plasma jet with the coating material is directed onto the workpiece surface to be coated, wherein the coating material is fed to the generated plasma jet by feeding a filament that contains or consists of the coating material to the generated plasma jet.
  • a coating of a workpiece surface is achieved with a lower risk potential for the operator of the coating device.
  • relatively high deposition rates and thus high layer thicknesses can be achieved with this method.
  • an atmospheric plasma jet is generated using a plasma nozzle.
  • An atmospheric plasma jet is understood to be a plasma jet that is operated in the range of atmospheric pressure, i.e. in particular when exiting the plasma nozzle, for example with a slight overpressure, it enters an environment in the range of atmospheric pressure.
  • the plasma jet can, for example, have a pressure in the range of +/- 300 mbar, preferably +/- 200 mbar around the surrounding atmospheric pressure.
  • the use of a plasma jet generated with a plasma nozzle also allows a targeted impact on the workpiece surface to be coated.
  • the coating can be applied in a targeted manner to the desired areas of the workpiece surface.
  • the thickness of the coating can be easily adjusted in this way.
  • the plasma nozzle can be moved relative to the workpiece surface, for example by means of a movement device provided for this purpose. In this way, a larger area of the workpiece surface can be exposed to the plasma jet.
  • coating material is fed to the generated plasma jet by feeding a filament that contains or consists of the coating material to the generated plasma jet.
  • a filament has the advantage that safety requirements can be met more easily and cost-effectively. For example, this means that the storage and use of possibly reactive precursor gases and/or precursor liquids and/or possibly respirable precursor powders can be dispensed with.
  • filaments can be procured and stored without any safety-related effort. It was also found that vapors and particles generated when a filament is fed to the plasma jet can be shielded using fairly simple means in order to protect the health of the user.
  • suitable filaments are generally readily available on the market, for example due to the proliferation of 3D printers. Furthermore, filaments can be fed into the plasma jet easily and in a controlled manner.
  • the coating material of the filament can be melted, fragmented and/or vaporized by the plasma jet. Furthermore, the coating material can be at least partially activated by the plasma jet so that it can better form a layer on the workpiece surface.
  • the coating material can be partially ionized by the plasma jet or reactive compounds or groups can be formed by the plasma jet, for example by breaking up chemical compounds, which enable better layer formation on the workpiece surface, for example through cross-linking or polymerization of the coating material.
  • the filament can be fed to the generated plasma jet, for example in the area where it is generated. If the plasma nozzle has electrodes, for example an inner electrode and an outer electrode, between which discharges are generated in a discharge area, the filament can be fed to the plasma jet, for example in the discharge area. In the discharge area, temperatures are particularly higher than downstream of the discharge area, which means that a higher filament throughput and higher deposition rates can be achieved during coating.
  • the area where the plasma jet is generated, in which electrical discharges are generated in the plasma nozzle, is also referred to as the area of the primary plasma.
  • the filament can therefore be fed into the plasma jet particularly in the area of the primary plasma.
  • the filament is preferably fed into the plasma jet at a distance from the internal electrode of the plasma nozzle. In this way, the direct effects of electrical discharges on the filament can be reduced.
  • the filament has electrically insulating properties. In this way, direct electrical discharges to the filament in the plasma nozzle can be avoided.
  • the filament preferably has a specific resistance of at least 10 k ⁇ -cm, preferably at least 100 k ⁇ -cm, in particular at least 1 M ⁇ -cm at 20 °C.
  • the filament can also be fed into the plasma jet downstream of its generation, in particular downstream of the discharge area.
  • the filament is thus exposed to lower temperatures, resulting in lower Deposition rates can be better adjusted.
  • temperature-sensitive filaments can be used more easily.
  • electrically conductive filaments it is advantageous to feed them downstream of the discharge area in order to avoid electrical discharges to the filaments.
  • the area of the plasma jet in which no electrical discharges are caused in the plasma nozzle is also called the area of the secondary plasma or the relaxing area of the plasma.
  • the plasma of the plasma jet begins to relax, in particular to recombine.
  • the temperature and the electrical potential of the plasma jet are lower in the relaxing area or in the area of the secondary plasma than in the generation area or in the area of the primary plasma.
  • the filament can therefore also be fed to the plasma jet in particular in the area of the secondary plasma.
  • the plasma nozzle can have a discharge catcher that separates the discharge region or the region of the primary plasma from a region downstream of the discharge region or from the region of the secondary plasma.
  • the discharge catcher can be, for example, an electrically conductive grid or perforated sheet that is preferably conductively connected to the counter electrode and/or grounded. Such a discharge catcher can prevent discharges, for example discharge streamers, from extending downstream far beyond the discharge region. In this way, a plasma jet with a low electrical potential can be provided downstream of the discharge catcher. This is advantageous for certain applications, such as battery production.
  • the filament is preferably introduced into the plasma jet downstream of the discharge catcher. In this way, clogging of the discharge catcher, in particular the grid or perforated plate, by the coating material is prevented. Furthermore, the filament can be introduced downstream of the discharge catcher before direct contact with electrical discharges, which is particularly advantageous for temperature-sensitive and/or electrically conductive filaments.
  • the plasma jet containing the coating material is directed at the workpiece surface to be coated.
  • the coating material is carried to the workpiece surface by the plasma jet and forms a coating on the workpiece surface.
  • the device can be used in particular when carrying out the above-mentioned method or an embodiment thereof.
  • the above-mentioned object is further achieved according to the invention by the use of the above-described device or an embodiment thereof for coating a workpiece surface, in particular for carrying out the above-described method or an embodiment thereof.
  • the plasma jet is generated by means of electrical discharges in a working gas, in particular by means of high-frequency high-voltage discharges, in particular between at least two electrodes of the Plasma nozzle.
  • the plasma nozzle is designed to generate the plasma jet by means of electrical discharges in a working gas, in particular by means of high-frequency high-voltage discharges, in particular between at least two electrodes of the plasma nozzle. In this way, a plasma jet is generated that can be easily focused and is well suited for plasma coating.
  • the atmospheric plasma jet can be generated by means of an arc-like discharge in a working gas, wherein the arc-like discharge is generated by applying a high-frequency high voltage between electrodes.
  • the high-frequency high voltage for generating a high-frequency arc-like discharge has in particular a voltage in the range of 1 - 100 kV, preferably 1 - 50 kV, more preferably 10 - 50 kV, and a frequency of 1 - 300 kHz, in particular 1 - 100 kHz, preferably 10 - 100 kHz, more preferably 10 - 50 kHz.
  • the plasma nozzle can in particular have an inner electrode.
  • the filament feed is preferably arranged at a distance from the inner electrode. In this way, for example in the case of temperature-sensitive or electrically conductive filaments, direct contact of the filament with electrical discharges from or to the inner electrode can be reduced or avoided.
  • the filament contains at least one plastic. In another embodiment, the filament is based on at least one plastic. In another embodiment, the filament consists of plastic.
  • the plastic contains in particular one or more polymers. In the one or more several polymers can be homopolymers and/or copolymers.
  • the plastic can be a thermoplastic and/or an elastomer.
  • the plastic can be a thermoplastic elastomer, a thermoplastic vulcanizate or a thermoplastic urethane.
  • the plastic can be polypropylene (PP), polylactide (PLA), polyethylene (PE), polyethylene terephthalate (PET), polycarbonate (PC), polypropylene-polyethylene copolymer, polyamide (PA), such as polyamide 6 (PA6), acrylonitrile-butadiene-styrene copolymer (ABS), acrylonitrile-styrene-acrylate (ASA), polyvinyl acetate (PVA), polyvinyl chloride (PVC), polystyrene (PS), polyetheretherketone (PEEK), polyvinyl butyral (PVB), polyvinylidene fluoride (PVDF), polyphenylene sulfide (PPS), polymethyl methacrylate (PMMA) or mixtures thereof.
  • PP polypropylene
  • PLA polylactide
  • PE polyethylene
  • PET polyethylene terephthalate
  • PC polycarbonate
  • PA polypropylene-polyethylene copolymer
  • the polymer can also be a thermoset such as thermosetting polyurethane (PU). It has been found that the plasma jet can break up some of the cross-links in thermosetting material, so that the thermosetting material can again be used with the plasma jet to form a coating on a workpiece surface.
  • PU thermosetting polyurethane
  • a plastic coating can be created on the workpiece surface. It has been found that this method makes it possible to coat workpieces made of a variety of materials. In particular, the process can also be used to coat temperature-sensitive workpieces.
  • the filament contains additives, such as fillers, primers or functional substances.
  • additives such as fillers, primers or functional substances.
  • fillers can increase the deposition rate.
  • Flame-retardant fillers also enable the application of flame-retardant coatings.
  • primers as additives enables the application of coatings with adhesion-promoting properties.
  • other functional substances can influence the properties of the coating, for example optical, electrical or antimicrobial properties of the coating.
  • Possible additives include, for example, metallic particles, in particular metal powder, glassy particles, in particular glass particles, stone powder, carbon-based particles, reinforcing fibers, in particular glass and/or carbon fibers, wood fibers, fluorescent substances, or mixtures thereof.
  • the additives When using a polymer-based filament, the additives can be embedded in the polymer matrix formed by the polymer. In this way, an even distribution of the additives in the filament can be achieved. Furthermore, particulate additives in particular can be bound in the filament, which reduces the safety risks of the particles due to the binding in the matrix.
  • the filament feed has a receptacle for a filament supply, in particular for a filament spindle.
  • Filaments are readily available on the market as spindles and can be stored easily and safely in this way.
  • the provision of a receptacle for a filament supply, in particular in the form of a filament spindle, allows uninterrupted coating operation over a longer period of time as well as easy refilling or simple replacement of the filament.
  • the filament is guided into the plasma nozzle, in particular in the area of a nozzle opening of the plasma nozzle.
  • the filament feed is designed to guide the filament into the plasma nozzle, in particular in the area of the nozzle opening of the plasma nozzle.
  • feeding the filament into the plasma jet is made possible under controlled conditions, for example controlled flow and/or temperature conditions, so that for example, a desired deposition rate can be set better.
  • more efficient operation is possible because the plasma jet inside the plasma nozzle has an even higher temperature and thus a more efficient melting and/or evaporation of the filament is achieved, which means higher deposition rates can be achieved.
  • the filament is fed to the plasma jet outside the plasma nozzle, in particular in the area in front of a nozzle opening of the plasma nozzle.
  • the filament feed is set up to introduce the filament outside the plasma nozzle into the plasma jet generated by the plasma nozzle during operation, in particular in the area in front of the nozzle opening of the plasma nozzle.
  • the plasma nozzle has a discharge catcher, such as a metal grid or perforated sheet, at the nozzle opening.
  • the filament feed has a filament transport device that is designed to feed the filament to the generated plasma jet at a predetermined speed.
  • the filament is fed to the plasma jet at a predetermined speed.
  • the predetermined speed can be constant or variable.
  • a variable speed can, for example, change the deposition rate over time, so that different deposition rates can be set for different areas of the workpiece surface, for example.
  • the filament transport device can in particular have a controllable motor, preferably a stepper motor, which drives one or more drive rollers for transporting the filament.
  • the filament is cooled before entering the plasma jet, in particular before entering the plasma nozzle.
  • the filament feed has a cooling device that is designed to cool the filament and/or part of the filament feed in the area of the plasma nozzle. In this way, the filament can be prevented from melting prematurely and clogging the filament feed.
  • the cooling device can, for example, have a heat sink for air cooling. Liquid-cooled cooling devices are also conceivable.
  • the device has a control device that is designed to control the operation of the device.
  • the control device can in particular be designed to control the operation of the filament feed and/or the operation of the plasma nozzle.
  • the control device can be designed to control the filament transport device in such a way that the filament is fed to the plasma jet at a predetermined speed.
  • control device can be set up to monitor the operation of the device, for example by means of one or more sensors provided.
  • a sensor can be provided that monitors the feed of the filament. In this way, for example, it can be determined when the filament feed is blocked, for example due to premature melting of the filament, so that such a blockage can be counteracted.
  • the control device can, for example, be set up to carry out a cleaning process, for example in response to a corresponding user input on a designated user interface or automatically, for example at predetermined times or when a blockage of the filament feed was detected.
  • the control device can be set up to let the plasma jet burn for a predetermined period of time without advancing the filament through the filament feed. In this way, the plasma jet can burn the plasma nozzle free, in particular of coating material, without the need to disassemble and mechanically remove the coating material.
  • Fig. 1 a plasma nozzle for generating an atmospheric plasma jet by means of a high-frequency arc-like discharge
  • Fig. 2 an embodiment of the method and the device for coating a workpiece surface
  • Fig. 3 shows a second embodiment of the method and device for coating a workpiece surface
  • Fig. 4 shows a third embodiment of the method and device for coating a workpiece surface
  • Fig. 5 shows a fourth embodiment of the method and the device for coating a workpiece surface.
  • Fig. 1 shows a schematic sectional view of a plasma nozzle 2 for generating an atmospheric plasma jet 26 by means of a high-frequency arc-like discharge
  • the plasma nozzle 2 has a nozzle tube 4 made of metal, to which a preferably replaceable outlet nozzle 25 with a nozzle opening 6 is connected at one end, towards which the nozzle tube 4 and the outlet nozzle 25 taper.
  • the nozzle tube 4 has a swirl device 8 with an inlet 10 for a gas flow, in particular a working gas, for example air or nitrogen.
  • a gas flow in particular a working gas, for example air or nitrogen.
  • An intermediate wall 12 of the swirl device 8 has a ring of holes 14 arranged obliquely in the circumferential direction, through which the gas flow is wired.
  • the downstream, conically tapered part of the nozzle tube is therefore flowed through by the gas flow in the form of a vortex 16, the core of which runs along the longitudinal axis of the nozzle tube.
  • An internal electrode 18 is arranged centrally on the underside of the intermediate wall 12, which projects coaxially into the nozzle tube in the direction of the tapered section.
  • the electrode 18 is electrically connected to the intermediate wall 12 and the other parts of the swirl device 8.
  • the swirl device 8 is electrically insulated from the nozzle tube 4 by a ceramic or quartz glass tube 20.
  • a high-frequency high voltage which is generated by a transformer 22, is applied to the electrode 18 via the swirl device 8.
  • the inlet 10 is connected via a hose (not shown) to a working gas source, in front of which the plasma nozzle 2 is supplied with a working gas flow 23 during operation.
  • the nozzle tube 4 and the outlet nozzle 25 connected to it are grounded.
  • the applied voltage generates a high-frequency discharge in the form of an arc 24 between the electrode 18 and the nozzle tube 4.
  • arc arc discharge
  • arc-like discharge arc-like discharge
  • the terms “arc”, “arc discharge” or “arc-like discharge” are used here as a phenomenological description of the discharge, since the discharge occurs in the form of an arc.
  • the term “arc” is also used elsewhere as a form of discharge in direct current discharges with essentially constant voltage values. In this case, it is However, it is a high-frequency discharge in the form of an arc, i.e. a high-frequency, arc-like discharge.
  • this arc is channeled in the vortex core on the axis of the nozzle tube 4, so that it only branches off in the area of the outlet nozzle 25 to the wall of the nozzle tube 4 or the outlet nozzle 25.
  • the working gas which rotates at a high flow rate in the region of the vortex core and thus in the immediate vicinity of the arc 24, comes into intimate contact with the arc 24 and is thereby partially converted into the plasma state, so that a plasma jet 26 is created in the plasma nozzle 2 at a pressure close to atmospheric pressure, for example in the pressure range 800 - 1300 mbar, and exits through the nozzle opening 6.
  • a bore 30 is provided in the wall of the outlet nozzle 25, to which a supply line 32 is connected, through which a filament 34 can be guided into the outlet nozzle 25 into the region of the plasma jet 26.
  • the filament 34 is introduced into the plasma jet 26 downstream of the discharge region in Fig. 1.
  • the plasma nozzle 2 can optionally have a discharge catcher, for example a metal grid, which separates the discharge region from the region downstream of the discharge region. If such a discharge catcher is provided, the filament 34 is preferably introduced into the plasma jet 26 downstream of the discharge catcher.
  • the filament 34 can also be introduced into the discharge region, ie in the immediate area of the arc 24 and thus in the area where the plasma jet 26 is created, for example through a correspondingly provided bore in the nozzle tube 4. Furthermore, it is conceivable that the filament is only introduced into the plasma jet outside the plasma nozzle 2, for example by a feed device arranged in front of the nozzle opening 6. This is particularly advantageous if the plasma nozzle 2 has a discharge catcher, in particular a metal grid, in the area of the nozzle opening 6.
  • a secondary nozzle with an enlarged cross-section is connected to the nozzle opening 6 and the filament is introduced into the plasma jet 26 in the region of the secondary nozzle.
  • Fig. 2 now shows an embodiment of a device for coating a workpiece surface in a schematic representation.
  • the device 100 has the plasma nozzle 2 from Fig. 1 and a filament feed 110.
  • the filament feed 110 comprises a receptacle 112 for a filament supply, into which a filament supply 113 in the form of a spindle filament 34 can be inserted.
  • the filament feed 110 also comprises a filament transport device 116 with a filament drive unit 120 driven by a stepper motor 118.
  • the filament feed 110 also comprises a cooling device 122 and a filament guide 124 in order to guide the filament 34 through the filament transport device 116 and the cooling device 122 into the feed line 32.
  • the filament drive unit 120 is formed in Fig. 2 by two rollers 120a-b driven in opposite directions by the stepper motor 118, between which the filament 34 is guided.
  • the cooling device 122 is designed in Fig. 2 as a heat sink with cooling fins for air cooling. Additionally or alternatively, a cooling device with liquid cooling, for example water cooling, can also be provided.
  • the filament guide 124 in Fig. 2 comprises respective openings and channels, such as the supply line 32, through which the filament 34 runs from the filament supply 113 to the plasma jet 26.
  • the device 100 preferably has a displacement device (schematically illustrated by arrows 130) for moving the plasma nozzle 2 relative to a workpiece 132 to be coated. Additionally or alternatively, a movable workpiece holder can also be provided in order to move the workpiece relative to the plasma nozzle 2.
  • the device 100 further comprises a control device 136 which is designed to control the plasma nozzle 2, the filament transport device 116 and the displacement device 130 and is connected to them for this purpose via wired or wireless communication connections (not shown).
  • a control device 136 which is designed to control the plasma nozzle 2, the filament transport device 116 and the displacement device 130 and is connected to them for this purpose via wired or wireless communication connections (not shown).
  • sensors such as sensors for determining the transport speed of the filament or temperature sensors for determining the temperature of the supply line to the cooling device, can be provided and connected to the control device 136 via communication links, so that the control device 136 can monitor and regulate the operation of the device 100.
  • the plasma nozzle 2 generates an atmospheric plasma jet 26.
  • the transformer 22 is used to generate a high frequency high voltage between the inner electrode 18 and the nozzle tube 4 or the outlet nozzle 25, while a working gas stream 23 is introduced into the plasma nozzle 2, so that, as described above in connection with Fig. 1, a plasma jet 26 is formed, which exits from the nozzle opening 6 of the plasma nozzle 2 and is directed onto a workpiece surface 133 of a workpiece 132 to be coated.
  • filament 34 is fed through the cooling device 122 to the outlet nozzle 25 of the plasma nozzle 2 and thus introduced into the plasma jet 26.
  • the filament 34 which can be a polypropylene filament, for example, is partially melted and/or fragmented in the plasma jet 26 and, together with the plasma jet 26, reaches the workpiece surface 133, where it forms a coating 134.
  • Fig. 3 shows a second embodiment of a device for coating a workpiece surface in a schematic representation.
  • the device 200 has a similar structure to the device 100 from Fig. 2 and differs from it essentially only in the design of the lower part of the plasma nozzle 2 and the arrangement of the supply line 32 to the plasma nozzle 2, which are shown schematically in Fig. 3.
  • the outlet nozzle 25 has a adjoining section 204 with essentially constant cross-section with the bore 30 to which the supply line 32 is connected.
  • a discharge catcher 206 preferably a metal grid or perforated metal sheet, is preferably arranged, which separates the discharge region (upstream of the discharge catcher 206) from the region downstream of the discharge region (downstream of the discharge catcher 206).
  • the filament can be introduced into the plasma jet 26 in an area in which no discharges occur between the inner electrode 18 and the nozzle tube 4 or outlet nozzle 25. In this way, direct discharges onto the filament 34 can be prevented, for example in the case of a conductive filament 34. Furthermore, the filament 34 can be introduced into an area of the plasma jet 26 with a lower temperature, which can be advantageous, for example, in the case of temperature-sensitive filaments 34 or when low deposition rates are desired.
  • Fig. 4 shows a second embodiment of a device for coating a workpiece surface in a schematic representation.
  • the device 300 has a similar structure to the device 200 of Fig. 3 and differs from it only in the design of the outlet nozzle 25 at the lower part of the plasma nozzle 2, which is shown schematically in Fig. 3.
  • the outlet nozzle 25 has the section 202 in which the interior of the plasma nozzle 2 tapers, as well as an adjoining section 304 whose cross-section is larger than the smallest cross-section of section 202.
  • the section can increase in size from section 202 to section 304, as shown in Fig. 4, or continuously.
  • the cross-section can remain the same in the further course of section 304 (as in Fig. 4) or increase further.
  • the bore 30 is located, to which the supply line 32 is connected.
  • the filament 34 can be introduced into a cooler area of the plasma jet 26, which is advantageous, for example, for temperature-sensitive filaments or when low deposition rates are desired.
  • cross-sectional expansion in section 304 can widen the plasma jet 26 so that, for example, a larger surface area of a workpiece can be coated simultaneously.
  • Fig. 5 shows a second embodiment of a device for coating a workpiece surface in a schematic representation.
  • the device 400 has a similar structure to the device 100 of Fig. 2 and differs from it only in the design of the lower part of the plasma nozzle 2 and the arrangement of the supply line 32 to the plasma nozzle 2, which are shown schematically in Fig. 3.
  • Components corresponding to the components in Figs. 1 and 2 are provided in Fig. 3 with the corresponding reference numerals from Figs. 1 and 2, even if they may be partially structurally different and/or arranged differently in Fig. 3 than in Figs. 1 and 2. In this respect, reference is made to the corresponding description of Figs. 1 and 2.
  • the feed line 32 is arranged such that the filament 34 is introduced into the plasma jet 26 after it has exited the plasma nozzle 2 through the nozzle opening 6.
  • the bore 30 is accordingly unnecessary in the device 400.
  • the plasma jet 26 relaxes and/or cools down, so that the filament 34 can be introduced into a cooler region of the plasma jet 26, which is advantageous for temperature-sensitive filaments 34 or when lower deposition rates are desired.
  • the embodiment in Fig. 4 allows a more flexible setting of the point at which the filament 34 is introduced into the plasma jet 26 by adjusting the distance between the nozzle opening 6 and the feed line 32.
  • the distance can be adapted, for example, to the filament material used or the desired application rate.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Electromagnetism (AREA)
  • Combustion & Propulsion (AREA)
  • Spectroscopy & Molecular Physics (AREA)
  • Nozzles (AREA)

Abstract

L'invention concerne un procédé de revêtement d'une surface de pièce à usiner (133), dans lequel un faisceau de plasma atmosphérique (26) est généré au moyen d'une buse de plasma (2), un matériau de revêtement est fourni au faisceau de plasma généré (26) et le faisceau de plasma, avec le matériau de revêtement, est dirigé vers la surface de pièce à usiner (133) à revêtir, le matériau de revêtement étant fourni au faisceau de plasma généré (26) en ce qu'un filament (34) est fourni au faisceau de plasma généré (26), ce filament contenant le matériau de revêtement ou étant constitué de celui-ci. L'invention concerne également un dispositif (100, 200, 300, 400) pour revêtir la surface d'une pièce à usiner (133), comprenant une buse à plasma (2) conçue pour générer un faisceau de plasma atmosphérique (26), la buse à plasma (2) comprenant une ouverture de buse (6) d'où sort le faisceau de plasma (26) pendant le fonctionnement, et comprenant un élément d'alimentation en filament (124) disposé et conçu de manière à fournir un filament (34) au faisceau de plasma généré (26) pendant le fonctionnement. L'invention concerne en outre l'utilisation du dispositif (100, 200, 300, 400).
PCT/EP2024/067888 2023-06-27 2024-06-26 Procédé et dispositif de revêtement d'une surface de pièce à usiner Pending WO2025003180A1 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
DE102023116854 2023-06-27
DE102023116854.1 2023-06-27
DE102023121696.1 2023-08-14
DE102023121696.1A DE102023121696A1 (de) 2023-06-27 2023-08-14 Verfahren und vorrichtung zur beschichtung einer werkstückoberfläche

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WO2025003180A1 true WO2025003180A1 (fr) 2025-01-02

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Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4604306A (en) * 1985-08-15 1986-08-05 Browning James A Abrasive blast and flame spray system with particle entry into accelerating stream at quiescent zone thereof
GB2367521A (en) * 2000-07-21 2002-04-10 Ford Global Tech Inc Electric arc metal spraying
WO2011042459A1 (fr) 2009-10-06 2011-04-14 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé à plasma à pression atmosphérique pour fabriquer des particules modifiées en surface et des revêtements
US20140166630A1 (en) * 2012-12-17 2014-06-19 Fuji Engineering Co., Ltd. Plasma spraying apparatus
US20150376761A1 (en) * 2014-06-30 2015-12-31 United Technologies Corporation Systems and methods for plasma spray coating
US20210078073A1 (en) * 2018-03-27 2021-03-18 Materion Corporation Copper alloy compositions having enhanced thermal conductivity and wear resistance

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4604306A (en) * 1985-08-15 1986-08-05 Browning James A Abrasive blast and flame spray system with particle entry into accelerating stream at quiescent zone thereof
GB2367521A (en) * 2000-07-21 2002-04-10 Ford Global Tech Inc Electric arc metal spraying
WO2011042459A1 (fr) 2009-10-06 2011-04-14 Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung e.V. Procédé à plasma à pression atmosphérique pour fabriquer des particules modifiées en surface et des revêtements
US20140166630A1 (en) * 2012-12-17 2014-06-19 Fuji Engineering Co., Ltd. Plasma spraying apparatus
US20150376761A1 (en) * 2014-06-30 2015-12-31 United Technologies Corporation Systems and methods for plasma spray coating
US20210078073A1 (en) * 2018-03-27 2021-03-18 Materion Corporation Copper alloy compositions having enhanced thermal conductivity and wear resistance

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