www bzfxw com BRITISH STANDARD BS EN 657 1994 Thermal spraying — Terminology, classification UDC 621 793 7 001 4 BS EN 657 1994 This British Standard, having been prepared under the direction of the M[.]
BRITISH STANDARD Thermal spraying — Terminology, classification UDC 621.793.7:001.4 BS EN 657:1994 BS EN 657:1994 Cooperating organizations The European Committee for Standardization (CEN), under whose supervision this European Standard was prepared, comprises the national standards organizations of the following countries: Austria Belgium Denmark Finland France Germany Greece Iceland Ireland Italy Luxembourg Netherlands Norway Portugal Spain Sweden Switzerland United Kingdom This British Standard, having been prepared under the direction of the Materials and Chemicals Sector Board, was published under the authority of the Standards Board and comes into effect on 15 December 1994 © BSI 11-1999 The following BSI references relate to the work on this standard: Committee reference STI/40 Draft for comment DC 92/53909 ISBN 580 23321 Oesterreichisches Normungsinstitut Institut belge de normalisation Dansk Standard Suomen Standardisoimisliito, r.y Association franỗaise de normalisation Deutsches Institut fỹr Normung e.V Hellenic Organization for Standardization Technological Institute of Iceland National Standards Authority of Ireland Ente Nazionale Italiano di Unificazione Inspection du Travail et des Mines Nederlands Normalisatie-instituut Norges Standardiseringsforbund Instituto Portuguès da Qualidade Asociación Espola de Normalización y Certificación Standardiseringskommissionen i Sverige Association suisse de normalisation British Standards Institution Amendments issued since publication Amd No Date Comments BS EN 657:1994 Contents Cooperating organizations National foreword Foreword Text of EN 657 National annex NA (informative) Committees responsible © BSI 11-1999 Page Inside front cover ii Inside back cover i BS EN 657:1994 National foreword This British Standard, has been prepared under the direction of the Materials and Chemicals Sector Board and is the English language version of EN 657 Thermal spraying — Terminology, classification, published by the European Committee for Standardization (CEN) A British Standard does not purport to include all the necessary provisions of a contract Users of British Standards are responsible for their correct application Compliance with a British Standard does not of itself confer immunity from legal obligations Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, the EN title page, pages to 10, an inside back cover and a back cover This standard has been updated (see copyright date) and may have had amendments incorporated This will be indicated in the amendment table on the inside front cover ii © BSI 11-1999 EUROPEAN STANDARD EN 657 NORME EUROPÉENNE April 1994 EUROPÄISCHE NORM UDC 621.793.7:001.4 Descriptors: Thermal spraying, vocabulary, classifications English version Thermal spraying — Terminology, classification Projection thermique — Terminologie, classification Thermisches Spritzen — Begriffe, Einteilung ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ This European Standard was approved by CEN on 1994-04-01 CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CEN member This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official versions CEN members are the national standards bodies of Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom CEN European Committee for Standardization Comité Européen de Normalisation Europäisches Komitee für Normung Central Secretariat: rue de Stassart 36, B-1050 Brussels © 1994 Copyright reserved to CEN members Ref No EN 657:1994 E EN 657:1994 Foreword This European Standard was prepared by the Technical Committee CEN/TC 240, Thermal spraying and thermally sprayed coating, of which the secretariat is held by DIN CEN/TC 240 has decided to submit the final draft for formal vote by its resolution The result was positive This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by October 1994, and conflicting national standards shall be withdrawn at the latest by October 1994 According to the CEN/CENELEC Internal Regulations, the following countries are bound to implement this European Standard: Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom Contents Foreword Scope Normative references Definition Process variations 4.1 Classification according to the type of spray material 4.2 Classification according to the operation 4.2.1 Manual spraying 4.2.2 Mechanized spraying 4.2.3 Automatic spraying 4.3 Classification according to the energy carrier 4.3.1 Molten-bath spraying 4.3.2 Flame spraying 4.3.2.1 Wire flame spraying 4.3.2.2 Powder flame spraying 4.3.3 High velocity flame spraying 4.3.4 Detonation spraying 4.3.5 Arc spraying 4.3.6 Plasma spraying 4.3.6.1 Plasma spraying in air 4.3.6.2 Plasma spraying in chambers 4.3.6.3 Liquid-stabilized plasma spraying 4.3.7 Laser spraying Page 3 3 3 3 3 3 4 5 5 6 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 5.17 6.1 6.2 6.3 6.4 6.5 6.6 General terms Spray gun Spray material Spray deposit Carrier gas Atomizing gas Propellant gas Spray distance Spray angle Masking Spray particles Spray losses Spray efficiency Sprayed coating Thermal treatment Fusing of sprayed deposits Spray stream Unmelted particles Thermal spraying equipment, terms Spray nozzle Supplementary nozzle Contact tube Wire feed mechanism Powder feeder Powder injector Properties of thermal sprayed deposits, terms 7.1 Tensile adhesive strength, RH 7.2 Hardness 7.3 Other properties Master chart of thermal spraying processes Annex A (informative) Keyword index Figure — Molten-bath spraying Figure — Wire flame spraying Figure — Powder flame spraying Figure — High velocity flame spraying Figure — Detonation spraying Figure — Arc spraying Figure — Plasma spraying in air Figure — Plasma spraying in a chamber Figure — Liquid stabilized plasma spraying Figure 10 — Laser spraying Figure 11 — Classification according to the energy carriers used for spraying Page 6 6 6 6 7 7 7 7 7 7 7 7 ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ 7 7 4 5 6 © BSI 11-1999 EN 657:1994 Scope 4.2 Classification according to the operation This Standard defines processes and general terms for thermal spraying It also classifies the thermal spraying processes according to type of spray material, to type of operation, to type of energy carrier 4.2.1 Manual spraying Normative references This European Standard incorporates by dated or undated reference, provisions from other publications These normative references are cited at the appropriate places in the text and the publications are listed hereafter For dated references subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporates in it by amendment or revision For undated references the latest edition of the publication referred to applies EN 582, Thermal spraying — Determination of tensile adhesive strength ISO 6507-1:1982, Metallic materials — Hardness test — Vickers test — Part 1: HV to HV 100 ISO 6507-2:1983, Metallic materials — Hardness test — Vickers test — Part 2: HV 0,2 to less than HV ISO 6508:1986, Metallic materials — Hardness test — Rockwell test (scales A–B–C–D–E–F–G–H–K) All operations typical of the spraying process are manual 4.2.2 Mechanized spraying All operations typical of the spraying processes are mechanized 4.2.3 Automatic spraying All operations typical of the spraying process are fully mechanized including all handling (e.g workpiece loading and unloading) and are integrated in a programmed system 4.3 Classification according to the energy carrier 4.3.1 Molten-bath spraying A surfacing material is heated to the molten state, in most cases in a reservoir, and propelled onto the prepared substrate by a preheated atomizing gas (e.g compressed air) (see Figure 1) ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ Definition For the purpose of this standard the following definition applies: thermal spraying thermal spraying comprises processes, in which surfacing materials are heated to the plastic or molten state, inside or outside of the spraying gun/torch, and then propelled onto a prepared surface The substrate remains unfused NOTE Spray coatings could be applied by thermal spraying of materials in its liquid or plastic pasty state NOTE To obtain specific properties of the deposit, a subsequent thermal mechanical or sealing treatment may be used Process variations 4.1 Classification according to the type of spray material Distinction of following variations: — wire spraying; — rod spraying; — cord spraying; — powder spraying; — molten-bath spraying © BSI 11-1999 Figure — Molten-bath spraying 4.3.2 Flame spraying Flame spraying is a process in which a surfacing material is heated in oxyfuel gas flame and then propelled in atomized form onto a substrate The material may be initially in the form of powder, rod, cord, or wire The hot material is projected onto the substrate by the oxyfuel gas jet alone or with the additional aid of an atomizing gas e.g compressed air 4.3.2.1 Wire flame spraying In wire flame spraying the metal wire to be deposited is supplied to the gun continuously It is heated to the molten state by the oxyfuel gas flame and propelled onto the prepared substrate surface by the additional aid of an atomizing gas, e.g compressed air (see Figure 2) EN 657:1994 The fuel gases predominantly used are e.g acetylene, propane, and hydrogen Variations are rod flame spraying, where cut lengths of material rod are used and cord flame spraying, where cords of surfacing material are used 4.3.3 High velocity flame spraying In high velocity flame spraying continuous combustion is obtained in a combustion chamber The high pressure generated in the chamber, in conjunction with an expanding nozzle at the chamber outlet, produces a particularly high velocity of flow in the gas jet Material is fed into the high velocity gas stream, ensuring a rapid acceleration of the particles (see Figure 4) Fuel gases, such as acetylene, propane, propylene, methylacetylene-propadiene, and hydrogen may be used and liquid fuels such as diesel or kerosene may also be used Figure — Wire flame spraying 4.3.2.2 Powder flame spraying With this method the material to be sprayed is supplied to the gun in powder form and heated to the plastic or molten state in the oxyfuel gas flame It is propelled onto the prepared substrate by expanding fuel gases In some cases, an additional gas jet may be used to accelerate the powder particles (see Figure 3) The fuel gases commonly used are acetylene, propane, and hydrogen Figure — Powder flame spraying ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ Figure — High velocity flame spraying 4.3.4 Detonation spraying In detonation spraying the gun contains a chamber into which are injected certain quantities of a powder The gas mixture in the chamber is detonated at controlled intervals This creates a hot, high velocity gas stream that heats the powder to its plastic or molten state and accelerates the particles as they leave the gun barrel The so-called “detonation gun” consists of this barrel and the gun chamber The injected gas and powder mixture is detonated by an electric spark The resulting shock wave generated in the barrel accelerates the particles, which are further heated in the flame front and are propelled in a directed jet onto the prepared substrate Nitrogen is used to flush clean gun chamber and barrel after every detonation (see Figure 5) © BSI 11-1999 EN 657:1994 The plasma is produced by an arc established between the electrode (cathode) and the nozzle (anode) (partial or complete ionization of the plasma gases) and the high velocity of the plasma jet emerging from the nozzle is generated by the thermal expansion of the gases The plasma gases commonly used are argon, hydrogen, helium, nitrogen, or mixtures of these gases (see Figure 7) Figure — Detonation spraying 4.3.5 Arc spraying Arc spraying utilises an electric arc between two wires to melt their tips; the wires may be of identical or dissimilar composition A jet or jets of gas, normally compressed air, atomizes the molten metal and projects the particles onto the prepared substrate (see Figure 6) Figure — Plasma spraying in air 4.3.6.2 Plasma spraying in chambers ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ Figure — Arc spraying 4.3.6 Plasma spraying Plasma spraying is done in a sealed chamber containing a defined gas atmosphere The plasma gases commonly used are argon, helium, hydrogen, nitrogen, or mixtures of these gases Manipulation of torch and workpiece is done via suitable handling systems Powder is continuously fed into the torch from external feeder units suitable for the specified conditions (see Figure 8) Vacuum plasma spraying is a special case where the pressure in the chamber is reduced Plasma spraying in chambers may also be done at elevated pressure In the chamber, when the atmosphere is controlled a substrate and deposit cooling system by jets of liquid gas sprayed in the form of fine droplets may also be combined 4.3.6.1 Plasma spraying in air In plasma spraying in the atmosphere a plasma jet is used to heat the spray material to its plastic of molten state and project it onto the prepared surface of the substrate The powder may be injected by means of carrying gas into the plasma jet inside (internal feed) or outside (external feed) the nozzle © BSI 11-1999 EN 657:1994 4.3.7 Laser spraying The process of laser-spraying is characterized by the injection of a powder in the laser beam, using a suitable powder nozzle The laser radiation melts the powder The spray particles to the substrate by the carrier gas and by gravity The deposit may be protected by a shielding gas (see Figure 10) Figure — Plasma spraying in a chamber 4.3.6.3 Liquid-stabilized plasma spraying In liquid-stabilized plasma spraying the plasma gas is generated from liquids, e.g water, ethanol or methanol Between a graphite cathode and a rotating, water-cooled anode an arc is established The liquid is introduced into the chamber with a swirling motion to stabilize the arc and produce the plasma jet The continuously regenerated sheath of liquid provides thermal as well as electrical insulation against the chamber wall and, at the same time, serves as a coolant Some part of the stabilizing liquid evaporates and the high temperatures present in the chamber provide its dissociation and ionization The spray material is introduced into the high velocity plasma jet outside the nozzle, heated to the plastic or molten state and projected onto the prepared substrate (see Figure 9) ｗｗｗ．ｂｚｆｘｗ．ｃｏｍ Figure 10 — Laser spraying General terms 5.1 Spray gun Unit, with which the spraying material, is heated to the plastic or molten state, accelerated, and projected onto the prepared substrate surface 5.2 Spray material Coating material for thermal spraying initially different in form and/or composition to suit the employed process variation and type of application 5.3 Spray deposit Spray material as deposited 5.4 Carrier gas Carrying gas for the injection of spray material in powder form into the hot gas stream or flame 5.5 Atomizing gas Gas for the atomization and acceleration of molten spray material in wire, rod or cord form 5.6 Propellant gas Gas utilized to accelerate of spray particles 5.7 Spray distance Figure — Liquid stabilized plasma spraying Distance between the nozzle face and the workpiece surface © BSI 11-1999 EN 657:1994 5.8 Spray angle 6.4 Wire feed mechanism The angle between the centre of the spray stream and the workpiece surface The wire feed mechanism is a mechanically operated unit for a controlled delivery of the spray material in the form of wire, rod, or cord 5.9 Masking Protective measure for area of a workpiece, that are not to be coated 5.10 Spray particles Plastic or molten particles, that emerge from the spray gun 5.11 Spray losses Total loss of spray material resulting from evaporation, burn-off, projection outside the intended substrate area, and rebound, i.e material not contributing to produce the desired deposit 5.12 Spray efficiency Ratio of total weight of spray deposit to total weight of spray material applied 5.13 Sprayed coating Deposit applied by thermal spraying 5.14 Thermal treatment Controlled heat treatment before, during, and/or after the thermal spraying operation 5.15 Fusing of sprayed deposits Heating of sprayed deposits to temperatures in the melting range to obtain a homogeneous deposit, diffusion bonded within itself and with substrate typically applied to self-fluxing alloys 5.16 Spray stream The stream of spray particles emerging from the spray gun 5.17 Unmelted particles Particles entrained in the deposit which have not been heated sufficiently to deform at the substrate Thermal spraying equipment, terms 6.1 Spray nozzle The spray nozzle is that part of the spray gun, which contains the outlet opening for the spray stream 6.2 Supplementary nozzle Supplementary nozzles are designed for controlled configuration and direction of the spray stream They can be designed as broad spray, narrow angular, rotating angular spray nozzles or for cooling purposes 6.3 Contact tube 6.5 Powder feeder Powder feeding units are systems for a controlled supply of spray material in the form of powder 6.6 Powder injector Powder injectors deliver and guide spray powders into the gas stream They may be integrated in the spray gun or mounted outside of it Properties of thermal sprayed deposits, terms 7.1 Tensile adhesive strength, RH The tensile adhesive strength RH is the strength obtained in the tension test, calculated from the quotient of the maximum load Fm and the cross-section of the specimen at the fractured surface The tensile adhesive strength can be determined according to EN 582 7.2 Hardness NOTE There are several types of tests to determine the hardness of a spray deposit The preferred test method, however, is the Vickers hardness test (see ISO 6507-1:1982 and ISO 6507-2:1983) The method applicable to extremely soft deposits is the Rockwell surface hardness test covered in ISO 6508:1986 7.3 Other properties Other typical properties of thermal sprayed coatings are e.g.: — corrosion resistance; — heat resistance; — frictional characteristics; — wear resistance; — thermal and electrical insulation; — thermal and electrical conductivity; — thermal expansion; — abradability; — surface roughness; — thermal shock resistance; — permeability Master chart of thermal spraying processes Figure 11 shows a classification according to the energy carriers used for spraying The contact tube is an electrically conductive part (electric conduit) of the nozzle system of an arc spray gun to which wires are guided along electrical contacts toward a point of intersection, and short circuiting, at a desired angle © BSI 11-1999 EN 657:1994 Figure 11 — Classification according to the energy carriers used for spraying © BSI 11-1999 EN 657:1994 Annex A (informative) Keyword index The figures behind the keywords are clause and subclause numbers Arc spraying 4.3.5 Atomizing gas 5.5 Automatic 4.2.3 Carrier gas 5.4 Classification according to type of operation 4.2 type of energy carrier 4.3 type of spray material 4.1 Contact tube 6.3 Detonation spraying 4.3.4 Flame spraying 4.3.2 Fusing of sprayed deposits 5.15 General terms Hardness 7.2 High velocity flame spraying 4.3.3 Laser spraying 4.3.7 Liquid-stabilized plasma spraying 4.3.6.3 Manual 4.2.1 Masking 5.9 Mechanized 4.2.2 Molten-bath spraying 4.3.1 Other properties 7.3 © BSI 11-1999 Plasma spraying 4.3.6 Plasma spraying in air 4.3.6.1 Plasma spraying in chambers 4.3.6.2 Powder flame spraying 4.3.2.2 Powder feeder 6.5 Powder injector 6.6 Process variations Propellant gas 5.6 Properties of thermal sprayed deposits, terms Spray angle 5.8 Spray deposit 5.3 Spray distance 5.7 Spray efficiency 5.12 Spray gun 5.1 Spray losses 5.11 Spray material 5.2 Spray nozzle 6.1 Spray particles 5.10 Spray stream 5.16 Sprayed coating 5.13 Supplementary nozzle 6.2 Tensile adhesive strength 7.1 Thermal spraying Thermal spraying equipment, terms Thermal treatment 5.14 Unmelted particles 5.17 Wire feed mechanism 6.4 Wire flame spraying 4.3.2.1 10 blank BS EN 657:1994 National annex NA (informative) Committees responsible The United Kingdom participation in the preparation of this European Standard was entrusted by the Materials and Chemicals Sector Board to Technical Committee STI/40, upon which the following bodies were represented: Aluminium Federation Association of Metal Sprayers British Steel Industry Society of Motor Manufacturers and Traders Limited Welding Institute Zinc Development Association Coopted member © BSI 11-1999 BS EN 657:1994 BSI — British Standards Institution BSI is the independent national body responsible for preparing British Standards It presents the UK view on standards in Europe and at the international level It is incorporated by Royal Charter Revisions British Standards are updated by amendment or revision Users of British Standards should make sure that they possess the latest amendments or editions It is the constant aim of BSI to improve the quality of our products and services We would be grateful if anyone finding an inaccuracy or ambiguity while using this British Standard would inform the Secretary of the technical 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