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Research and development progressive flame spray technology for manufacturing and renovation of parts in power industry

The aim of the project is research and development progressive flame spray technology for manufacturing and renovation of parts in power industry focused on increasing lifetime and reliability

The wear of machinery component surface is a frequent cause of the loss of machinery functionality and the reason for repair. Progressive wear of machinery components happens also in power engineering. The components which form the basic kinematic node points are carefully watched. The typical representatives are piston rods of hydraulic and air cylinders, shafts with sliding surfaces, or, generally, all abrasive and sealing shaft surfaces, which emerge from chambers with different pressure or media/agent in comparison with existing surroundings. The wear of such machinery components causes considerable loss to the machinery operator. The following situations can occur: • Unplanned down time of the machinery ( lowered dependability of the equipment) • Increased expenses spent on the purchase of new machinery components • Increased costs of repairs and equipment maintenance • Fault rate of the machinery There are several techniques commonly used to reach the required characteristics of surface layers of components stressed in such way: - Classical chemical – thermic treating with the formation of cemented or nitrided layer - Hard chromium plating - Formation of weld deposit made with a special material - Component coating with thermal spray technology The main reason for the whole project is an urgent need to improve surface characteristics of machinery components, which will prolong their life span, especially in cases they operate in extreme operating conditions and make up a node point with significant functional importance. The main goal of the whole project will be to create a database system as a file of suitable components, suitable accessory materials and follow-up technical-economic indicators for TST application in power engineering. As part of a common solution, material constants will be acquired. These constants will enable to simulate and, on the basis of conductive analysis calculation, predict residual life span of components with surfaces produced by means of TST. The solution of the whole project will also include the development of new materials suitable for specific applications in nuclear, hydraulic and heat-power engineering, including the optimization of TST parameters. A document called “General technical solution of TST application for dedicated parts in nuclear engineering“ will be produced for the area of nuclear engineering. The main tangible outcome will be thermal coating of actual components for engineering. These components will be observed during operation and there will be a final evaluation of this observation. Main solution phases (all project partners): Phase 1 – Initial analysis • Choosing the components with marginal wear, analysis of existing accessory materials, proposal of new materials and appropriate TST methods • Output – specification of the most suitable components for application and determination of optimal TST methods Solution period: from 1st March, 2013 to 31st December, 2013 Phase 2 – Verification of basic coating characteristics • Optimization of coating application parameters, preparation and implementation of laboratory tests, calculation analysis – simulation of residual life span, verification of functional characteristics by laboratory tests. • Output – proposal of methods and TST materials (including optimized technological coating parameters) for specific applications and specific working conditions Solution period: from 1st January, 2014 to 31st December, 2014 Phase 3 – Processing of documentation for operational test implementation • Processing of accompanying technical documentation for application in engineering in general, and also producing a special document “General technical solution of TST application for dedicated components in nuclear engineering“ for nuclear engineering • Output – elaboration and approval of technical documentation Solution period: from 1st January, 2015 to 31st December, 2015. Phase 4 – Coating of actual components for operational tests • Thermalle coating of actual components, observation of these components in operation, eventual adjustments of technological procedures • Output – completed and evaluated operational tests and eventual adjustments of accompanying technical documentation ( technological procedures) Solution period: from 1st January, 2015 to 31st December, 2016 Phase 5 – Processing of structured database of results achieved in the course of the whole project solution • Production of files of suitable components and relevant accessory materials attested by this project, including elaboration of technical – economic coefficients of TST application • Output – database with the indicator of the ratio between the price and life span of components in existing implementation and also for new components with coatings Solution period: from 1st January, 2016 to 31st December, 2016
Acronym: 
PLASMACOAT
Project ID: 
7 617
Start date: 
01-03-2013
Project Duration: 
46months
Project costs: 
1 150 000.00€
Technological Area: 
Coatings
Market Area: 
Education

Raising the productivity and competitiveness of European businesses through technology. Boosting national economies on the international market, and strengthening the basis for sustainable prosperity and employment.