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Fast Regime Fluidized Bed Machining (FR-FBM) of Thermally Sprayed Coatings

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Abstract

Finishing of thermally sprayed metallic, ceramic, and cermet coatings is required to meet tolerances and requirements on surface roughness in most industrial applications. Conventional machining is a costly and time-consuming process, and is difficult to automate. Therefore, this study investigates and develops a new technique highly amenable for automation: fast regime—fluidized bed machining (FR-FBM). Atmospheric plasma sprayed TiO2, Cr2O3, and HVOF-sprayed WC-17%Co and Tribaloy-800 coatings, deposited on AISI 1040 steel substrates, were subjected to FR-FBM treatment. The effects of the leading operational parameters, namely, abrasive size, jet pressure, and processing time, were evaluated on all coatings by using a two/three-levels full factorial design of experiments. The FR-FBM treated surfaces were observed by FE-SEM and their surface finishing was evaluated by contact profilometry. Significant improvements in surface finishing of all the machined thermally sprayed coatings can always be detected, with FR-FBM being able to guarantee the precision and to ensure the closest geometrical tolerances.

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Acknowledgments

The authors wish to thank Mr. Ceccarelli (Università di Roma ‘Tor Vergata’) for the setup of the apparatus. They also wish to acknowledge Mr. Bassani and Mr. Pighetti (Università di Modena e Reggio Emilia) for the preparation of the samples.

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Authors and Affiliations

  1. Dipartimento di Meccanica ed Aeronautica, ‘La Sapienza’ Università di Roma, Via Eudossiana, 18, 00184, Rome, Italy

    Massimiliano Barletta & Gianluca Rubino

  2. Dipartimento di Ingegneria dei Materiali e dell’Ambiente, Università degli Studi di Modena e Reggio Emilia, Via Vignolese, 905, 41100, Modena, Italy

    Giovanni Bolelli & Luca Lusvarghi

Authors
  1. Massimiliano Barletta
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  2. Gianluca Rubino
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  3. Giovanni Bolelli
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  4. Luca Lusvarghi
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Corresponding author

Correspondence to Massimiliano Barletta.

Additional information

This article is an invited paper selected from presentations at the 2008 International Thermal Spray Conference and has been expanded from the original presentation. It is simultaneously published in Thermal Spray Crossing Borders, Proceedings of the 2008 International Thermal Spray Conference, Maastricht, The Netherlands, June 2-4, 2008, Basil R. Marple, Margaret M. Hyland, Yuk-Chiu Lau, Chang-Jiu Li, Rogerio S. Lima, and Ghislain Montavon, Ed., ASM International, Materials Park, OH, 2008.

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Barletta, M., Rubino, G., Bolelli, G. et al. Fast Regime Fluidized Bed Machining (FR-FBM) of Thermally Sprayed Coatings. J Therm Spray Tech 17, 796–804 (2008). https://doi.org/10.1007/s11666-008-9266-1

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  • DOI: https://doi.org/10.1007/s11666-008-9266-1

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