Spray material on an iron base and method of manufacturing a spray material as well as thermal spray layer and spraying method

Abstract

The invention relates to a spray material on an iron base for the thermal coating of a substrate, in particular for the thermal coating of a running surface of a cylinder of a reciprocating combustion engine, wherein the spray material includes FeTiO 3 as a base material. In accordance with the invention, the spray material includes at least one first solid lubricant composed of a sulfide and one second solid lubricant composed of a fluoride. The invention further relates to a method for manufacturing a spray material, to a spray wire, in particular a spray filler wire for use in a thermal wire spraying method, to a thermal spray layer on an iron base, in particular for a running surface of a cylinder of a reciprocating combustion engine, to a spraying method for manufacturing a thermal spray layer, as well as to the use of a powder material and of a spray wire for manufacturing a thermal spray layer.

1 . A spray material based on iron for the thermal coating of a substrate, in particular for the thermal coating of a running surface of a cylinder of a reciprocating combustion engine, wherein the spray material includes FeTiO 3  as a base material, characterized in that the spray material includes at least one first solid lubricant composed of a sulfide and one second solid lubricant composed of a fluoride. 
     
     
         2 . A spray material in accordance with  claim 1 , wherein the proportion by volume of sulfide amounts to 0.1% to 15% by volume, preferably 1% to 6% by volume. 
     
     
         3 . A spray material in accordance with  claim 1 , wherein the sulfide is only MoS 2  and/or WS 2 , except for contaminants. 
     
     
         4 . A spray material in accordance with  claim 1 , wherein the proportion by volume of fluoride mounts to 0.05% to 20% by volume, preferably 1% to 10% by volume. 
     
     
         5 . A spray material in accordance with  claim 1 , wherein the fluoride is only CaF 2  and/or BaF 2 , except for contaminants. 
     
     
         6 . A spray material in accordance with  claim 5 , wherein CaF 2  and BaF 2  are present as a eutectic. 
     
     
         7 . A spray material in accordance with any one of the preceding claims  claim 1 , wherein the spray material is composed only of, except for contaminants, a sulfide, a fluoride and the remainder FeTiO 3  as a base material. 
     
     
         8 . A spray material in accordance with  claim 1 , wherein the spray material additionally includes a nitride. 
     
     
         9 . A spray material in accordance with  claim 8 , wherein the proportion by volume of nitride amounts to 0.1% to 8% by volume, preferably 1% to 5% by volume. 
     
     
         10 . A spray material in accordance with  claim 8 , wherein the nitride is only hexagonal BN and/or CrN. 
     
     
         11 . A spray material in accordance with  claim 8 , wherein the spray material is composed only of, except for contaminants, a nitride, a sulfide, a fluoride and the remainder FeTiO 3  as a base material. 
     
     
         12 . A spray material in accordance with  claim 1 , wherein the spray material is a powder material having a grain size distribution between 2 μm and 60 μm, preferably between 5 μm and 40 μm 
     
     
         13 . A spray material in accordance with  claim 1 , wherein the spray material is a spray powder for thermal spraying. 
     
     
         14 . A method of manufacturing a spray material in accordance with  claim 1 , wherein the base materials FeTiO 3  is manufactured by grinding and/or screening from ilmenite. 
     
     
         15 . A method in accordance with  claim 14 , wherein the base material FeTiO 3  is first remelted before the grinding and/or screening. 
     
     
         16 . A method in accordance with  claim 14 , wherein at least one of the solid lubricants is formed in the form of solid lubricant particles and is agglomerated by spray drying and/or cladding with particles of the base material FeTiO 3 . 
     
     
         17 . A spray wire for use in a thermal wire spraying method including a spray material in accordance with  claim 1 . 
     
     
         18 . A thermal spray layer based on iron for a substrate, in particular for a running surface of a cylinder of a reciprocating combustion engine, wherein the thermal spray layer includes FeTiO 3  as a base material, characterized in that the thermal spray layer includes at least one first solid lubricant composed of a sulfide and one second solid lubricant composed of a fluoride. 
     
     
         19 . A thermal spray layer in accordance with  claim 18 , wherein the proportion by volume of sulfide amounts to 0.1% to 15% by volume, preferably 1% to 6% by volume. 
     
     
         20 . A thermal spray layer in accordance with  claim 18 , wherein the sulfide is only MoS 2  and/or WS 2 , except for contaminants. 
     
     
         21 . A thermal spray layer in accordance with  claim 18 , wherein the proportion by volume of fluoride amounts to 0.05% to 20% by volume, preferably 1% to 10% by volume. 
     
     
         22 . A thermal spray layer in accordance with  claim 18 , wherein the fluoride is only CaF 2  and/or BaF 2 , except for contaminants. 
     
     
         23 . A thermal spray layer in accordance with  claim 22 , wherein CaF 2  and BaF 2  are present as a eutectic. 
     
     
         24 . A thermal spray layer in accordance with  claim 18 , wherein the thermal spray layer is composed only of, except for contaminants, a sulfide, a fluoride and the remainder of FeTiO 3  as a base material. 
     
     
         25 . A thermal spray layer in accordance with  claim 18 , wherein the thermal spray layer additionally includes a nitride. 
     
     
         26 . A thermal spray layer in accordance with  claim 25 , wherein the proportion by volume of nitride amounts to 0.1% to 8% by volume, preferably 1% to 5% by volume. 
     
     
         27 . A thermal spray layer in accordance with  claim 25 , wherein the nitride is only hexagonal BN and/or CrN. 
     
     
         28 . A thermal spray layer in accordance with  claim 25 , wherein the thermal spray layer is composed only of, except for contaminants, a nitride, a sulfide, a fluoride and the remainder of FeTiO 3  as a base material. 
     
     
         29 . A spraying method of manufacturing a thermal spray layer in accordance with  claim 18 , wherein the spraying method is a thermal spraying method. 
     
     
         30 . A spraying method in accordance with  claim 29 , wherein the thermal spraying method is a plasma spraying method. 
     
     
         31 . A spraying method in accordance with  claim 29 , wherein the thermal spraying method is a flame spraying method. 
     
     
         32 . A spraying method in accordance with  claim 29 , wherein the spraying method is a powder spraying method or a wire spraying method. 
     
     
         33 . Use of a spray powder composed of a spray material in accordance with  claim 1  for manufacturing a thermal spray layer. 
     
     
         34 . Use of a spray wire in accordance with  claim 17  for manufacturing a thermal spray layer.