3D printing conquers new branches of production due to becoming a more reliable and professional method of manufacturing. The benefits of additive manufacturing such as part optimization, weight reduction, and ease of prototyping were factors accelerating the popularity of 3D printing. Additive manufacturing has found its niches, inter alia, in automotive, aerospace and dentistry. Although further research in those branches is still required, in some specific applications, additive manufacturing (AM) can be beneficial. It has been proven that additively manufactured parts have the potential to out perform the conventionally manufactured parts due to their mechanical properties; however, they must be designed for specific 3D printing technology, taking into account its limitations. The maritime industry has a long-standing tradition and is based on old, reliable techniques; therefore it implements new solutions very carefully. Besides, shipbuilding has to face very high classification requirements that force the use of technologies that guarantee repeatability and high quality. This paper provides information about current R&D works in the field of implementing AM in shipbuilding, possible benefits, opportunities and threats of implementation.
Coatings of metal and ceramic composite were applied on the steel specimens using the subsonic process of flame spraying. The specimens were then subjected to both cold and hot plastic working by rolling and also cold pressing by the hydraulic press. Plastic working is an alternative to machining, as the method of finishing of coats applied by flame spraying. The article presents the findings of the research into the possibility of using plastic working (hot and cold rolling and pressing) to obtain the corrosion properties of the flame sprayed Ni-Al alloy coatings and Ni-Al-Al2O3composite coatings. The alloy coatings had a single-phase structure, of the maximum 10% aluminium solubility in the crystal lattice of nickel, whereas in the composite coatings the volume content of non-metallic material Al2O3was 15% and 30 %. After finishing the adhesion reduction, cracks on the surface and cross-sections of coatings was not observed. The largest value of strain hardening of alloy coating Ni-5%Al was stated after pressing. The composite coatings obtain by flame spraying be characterized by big surface roughness (Ra= 13.3 µm). The plastic working caused decrease surface roughness. Minimum value of Raparameter was observed after hot rolling. It was found that maximal roughness was presented after pressing. The corrosion tests were performed in 0.01 M H2SO4solution by potentiokinetic technique. The article presents the effect of dispersion phase of Al2O3on corrosion properties of composite coatings on the nickel base. The corrosion rate was dependent on method of plastic working. The increasing drafts resulted in rise corrosion current density and decrease in value of corrosion potential.
The paper presents the effect of dispersion phase of Al2O3 on selected potential properties of composite coatings on the nickel base. Coatings of Ni-Al-Al2O3 were applied on the steel specimens using the subsonic process of flame spraying. The specimens were then subjected to both cold and hot plastic working by rolling and also cold pressing by the hydraulic press. Plastic working is an alternative to machining, as the method of finishing of coats applied by flame spraying. The paper presents the findings of the research into the possibility of using plastic working (hot and cold rolling and pressing) to obtain the selected properties of the flame sprayed Ni-Al alloy coatings and Ni-Al-Al2O3 composite coatings. The alloy coatings had a single-phase structure, namely boundary solution α , of the maximum 10% aluminium solubility in the crystal lattice of nickel, whereas in the composite coatings the volume content of non-metallic material Al2O3 was: 0, 15, and 30 %.
Modern materials on intermetallic matrix are in the scope of research of many scientific – research centers in Poland [1]. Intermetallic systematic alloys containing aluminium have high resistance to oxidation, abrasive corrosion and fatigue as well as heat resistance. That is why they are applied in the production of machine parts used in hard service conditions (internal combustion turbine blades, exhaust valves, turbo-blower rotors) [2]. Intermetallic coatings can be obtained by means of plasma spraying. Thermal spraying technology is widely used due to the possibility of increasing the service properties in surface layers (strength property, tribological, anti-corrosive and decorative property) as well as coating application on machine parts elements, on tools for plastic working (forging moulds busters, piston rods, gear wheels teeth, crank journals, valve seats, and combustion engine cylinders) [3, 4]. NiAl and Ni3Al coatings are characterized by high fatigue resistance, heat resistance and considerable corrosion resistance [5]. Coatings obtained by thermal spraying have high surface roughness. Thus, subsequent plastic treatment is advisable for plasma-sprayed intermetallic coatings. Therefore it is vital to define to what extent the change of unit pressure will influence reduction of surface roughness of intermetallic coatings. For this purpose experimental upsetting research was carried out on C45 steel samples having NiAl and Ni3Al coatings for the following unit pressures p = 500 MPa, p = 800 MPa, p = 1100 MPa.
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