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Flame Spraying of Polymer-Abrasive Composites

Yu. Korobov, M. Belotserkovsky, A. Grishchenko


Polymer-based abrasive tools are distinguished by higher elasticity and resistance to chemically active media compared to tools with metal and ceramic binders. The former are effective at processing complex-profile and non-rigid surfaces. Tools based on coatings containing abrasive phenol- formaldehyde/epoxy resins and vulcanites are characterized by high cost and toxicity. In this paper, a study of composite flame-sprayed coatings, consisting of thermoplastic polymers and silicon carbide (volume ratio of 50-50), was conducted. Changes in adhesive strength, surface morphology, and wear resistance when varying spraying modes were evaluated. A rational range of technological parameters (surface pretreatment, oxidant-fuel ratio in the spray jet, coating cooling rate, ratios of abrasive and polymer particles) is established. This corresponds to the sprayed coating’s higher level of adhesion strength and wear resistance. An abrasive-polymer tool consisting of epoxy resin and an abrasive filler was used as an analogue. Full-scale tests on a root-crop cleaning machine showed that the wear of the developed thermal sprayed coatings did not exceed the permissible value for the analogue’s average service life.

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