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Thermally Sprayed Coatings as Effective Tool Surfaces in Sheet Metal Forming Applications

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Abstract

Two approaches to produce wear-resistant effective surfaces for deep drawing tools by thermal arc wire spraying of hard materials are presented. Arc wire spraying is a very economic coating technique due to a high deposition rate. The coated surface is very rough compared to that of conventional sheet metal forming tools. In the first approach, the coated surface is smoothed in a subsequent CNC-based incremental roller burnishing process. In this process, the surface asperities on the surface are flattened, and the roughness is significantly reduced. In the second approach, the hard material coatings are not sprayed directly on the tool but on a negative mould. Afterward, the rough “as-sprayed” side of the coating is backfilled with a polymer. The bonded hard metal shell is removed from the negative mould and acts as the surface of the hybrid sheet metal forming tool. Sheet metal forming experiments using tools based on these two approaches demonstrate that they are suitable to form high-strength steels. Owing to a conventional body of steel or cast iron, the first approach is suitable for large batch sizes. The application of the second approach lies within the range of small up to medium batch size productions.

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Acknowledgments

The Collaborative Research Center Program titled “3D-Surface Engineering of Tools for Sheet Metal Forming—Manufacturing, Modelling, Machining (SFB708)” is kindly supported by the German Research Foundation (DFG)—the central public funding organization for academic research in Germany.

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Authors and Affiliations

  1. Institute of Forming Technology and Lightweight Construction, TU Dortmund University, Baroper Straße 301, 44227, Dortmund, Germany

    V. Franzen, J. Witulski, A. Brosius, M. Trompeter & A. E. Tekkaya

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  1. V. Franzen
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  2. J. Witulski
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  3. A. Brosius
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  4. M. Trompeter
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  5. A. E. Tekkaya
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Correspondence to V. Franzen or J. Witulski.

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Franzen, V., Witulski, J., Brosius, A. et al. Thermally Sprayed Coatings as Effective Tool Surfaces in Sheet Metal Forming Applications. J Therm Spray Tech 20, 939–947 (2011). https://doi.org/10.1007/s11666-011-9627-z

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  • DOI: https://doi.org/10.1007/s11666-011-9627-z

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