COATING LAYER WITH PROTECTION AND THERMAL CONDUCTIVITY

Abstract

A coating layer with well protection and thermal conductivity has a workpiece; and a coating layer with a thickness ranged between 160˜500 micrometer deposited on the workpiece; wherein, the coating layer is formed by the feedstock material, the feedstock material is Al—Cu—Mo—W, Al/B4C, CoCrAlY/Al2O3, Cr3C2—NiCr/SiC—Ni, Cr3C2—NiCr/SiC—Ni treated with Ball mill or Ni—Al—Mo—W. The coating layer is able to avoid wear of the surface of the workpiece, and has well protection and thermal conductivity, to avoid the situation of damage or mechanical property changing occurred due to the temperature of the surface rising caused by the friction.

Description

This is a continuation in part of application Ser. No. 13/465,344, filed May 7, 2012, now abandoned.

TECHNICAL FIELD

The present disclosure relates to a coating layer with well protection and thermal conductivity.

TECHNICAL BACKGROUND

Operationally, modern wheel rims that are generated used on wheeled vehicles are constantly working under rough condition as the wheeled vehicles are designed to meet the challenge of bad weather, treacherous terrain. Nevertheless, due to lacking the consideration of surface protection and heat dissipation in design, most wheel rims that are currently available on the market can easily be damaged in operation by regional abrasion or by abnormal temperature fluctuations. Not to mention that a wheel rim without any protective coating can be vulnerable to and easily be eroded or corroded by environmental factors, such as rainfall and direct sunlight.

Although there are already a variety of coatings available, there is still none designed for and applied on wheel rims. Thus, beside for the means for forming a coating on a wheel rim, there are many to be improved in the porosity, microhardness, bonding strength and wear volume loss relating to the coatings that are currently available.

TECHNICAL SUMMARY

The present disclosure relates to a coating layer with well protection and thermal conductivity, being basically a method for forming a coating with satisfactory porosity, microhardness, bonding strength and wear volume loss on a workpiece for improving the surface protection and heat dissipation of the workpiece.

In an embodiment, the present disclosure provides a coating layer with protection and thermal conductivity, comprising:

• • a workpiece; and
  • a coating layer with a thickness ranged between 160˜500 micrometer deposited on the workpiece;
  • wherein, the coating layer is formed by the feedstock material, the feedstock material is Al—Cu—Mo—W, Al/B₄C, CoCrAlY/Al₂O₃, Cr₃C₂—NiCr/SiC—Ni, Cr₃C₂—NiCr/SiC—Ni treated with Ball mill or Ni—Al—Mo—W

The coating layer is featuring in that: the porosity, microhardness, bonding strength and wear volume loss of the coating layer are improved, and by the setting of the coating layer on a workpiece, both the surface protection and thermal conductivity of the workpiece are enhanced.

Moreover, in a condition when the workpiece is substantially a wheel rim, the coating layer on the wheel rim can protect the same from being damaged in operation by regional abrasion or by abnormal temperature fluctuations. Thereby, the wheel rim with the coating layer is protected from being eroded or corroded by environmental factors, such as rainfall and direct sunlight.

In addition, not only the coating layer can protect the surface of the workpiece from being damaged by any friction or collision happening on the surface of the workpiece, but also by the thermal conductivity of the coating layer, any regional abnormal temperature fluctuation on the surface of the workpiece can be dissipated rapidly for preventing the workpiece from being damaged thereby and thus maintaining the mechanical properties of the workpiece unchanged.

Further scope of applicability of the present application will become more apparent from the detailed description given hereinafter. However, it should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the disclosure, are given by way of illustration only, since various changes and modifications within the spirit and scope of the disclosure will become apparent to those skilled in the art from this detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The present disclosure will become more fully understood from the detailed description given herein below and the accompanying drawings which are given by way of illustration only, and thus are not limitative of the present disclosure and wherein:

FIG. 1 is a flow chart depicting the steps in a method for providing a coating layer with protection and thermal conductivity according to an exemplary embodiment of the present disclosure.

FIG. 2 is a cross sectional view of a workpiece used in the present disclosure.

FIG. 3 is a cross sectional view of a wheel rim, being used as a workpiece in the present disclosure.

FIG. 4 is a diagram showing the porosity achievable in a coating layer of the present disclosure.

FIG. 5 is a diagram showing the micro hardness achievable in a coating layer of the present disclosure.

FIG. 6 is a diagram showing the bonding strength achievable in a coating layer of the present disclosure.

FIG. 7 is a diagram showing the wear volume loss achievable in a coating layer of the present disclosure.

FIG. 8 is a diagram showing the deposition rate achievable in a coating layer of the present disclosure.

FIG. 9 is a diagram showing the bonding strength achievable in a coating layer of the present disclosure.

FIG. 10 is a diagram showing the micro hardness achievable in a coating layer of the present disclosure.

FIG. 11 is a diagram showing the wear volume loss achievable in a coating layer of the present disclosure.

FIG. 12 is a diagram showing the deposition rate achievable in a coating layer of the present disclosure.

FIG. 13 is a diagram showing the bonding strength achievable in a coating layer of the present disclosure.

FIG. 14 is a diagram showing the micro hardness achievable in a coating layer of the present disclosure.

FIG. 15 is a diagram showing the wear volume loss achievable in a coating layer of the present disclosure.

FIG. 16 is a diagram showing the deposition rate achievable in a coating layer of the present disclosure.

FIG. 17 is a diagram showing the bonding strength achievable in a coating layer of the present disclosure.

FIG. 18 is a diagram showing the micro hardness achievable in a coating layer of the present disclosure.

FIG. 19 is a diagram showing the wear volume loss achievable in a coating layer of the present disclosure.

FIG. 20 is a diagram showing the wear volume loss achievable in a coating layer of the present disclosure.

DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

For your esteemed members of reviewing committee to further understand and recognize the fulfilled functions and structural characteristics of the disclosure, several exemplary embodiments cooperating with detailed description are presented as the follows.

Please refer to FIG. 1, which is a flow chart depicting the steps perform in a method for providing a coating layer with protection and thermal conductivity according to an exemplary embodiment of the present disclosure. As shown in FIG. 1. the method starts from step 10. At the step 10, a feedstock material, which can be a cermet powder or a sintering powder, is provided; and then the flow proceeds to step 11. In an embodiment, the feedstock material is substantially a cermet powder, whereas the cermet powder can be a mixed powder of a ceramic powder with a metal coating and a metal powder, in which the ceramic powder can be made of a material selected from the group consisting of: aluminum oxide, titanium oxide, chromium oxide, titanium carbide, boron carbide, chromium carbide, silicon carbide, aluminum nitride, titanium nitride, boron nitride, titanium boride and the combinations of at least two forgoing materials. In a boarder picture, the ceramic powder is made of a material selected from the group consisting of: an oxide, a carbide, a nitride, a boride and the combinations of at least two forgoing materials. In addition, the metal coating is deposited onto the ceramic powder by a means of electroless plating, whereas the metal to be used for forming the metal coating can be a metal selected from the group consisting of: cobalt, nickel and aluminum. Furthermore, in this embodiment, the metal powder is made of a metal selected from the group consisting of: a aluminum powder, a aluminum alloy powder, a molybdenum powder, a molybdenum alloy powder, a tungsten powder, a tungsten alloy powder, a cobalt powder, a cobalt alloy powder, a nickel powder, a nickel alloy powder, an iron powder, an iron alloy powder, a niobium powder, a niobium alloy powder, a yttrium powder, a yttrium alloy powder, a nickel chromium powder, a nickel chromium alloy powder, a nickel chromium aluminum powder, a nickel chromium aluminum alloy powder, a cobalt chromium aluminum yttrium powder, a cobalt chromium aluminum yttrium alloy powder, a nickel chromium aluminum yttrium powder, a nickel chromium aluminum yttrium alloy powder, and the combinations of at least two forgoing materials.

In another embodiment when the feedstock material is substantially a sintering powder, the sintering powder is prepared and formed by a process comprising the steps of: mixing a ceramic powder with metal coating, a metal powder and a bonding agent so as to form a mud mixture; and granulating and sintering the mud mixture in a vacuumed environment at a temperature ranged between 900° C. to 1100° C. so as to improve the bonding strength between the metal powder and the ceramic powder and thus form the sintering powder.

At step 11, the feedstock material is coated onto a workpiece 20 into a coating layer 21 with a thickness ranged between 160˜500 micrometer, as shown in FIG. 2. It is noted that the workpiece 20 can be a metal substrate or a ceramic substrate, and the feedstock material can be coated to the workpiece by a spraying process, whereas the spraying process is a process selected from the group consisting of: a powder coating process, an arc spraying process, flame spraying process, a plasma thermal spraying process and a high velocity oxy-fuel (HVOF) process.

In an embodiment when a HVOF process is selected for spraying the coating layer 21, it is common to choose the cobalt chromium aluminum yttrium powder to be used as the metal powder in the feedstock material which is accounted for about 90 percent of the whole feedstock material; and the ceramic powder which is accounted for about 10 percent of the feedstock material should has a particle size ranged between 50 μm and 70 μm, and with 99% purity. In addition, the flow gas flow rate for the HVOF process should be controlled within the range of 20 l/min to 100 l/min, the oxygen flow rate of the same should be controlled within the range of 300 l/min to 500 l/min, and the carrier gas flow rate of the same should be controlled within the range of 10 l/min to 50 l/min.

Please refer to FIG. 3, which is a cross sectional view of a wheel rim, being used as a workpiece in the present disclosure. In this embodiment, the method for forming a coating layer is basically unchanged, but is different in that: the workpiece is a wheel rim 30 instead of the aforesaid metal or ceramic substrate, and accordingly, the coating layer 32 is formed on the surface relating to the two flanges of the wheel rim 30 at a thickness ranged between 160˜500 micrometer. Moreover, the wheel rim 30 can be made of a metallic material or a polymer material, whereas the metallic material is a material selected from the group consisting of: aluminum, an aluminum alloy, iron, and an iron alloy; and the polymer material is a material selected from the group consisting of: a plastic, rubber and a kind of fiber.

Please refer to FIG. 4 to FIG. 7, which are diagrams respectively showing the porosity, the microhardness, the bonding strength, and the wear volume loss that are achievable in a coating layer of the present disclosure. In FIG. 4 to FIG. 7, S1 represents an Al/B ₄C coating layer, S2 represents a Co—Cr—Al—Y/Al₂O₃ coating layer, S3 represents an Al—Cu—Mo—W coating layer, and S4 represents a Cr₃C₂—NiCr/SiC—Ni coating layer.

As shown in FIG. 4, the porosity of S1 is in a range of 6%˜17.8%, while the porosities of S2 and S3 can be lowered to 2%, whereas the porosity is a measure of the void (i.e., “empty”) spaces in the coating layer, and is a fraction of the volume of voids over the total volume of the coating layer.

As the result of a Vickers hardness test shown in FIG. 5, the microhardness of S1 is lower than 100 Mpa, the microhardness of S2 is ranged between 300 Mpa and 200 Mpa, the microhardness of S3 is ranged between 200 Mpa and 300 Mpa, and the microhardness of S4 is ranged between 500 Mpa and 700 Mpa.

As shown in FIG. 6, the bonding strength of S1 is ranged between 4000 psi and 5000 psi, the bonding strength of S2 is ranged between 8000 psi and 9000 psi, and the bonding strength of S3 and S4 are respectively ranged between 7000 psi and 8000 psi.

As shown in FIG. 7, the wear volume loss of S1 is ranged between 160 mm³ and 200 mm³, the wear volume loss of S2 and S4 are respectively ranged between 0 mm³ and 50 mm³, and the wear volume loss of S3 is ranged between 100 mm³ and 170 mm³.

As the characteristic values disclosed in FIG. 4 to FIG. 7, it is obvious that the coating layer of the present disclosure can perform better than other coating layer currently available in porosity, in microhardness, in bonding strength and in wear volume loess. Moreover, in a thermal conductivity test, it is realized that by the addition of silicon carbide into Cr₃C₂, the thermal conductivity of the resulting coating layer can be increased from 45.88 W/mK to 70.8 W/mK.

In an embodiment, the feedstock material is Al—Cu—Mo—W, Al/B₄C, CoCrAlY/Al₂O₃, Cr₃C₂—NiCr, Cr₃C₂—NiCr/SiC—Ni or Cr₃C₂—NiCr/SiC—Ni treated with Ball mill.

The composition of Al—Cu—Mo—W is 30˜35 wt % Al—Cu, 30˜35 wt % Mo and 30˜35 wt % W. The best composition of Al—Cu—Mo—W is 33.3 wt % Al—Cu, 33.3 wt %

Mo and 33.3 wt % W.

The composition of Al/B₄C is 20˜40 wt % B₄C and 80˜60 wt % Al. The best composition of Al/B₄C is 30 wt % B₄C.

The composition of Cr₃C₂—NiCr is 15˜30 wt % NiCr and 85˜70 wt %Cr3C₂. The best composition of Cr₃C₂—NiCr is 22 wt % NiCr.

The composition of CoCrAlY/Al₂O₃ is 10˜20 wt % Al₂O₃ and 90˜80 wt % CoCrAlY. The best composition of CoCrAlY/Al₂O₃ is 17 wt % Al₂O₃.

The composition of Cr₃C₂—NiCr/SiC—Ni is 20˜40 wt % SiC—Ni and 80˜60 wt % Cr₃C₂—NiCr. The best composition of Cr₃C₂—NiCr/SiC—Ni is 30 wt % SiC—Ni.

In an embodiment, the feedstock material is Ni—Al—Mo—W. The composition of Ni—Al—Mo—W is 30˜35 wt % Ni-5Al, 30˜35 wt % Mo and 30˜35 wt % W. The best composition of Ni—Al—Mo—W is 33.3 wt % Ni-5Al, 33.3 wt % Mo and 33.3 wt % W. As shown in FIG. 8, the deposition rate of D1 is ranged between 23 μ/pass and 26 μ/pass, the deposition rate of D2 is ranged between 4 μ/pass and 6 μ/pass, the deposition rate of D3 is ranged between 18 μ/pass and 22 μ/pass, the deposition rate of D4 is ranged between 12 μ/pass and 16 μ/pass, the deposition rate of D5 is ranged between 7 μ/pass and 9 μ/pass, and the deposition rate of D6 is ranged between 2 μ/pass and 4 μ/pass.

The D1 represents the deposition rate of Al—Cu—Mo—W coating layer. The D2 represents the deposition rate of Al/B₄C coating layer. The D3 represents the deposition rate of CoCrAlY/Al₂O₃ coating layer. The D4 represents the deposition rate of Cr₃C₂—NiCr coating layer. The D5 represents the deposition rate of Cr₃C₂—NiCr/SiC—Ni coating layer. The D6 represents the deposition rate of Cr₃C₂—NiCr/SiC—Ni treated with Ball mill coating layer. The feedstock material of Al—Cu—Mo—W and the CoCrAlY/Al₂O₃ can reduce the cost of the coating layer manufacturing.

The thickness of D1 is 240˜270 μm, the better thickness is 259 μm. The thickness of D2 is 238˜265 μm, the better thickness is 252 μm. The thickness of D3 is 225˜250 μm, the better thickness is 237 μm. The thickness of D4 is 235˜260 μm, the better thickness is 242 μm. The thickness of D5 is 225˜250 μm, the better thickness is 236 μm. The thickness of D6 is 230˜250 μm, the better thickness is 240 μm.

As shown in FIG. 9, the bonding strength of B1 is ranged between 6500 psi and 7200 psi, the bonding strength of B2 is ranged between 3800 psi and 5800 psi, the bonding strength of B3 is ranged between 7200 psi and 9000 psi, the bonding strength of B4 is ranged between 7200 psi and 12000 psi, the bonding strength of B5 is ranged between 8100 psi and 9000 psi, and the bonding strength of B6 is ranged between 6200 psi and 8100 psi.

The B1 represents the bonding strength of Al—Cu—Mo—W coating layer. The B2 represents the bonding strength of Al/B₄C coating layer. The B3 represents the bonding strength of CoCrAlY/Al₂O₃ coating layer. The B4 represents the bonding strength of Cr₃C₂—NiCr coating layer. The B5 represents the bonding strength of Cr₃C₂—NiCr/SiC—Ni coating layer. The B6 represents the bonding strength of Cr₃C₂—NiCr/SiC—Ni treated with Ball mill coating layer. The B3, B4 and B5 are with better bonding strength.

As shown in FIG. 10, the micro hardness of M1 is ranged between 200 (Hv300) and 300 (Hv300), the micro hardness of M2 is ranged between 100 (Hv300) and 180 (Hv300), the micro hardness of M3 is ranged between 350 (Hv300) and 450 (Hv300), the micro hardness of M4 is ranged between 610 (Hv300) and 900 (Hv300), the micro hardness of M5 is ranged between 750 (Hv300) and 860 (Hv300), and the micro hardness of M6 is ranged between 540 (Hv300) and 630 (Hv300).

The M1 represents the micro hardness of Al—Cu—Mo—W coating layer. The M2 represents the micro hardness of Al/B₄C coating layer. The M3 represents the micro hardness of CoCrAlY/Al₂O₃ coating layer. The M4 represents the micro hardness of Cr₃C₂—NiCr coating layer. The M5 represents the micro hardness of Cr₃C₂—NiCr/SiC—Ni coating layer. The M6 represents the micro hardness of Cr₃C₂—NiCr/SiC—Ni treated with Ball mill coating layer. The M4, M5 and M6 are with better micro hardness.

As shown in FIG. 11, the wear loss of W1 is ranged between 150 mm ³ and 250 mm ³, the wear loss of W2 is ranged between 80 mm ³ and 180 mm ³, the wear loss of W3 is ranged between 150 mm ³ and 200 mm ³, the wear loss of W4 is ranged between 15 mm ³ and 40 mm ³, and the wear loss of W5, W6 and W7 are ranged between 5 mm ³ and 20 mm ³.

The W1 represents the wear loss of Al substrate coating layer. The W2 represents the wear loss of Al—Cu—Mo—W coating layer. The W3 represents the wear loss of Al/B₄C coating layer. The W4 represents the wear loss of CoCrAlY/Al₂O₃ coating layer. The W5 represents the wear loss of Cr₃C₂—NiCr coating layer. The W6 represents the wear loss of Cr₃C₂—NiCr/SiC—Ni coating layer. The W7 represents the wear loss of Cr₃C₂—NiCr/SiC—Ni treated with Ball mill. The W4˜W7 are with better anti-wear loss.

As shown in FIG. 12, the deposition rate of D7 is ranged between 20 μ/pass and 31 μ/pass, the deposition rate of D8 is ranged between 24 μ/pass and 50 μ/pass, the deposition rate of D9 is ranged between 30 μ/pass and 49 μ/pass, the deposition rate of D10 is ranged between 24 μ/pass and 45 μ/pass, the deposition rate of D11 is ranged between 11 μ/pass and 25 μ/pass, and the deposition rate of D12 is ranged between 30 μ/pass and 50 μ/pass.

The D7 represents the deposition rate of APS (Air. Plasma Spray) W (Wolfram) coating layer. The D8 represents the deposition rate of APS Mo (Manganese) coating layer. The D9 represents the deposition rate of APS Al—Cu—Mo—W coating layer. The D11 represents the deposition rate of HVOF (High Velocity Oxy-Fuel) Ni-5Al—Mo—W coating layer. The D12 represents the deposition rate of Arc Spary Mo coating layer.

The thickness of D7 is 225˜240 μm, the better thickness is 234.5 μm. The thickness of D8 is 195˜215 μm, the better thickness is 205.8 μm. The thickness of D9 is 230˜245 μm, the better thickness is 237.8 μm. The thickness of D10 is 280˜295 μm, the better thickness is 287.5 μm. The thickness of D11 is 250˜270 μm, the better thickness is 260 μm. The thickness of D12 is 260˜275 μm, the better thickness is 266.3 μm. The D7˜D12 are with the better deposition rate.

As shown in FIG. 13, the bonding strength of B7 (APS W coating layer) is ranged between 750 psi and 4300 psi, the bonding strength of B8 (APS Mo coating layer) is ranged between 4000 psi and 7600 psi, the bonding strength of B9 (APS Al—Cu—Mo—W coating layer) is ranged between 6000 psi and 10000 psi, the bonding strength of B10 (APS Ni-5Al—Mo—W coating layer) is ranged between 7500 psi and 8500 psi, the bonding strength of B11 (HVOF Ni-5Al—Mo—W coating layer) is ranged between 8000 psi and 10000 psi, and the bonding strength of B12 (Arc Spray Mo coating layer) is ranged between 2000 psi and 7500 psi. The B9˜B11 are better choices, if considered of the bonding strength.

As shown in FIG. 14, the micro hardness of M7 (APS W coating layer) is ranged between 200 (Hv300) and 300 (Hv300), the micro hardness of M8 (APS Mo coating layer) is ranged between 200 (Hv300) and 550 (Hv300), the micro hardness of M9 (APS Al—Cu—Mo—W coating layer) is ranged between 150 (Hv300) and 250 (Hv300), the micro hardness of M10 (APS Ni-5Al—Mo—W coating layer) is ranged between 210 (Hv300) and 390 (Hv300), the micro hardness of M11 (HVOF Ni-5Al—Mo—W coating layer) is ranged between 220 (Hv300) and 370 (Hv300), and the micro hardness of M12 (Arc Spray Mo coating layer) is ranged between 300 (Hv300) and 800 (Hv300). The M12, M11 and M8 are with the better micro hardness.

As shown in FIG. 15, the wear loss of W8 (Al substrate coating layer) is ranged between 150 mm ³ and 250 mm ³, the wear loss of W9 (APS W coating layer) is ranged between 60 mm ³ and 100 mm ³, the wear loss of W10 (APS Mo coating layer) is ranged between 40 mm ³ and 75 mm ³, the wear loss of W11 (APS Al—Cu—Mo—W coating layer) is ranged between 60 mm ³ and 90 mm ³, the wear loss of W12 (APS Ni-5Al—Mo—W coating layer) is ranged between 45 mm ³ and 50 mm ³, the wear loss of W13 (HVOF Ni-5Al—Mo—W coating layer) is ranged between 75 mm ³ and 95 mm ³ , the wear loss of W14 (Arc Spray Mo coating layer) is ranged between 25 mm ³ and 35 mm ³. The W10, W12 and W14 are with the better anti-wear loss.

As shown in FIG. 16, the deposition rate of D13 (HOVF DJ GUN Cr₃C₂—NiCr5260 coating layer, shorted as DJ Cr₃C₂—NiCr5260 ) is ranged between 15 μ/pass and 20 μ/pass, the deposition rate of D14 (DJ Cr₃C₂—NiCr coating layer) is ranged between 10 μ/pass and 16 μ/pass, and the deposition rate of D15 (DJ Cr₃C₂—NiCr/SiC—Ni coating layer) is ranged between 3 μ/pass and 8 μ/pass. The D13 is with the better deposition rate.

As shown in FIG. 17, the bonding strength of B13 (DJ Cr₃C₂—NiCr5260 coating layer) is ranged between 7500 psi and 11500 psi, the bonding strength of B14 (DJ Cr₃C₂—NiCr coating layer) is ranged between 6000 psi and 12000 psi, and the bonding strength of B15 (DJ Cr₃C₂—NiCr/SiC—Ni coating layer) is ranged between 8500 psi and 13500 psi. The B13˜B15 are with the better bonding strength.

As shown in FIG. 18, the micro hardness of M13 (DJ Cr₃C₂—NiCr5260) is ranged between 850 (Hv300) and 1150 (Hv300), the micro strength of M14 (DJ Cr₃C₂—NiCr coating layer) is ranged between 870 (Hv300) and 1175 (Hv300), and the micro strength of M15 (DJ Cr₃C₂—NiCr/SiC—Ni coating layer) is ranged between 650 (Hv300) and 870 (Hv300). The M13˜M15 are with the better micro strength.

As shown in FIG. 19, the wear loss of W15 (Al substrate coating layer) is ranged between 150 mm³ and 250 mm³, the wear loss of W16 (DJ Cr₃C₂—NiCr5260 coating layer) is ranged between 1 mm³ and 5 mm³, the wear loss of W17 (DJ Cr₃ C₂—NiCr coating layer) is ranged between 1 mm³ and 5 mm³, and the wear loss of W16 (Cr₃C₂—NiCr/SiC—Ni coating layer) is ranged between 1 mm³ and 5 mm³. The W16˜W19 are with the better anti-weat loss.

As shown in FIG. 20, the wear loss of S5 (Al substrate coating layer) is ranged between 170 mm³ and 255 mm³, the wear loss of S6 (HVOF Al—Cu—Mo—W coating layer) is ranged between 125 mm³ and 180 mm³, the wear loss of S7 (HVOF Al—B₄C coating layer) is ranged between 150 mm³ and 200 mm³, the wear loss of S8 (HVOF CoCrAlY/Al₂O₃ coating layer) is ranged between 15 mm³ and 40 mm³, the wear loss of S9 (HVOF Cr₃C₂—NiCr coating layer) is ranged between 1 mm³ and 5 mm³, the wear loss of S10 (HVOF Cr₃C₂—NiCr/SiC—Ni coating layer) is ranged between 1 mm³ and 5 mm³, the wear loss of S11 (HVOF Cr₃C₂—NiCr/SiC—Ni treated with Ball Mill coating layer) is ranged between 1 mm³ and 5 mm³, the wear loss of S12 (APS W coating layer) is ranged between 75 mm³ and 101 mm³, the wear loss of S13 (APS Mo coating layer) is ranged between 25 mm³ and 55 mm³, the wear loss of S14 (APS Al—Cu—Mo—W coating layer) is ranged between 75 mm³ and 90 mm³, the wear loss of S15 (APS Ni-5Al—Mo—W coating layer) is ranged between 45 mm³ and 50 mm³, the wear loss of S16 (HVOF Ni-5Al—Mo—W coating layer) is ranged between 75 mm³ and 90 mm³, the wear loss of S17 (Arc Spray Mo coating layer) is ranged between 30 mm³ and 40 mm³, the wear loss of S18 (DJ Cr₃C₂—NiCr5260 coating layer) is ranged between 1 mm³ and 5 mm³, the wear loss of S19 (DJ Cr₃C₂—NiCr5 coating layer) is ranged between 1 mm³ and 5 mm³, and the wear loss of S20 (DJ Cr₃C₂—NiCr/SiC—Ni coating layer) is ranged between 1 mm³ and 5 mm³. The S9˜S11 and S18˜S20 are with the better anti-wear loss.

To sum up, the present disclosure provides a method for forming a coating layer on a workpiece using a feedstock material with better surface protection and thermal conductivity. Thereby, the coating layer can protect the operating workpiece from being damaged by regional abrasion, and also is capable of conducting heat out of the workpiece so as to be dissipated for preventing the workpiece from being damaged by abnormal temperature fluctuations.

Taking a wheel rim for instance, it is known that an operating wheel rim without the coating layer of the present disclosure can easily be damaged by regional abrasion or by abnormal temperature fluctuations, but by the coating layer with improved porosity, microhardness, bonding strength and wear volume loss, not only the wheel rim is protected from any region abrasion, but also the heat that is generated in the operation of the wheel rim can be conducted out of the same so as to be dissipated. Moreover, a wheel rim with the coating is protected from being eroded or corroded by environmental factors, such as rainfall and direct Sun tight.

With respect to the above description then, it is to be realized that the optimum dimensional relationships for the parts of the disclosure, to include variations in size, materials, shape, form, function and manner of operation, assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present disclosure.

Claims

1. A coating layer with well protection and thermal conductivity comprising:

a workpiece; and

a coating layer with a thickness ranged between 160˜500 micrometer deposited on the workpiece;

wherein, the coating layer is formed by the feedstock material, the feedstock material is Al—Cu—Mo—W, Al/B4C, CoCrAlY/Al2O3, Cr3C2—NiCr/SiC—Ni, Cr3C2—NiCr/SiC—Ni treated with Ball mill or Ni—Al—Mo—W.

2. The coating layer of claim 1, wherein a composition of Al—Cu—Mo—W is 30˜35 wt % Al—Cu, 30˜35 wt % Mo and 30˜35 wt % W. The best composition of Al—Cu—Mo—W is 33.3 wt % Al—Cu, 33.3 wt % Mo and 33.3 wt % W.

3. The coating layer of claim 1, wherein a composition of Al/B4C is 20˜40 wt % B4C.

4. The coating layer of claim 1, wherein a composition of CoCrAlY/Al2O3 is 10˜20 wt % Al2O3.

5. The coating layer of claim 1, wherein a composition of Cr3C2-NiCr/SiC—Ni is 20˜40 wt % SiC—Ni.

6. The coating layer of claim 1, wherein a composition of Cr3C2-NiCr/SiC—Ni treated with Ball mill is 20˜40 wt % SiC—Ni.

7. The coating layer of claim 1, wherein a composition of Ni—Al—Mo—W is is 30—35 wt % Ni-5Al, 30˜35 wt % Mo and 30˜35 wt % W.