Functionally Gradient Materials - Synthesis, Process and Performance

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Project Title: Functionally Gradient Materials - Synthesis, Process and Performance
NIST/ATP Project No. 93-01-0055

Date Last Updated: 9/99 Project completed. Summary will not be revised again.

Project Summary:
Caterpillar is developing metal and ceramic deposition technologies for a cost-effective method of applying functional gradient materials (FGM) coatings. The FGM technique produces high-performance coatings on relatively inexpensive base materials such as steel in which the mix of components in the coating changes continuously from the base materials out. FGM coatings can improve wear resistance and strength and reduce the size of gears and bearings; reduce the weight, size, and cost of transmissions and gear boxes for heavy equipment; and extend wear life on cutting surfaces of drilling and earthmoving equipment.

Problems with the current technology include adherence of coatings, and materials costs. Caterpillar will address these problems by evaluating spray deposit consolidation (SDC) and high deposition spray processing (HDSP). SDC combines processes for applying thermomechanical stress to forge a tough metallurgical bond between conventional substrate and coating. HDSP is a new thermal spray technique which lays coatings down 10 to 20 times faster than conventional techniques, and can use much coarser powdered materials at a considerable reduction in cost.

To date, economic analyses and evaluation of spray samples have proven that development of FGM coatings is feasible. Future work will be directed toward development of prototype FGM coatings for additional testing.

Project Keywords: metals, ceramic materials, depositions, despoits, coatings, spray coating, metal spraying

Organization Performing Research: Caterpillar Inc.

Primary Research Contact:
Keith H. Butterfield
Caterpillar Inc.
Technical Center - TCE
131 East Cedar Hills Drive
Mossville, IL 61552
phone: 309-675-1307
fax: 309-675-5815

Date Research Started/Completed: 2/94 - 1/97

Publications Based on Research: None available.

Approximate Project Budget: $3,552,000

Primary Project Funder: US Dept. of Commerce, Technology Administration, National Institute of Standards and Technology (NIST), Advanced Technology Program (ATP)

Funder Contact:
Clare Allocca
US Dept. of Commerce, Technology Administration
National Institute of Standards and Technology (NIST)
Advanced Technology Program (ATP)
100 Bureau Drive, Stop 4701
Administration Building 101, Room. A407
Gaithersburg, MD 20899-4701
phone: 301-975-4359 or 1-800-ATP-FUND (1-800-287-3863)
fax: 301-926-9524 or 301-869-1150
e-mail: clare.allocca@nist.gov
web: http://www.atp.nist.gov