EP0549298A2 - Flame sprayed composite coating - Google Patents

Flame sprayed composite coating Download PDF

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Publication number
EP0549298A2
EP0549298A2 EP92311644A EP92311644A EP0549298A2 EP 0549298 A2 EP0549298 A2 EP 0549298A2 EP 92311644 A EP92311644 A EP 92311644A EP 92311644 A EP92311644 A EP 92311644A EP 0549298 A2 EP0549298 A2 EP 0549298A2
Authority
EP
European Patent Office
Prior art keywords
powder
layer
substrate
metal
composite coating
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP92311644A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP0549298A3 (es
Inventor
James H. Reimer
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Plastic Flamecoat Systems Inc
Original Assignee
Plastic Flamecoat Systems Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Plastic Flamecoat Systems Inc filed Critical Plastic Flamecoat Systems Inc
Publication of EP0549298A2 publication Critical patent/EP0549298A2/en
Publication of EP0549298A3 publication Critical patent/EP0549298A3/xx
Withdrawn legal-status Critical Current

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    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material

Definitions

  • This invention relates to composite coatings applied by flame spraying to an underlying substrate. More particularly, the invention relates to composite flame sprayed coatings comprising an intermediate plastic layer that is flame sprayed onto a substrate, and an overlying metal, metal-containing, or ceramic layer that is flame sprayed onto the plastic layer.
  • thermoplastic material by means of flame spraying
  • methods and devices enable a user to melt powdered thermoplastic resin and apply it to a substrate at coverage rates that make the process acceptable for applying protective coatings over a wide variety of uses.
  • uses can include, for example, coating structural steel used in bridges or other construction, coating piping or vessels that may be subjected to corrosion, coating ship hulls to reduce the rate of barnacle formation and facilitate barnacle removal, and the like.
  • a substrate coating and method of application are disclosed that utilize an intermediate layer of flame sprayed plastic in combination with an overlying layer of flame sprayed, powdered metal, metal-containing particles or ceramic particles.
  • Preferred substrates are metal surfaces, although other substrates can also be used within the scope of the invention.
  • Application of the coating disclosed herein does not require melting or ionization of the metal, metal-containing or ceramic particles used to form the overlying layer.
  • the invention provides a protective composite coating for a substrate, the coating comprising a first continuous layer of flame sprayed thermoplastic, and a second continuous overlying layer of flame sprayed powder partially embedded in the first layer, said powder having a higher melting point than the first layer, and being selected from the group consisting of metal, metal containing materials, and ceramics.
  • the powder is selected from the group of metal-containing materials consisting of metal alloys, metal oxides and metal nitrides.
  • the powder may be selected from the group of metals consisting of copper, aluminium, carbide, tungsten carbide, stellite, chromium, stainless steel, nickel, titanium and alloys thereof.
  • the powder may comprise glass beads.
  • thermoplastic is selected from the group consisting of ethylene methacrylic acid copolymer, ethylene vinyl acetate copolymer and polypropylene.
  • the thermoplastic may be ethylene methacrylic acid copolymer.
  • the substrate is selected from the group consisting of metals, metal-containing materials, ceramic materials, cellulosic materials and polymeric materials.
  • the first layer may have a thickness ranging from about 8mils to about 12mils.
  • the first layer may have a thickness of about 10mils.
  • the second layer has a thickness up to about the thickness of the first layer.
  • the powder has an average particle size that does not exceed the thickness of the first layer.
  • the invention provides a method for coating a substrate comprising the steps of: providing a first powder comprising a major portion of a thermoplastic resin; flame spraying the first powder on to the substrate to form a substantially continuous intermediate layer of thermoplastic resin having an outwardly facing surface opposite the substrate; providing a second powder comprising a major portion of unmelted particles of a material selected from the group consisting of powdered metals, powdered metal-containing materials, and ceramics; and flame spraying the unmelted particles of the second powder onto the intermediate layer in such manner that a substantially continuous overlaying layer is formed which comprises unmelted particles of the second powder embedded in the outwardly facing surface of the intermediate layer.
  • the method may also comprise a step of cleaning the surface of the substrate.
  • the first powder is flame sprayed onto the substrate at a temperature greater than the melting point of the thermoplastic resin.
  • the second powder is flame sprayed onto the substrate at a temperature greater than the melting point of the thermoplastic resin, but less than the melting point of the major portion of the second powder.
  • the method comprises the additional step of cooling the intermediate layer prior to applying the overlying layer.
  • the method comprises the additional step of polishing the overlying layer.
  • the second powder comprises an anti-foulant material.
  • the second powder comprises an abrasion-resistant material.
  • the second powder comprises a corrosion-resistant material.
  • the invention provides a composite coating for a substrate, the coating comprising a first layer of thermoplastic that is flame sprayed onto the substrate, and a second layer of powdered material that is flame sprayed onto the first layer.
  • the thermoplastic is selected from the group consisting of ethylene methacrylic acid, ethylene vinyl acetate and polypropylene.
  • the thermoplastic may be ethylene methacrylic acid.
  • the powdered metal comprises a material selected from the group consisting of copper, aluminium, carbide, tungsten carbide, stellite, chromium, stainless steel, nickel, titanium, and alloys thereof.
  • the powdered metal may comprise copper.
  • the substrate is a metallic surface.
  • the first layer has a thickness ranging from about 8mils to about 12mils.
  • the thickness of the first layer may be about 10mils.
  • the second layer has a thickness that is up to about the thickness of the first layer.
  • the metal powder has an average particle size that does not exceed the thickness of the first layer.
  • the invention provides a composite coating for a substrate, the coating comprising a first layer of thermoplastics that is flame sprayed onto the substrate, and a second layer of powder having a higher melting point than the first layer that is flame sprayed onto the first layer, said powder being selected from the group consisting of metals, metal-containing materials, and ceramics.
  • the invention also extends to a coating as aforesaid, in combination with a substrate.
  • powdered thermoplastic material preferably ethylene methacrylic acid (EMAA) copolymer
  • EVA ethylene methacrylic acid
  • the powder used to form the overlying layer is then heated in a flame sprayer device to a temperature greater than the melting point of the thermoplastic material comprising the intermediate layer, but lower than the melting point of the metal.
  • the heated powder preferably metal or a metal oxide, is then sprayed over the thermoplastic intermediate layer, causing the powder particles to embed in the surface of the thermoplastic.
  • additional metal will not adhere because the metal is not in a molten state.
  • the composite coatings of the invention can be specially adapted for uses such as corrosion-resistant, antifoulant or wear-resistant applications by selecting a powdered material for the overlying layer which exhibits the desired property.
  • an improved spray coating comprises an intermediate layer comprising a major portion of a thermoplastic resin, and an overlying layer that comprises a major portion of a metal, metal-containing, or ceramic powder.
  • the spray coating of the invention can be applied to a wide variety of substrate materials to achieve desirable surface properties and characteristics. Depending upon the particular substrate and the coating materials employed, such application can be performed in the field, at the use site, or in a plant.
  • Exemplary substrates that can be coated in accordance with the present invention include metals, metal-containing materials, ceramic materials, cellulosic materials materials and polymeric materials, provided that such surfaces have been satisfactorily clean, brushed, or otherwise prepared as necessary to facilitate bonding of a thermoplastic intermediate layer to which an overlying layer of powdered metal, metal-containing or ceramic material can subsequently be applied.
  • the surface to be coated is prepared by sand blasting, if necessary, to an SSPC-6 specification to remove all dust and extraneous matter.
  • a powdered thermoplastic material is applied to the substrate to form an intermediate surface coating preferably having a thickness ranging from about 8 to about 12 mils.
  • the intermediate surface coating is flame sprayed onto the substrate as disclosed in United States Patent No. 4,934,595, or in pending United States Patent Application Ser. No. 07 ⁇ 760,866, filed September 16, 1991, the entire specifications of which are incorporated by reference herein.
  • thermoplastic resins for use in forming the intermediate layer of the coating disclosed herein include, for example, EMAA, ethylene vinyl acetate (EVA) and polypropylene, although other similarly effective resins can likewise be used within the scope of the invention.
  • substrates to be coated as provided herein are preferably made of metal, substrates made of other materials can likewise be coated within the scope of the invention provided that the thermoplastic resin flame sprayed onto the substrate to form the intermediate layer will adhere to the substrate surface.
  • an overlying layer is applied that preferably comprises a major portion of a powdered metallic material.
  • a metallic material is preferred for use in forming the overlying layer of the composite coating of the invention, it will be appreciated, however, that powdered metal-containing or ceramic materials can also be applied to a substrate using the methods disclosed herein, and the use of such materials likewise falls within the scope of the present invention.
  • Metal-containing materials can include, for example, metal oxides, metal nitrides, and the like.
  • a preferred metallic material for use in forming the overlying layer of the subject composite coating is powdered copper, although other metallic materials such as, for example, aluminum, carbide, tungsten carbide, stellite, chromium, stainless steel, nickel, titanium, metal oxides, metal alloys, and the like, can also be used.
  • the metallic overlying layer is applied to the thermoplastic-coated substrate in the same manner as the thermoplastic layer, except that the powdered metal is substituted for the powdered thermoplastic, and a surface preparation step is not generally required.
  • the overlying layer can be applied either before or after the thermoplastic layer has cooled to ambient temperature. Surface preparation, usually just washing, of the thermoplastic intermediate layer should not be needed unless the plastic surface has been contaminated such as by oil or the like prior to application of the overlying layer.
  • the powdered metal, metal-containing or ceramic particles used to form the overlying layer are preferably heated by combustion from the flame spray gun to a temperature greater than the melting point of the thermoplastic material used to form the intermediate layer of the composite coating, but less than the temperature that will char, ignite or otherwise degrade the thermoplastic, and less than the melting point of the powder particles.
  • the powder particles When heated to such temperature, the powder particles will become partially embedded in the surface of the thermoplastic layer when propelled against it by the force of the stream emanating from the flame spray gun coupled with a softening or melting of the thermoplastic at the surface of the intermediate layer due to the relatively greater temperature of the heated powder particles.
  • thermoplastic particle sizes ranging from about 40 mesh to about 120 mesh are preferred.
  • the thickness of the intermediate layer of thermoplastic material will preferably range from about 8 to about 12 mils, it will be understood that the preferred thickness can vary either above or below that range, depending upon factors such as, for example, the size, geometry and material of the substrate; the intended use; the use environment; the nature and amount of abrasion likely to be experienced during use; the type, particle size and thickness of the metal powder to be applied over the thermoplastic layer; and the like.
  • the size of the powder particles used in flame spraying the overlying layer can vary according to the type of material, the substrate, the intended use, the thermoplastic material, the temperature used in the flame spray gun, and the desired thickness of the overlying layer.
  • the average particle size will have a maximum diameter that is less than or equal to the thickness of the intermediate layer onto which the particles are sprayed.
  • the thickness of the overlying layer of metallic or ceramic material will preferably range from about one to about ten mils, it will be understood that the preferred thickness can vary, depending upon factors such as the particle dimensions, the extent to which the particles are embedded in the intermediate layer, the intended use, the use environment, the amount and nature of any abrasion to which the coating will be subjected during use, and the like.
  • the overlying layer of the subject composite coating has been applied, further processing can be done, if desired, to achieve particular finishes.
  • the resultant flame sprayed metal surface can be polished to achieve a slick, shiny surface appearance.
  • repair is usually easily accomplished by spraying additional metal, metal-containing or ceramic powder onto the remaining thermoplastic material of the intermediate layer.
  • a test coupon of aluminum was prepared for use as a substrate by sandblasting the surface to a one to three mil anchor profile.
  • the test coupon was then coated with an intermediate layer of PF 111 (a product designation of Plastic Flamecoat Systems, Inc. for EMAA having a melting point of about 160°F, 71°C.) by flame spraying the material onto the top surface of the aluminum to achieve a thermoplastic layer having a thickness of about ten mils. After allowing the thermoplastic-coated substrate to cool to ambient temperature, an overlying layer of powdered copper was flame sprayed onto the thermoplastic intermediate layer.
  • PF 111 a product designation of Plastic Flamecoat Systems, Inc. for EMAA having a melting point of about 160°F, 71°C.
  • the thickness of the overlying layer was about three mils, and the powdered copper was heated to a temperature of about 300°F (149°C) by the flame spray gun prior to application to the coupon.
  • the fuel gas used in the flame spray gun was propane.
  • a cross-sectional cut was thereafter made through the coupon, and the structure of the cross-section is shown in the accompanying photomicrograph identified as Figure 1.
  • the substrate, intermediate and overlying layers referred to above are clearly visible in Figure 1.
  • a test coupon of aluminum was prepared for use as a substrate by sandblasting the surface to a one to three mil anchor pattern.
  • the test coupon was then coated with an intermediate layer of PF 111 by flame spraying the material onto the top surface of the aluminum to achieve a thermoplastic layer having a thickness of about ten mils.
  • an overlying layer of powdered tungsten carbide was flame sprayed onto the thermoplastic intermediate layer.
  • the thickness of the overlying layer was about three mils and the powdered tungsten carbide was heated to a temperature of about 300°F (149°C) by the flame spray gun prior to application to the coupon.
  • the fuel gas used in the flame spray gun was propane.
  • a cross-sectional cut was thereafter made through the coupon, and the structure of the cross-section is shown in the accompanying photomicrograph identified as Figure 2.
  • the substrate, intermediate and overlying layers referred to above are clearly visible in Figure 2.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Laminated Bodies (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)
EP92311644A 1991-12-23 1992-12-21 Flame sprayed composite coating Withdrawn EP0549298A2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US81270791A 1991-12-23 1991-12-23
US812707 1991-12-23

Publications (2)

Publication Number Publication Date
EP0549298A2 true EP0549298A2 (en) 1993-06-30
EP0549298A3 EP0549298A3 (es) 1994-01-05

Family

ID=25210398

Family Applications (1)

Application Number Title Priority Date Filing Date
EP92311644A Withdrawn EP0549298A2 (en) 1991-12-23 1992-12-21 Flame sprayed composite coating

Country Status (8)

Country Link
EP (1) EP0549298A2 (es)
JP (1) JPH05345966A (es)
KR (1) KR930012290A (es)
CN (1) CN1073697A (es)
BR (1) BR9205092A (es)
CA (1) CA2085852A1 (es)
MX (1) MX9207501A (es)
TW (1) TW247290B (es)

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4443440A1 (de) * 1994-01-26 1995-07-27 Forschungskuratorium Maschinen Verschleißschutzschicht und Verfahren zum Auftragen dieser auf Bauteile
WO1998053140A1 (fr) * 1997-05-22 1998-11-26 Laurent Kropf Lame composite utilisable notamment dans l'industrie papetiere
WO2002004694A1 (de) * 2000-07-07 2002-01-17 Linde Ag Kunststoffoberfläche mit thermisch gespritzter beschichtung und verfahren zu ihrer herstellung
DE102004046111A1 (de) * 2004-09-23 2006-04-06 Elringklinger Ag Verfahren zum Beschichten von Flachdichtungen
US20130309409A1 (en) * 2008-03-04 2013-11-21 Gerhard Johner Coating of a body of steel or carbon fiber reinforced plastic and method for producing such coating
CN112758349A (zh) * 2020-12-29 2021-05-07 成都成发泰达航空科技有限公司 用于超高温环境模拟及考核试验的测试装置与测试方法
CN113234311A (zh) * 2021-05-07 2021-08-10 广州维邦新材料科技有限公司 一种自隔离耐火阻燃pc、pbt复合材料

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN100545636C (zh) * 2005-07-19 2009-09-30 沈阳黎明航空发动机(集团)有限责任公司 一种柔性线材成分分析方法
CN100372616C (zh) * 2005-10-12 2008-03-05 吴德明 涂料表面制造工艺
JP2010065509A (ja) * 2008-09-12 2010-03-25 Tokyo Seiko Co Ltd 屋外設置金属支柱
WO2012006687A1 (en) * 2010-07-15 2012-01-19 Commonwealth Scientific And Industrial Research Organisation Surface treatment
CN105177246A (zh) * 2015-08-28 2015-12-23 济南昊泽环保科技有限公司 一种工件防氧化脱碳处理工艺
CN105537075A (zh) * 2015-12-22 2016-05-04 龙岩紫荆创新研究院 钕铁硼的热喷涂涂层及其制备方法
CN110129709B (zh) * 2019-06-11 2021-09-10 华东理工大学 一种陶瓷层的制备方法以及由此得到的陶瓷层及其热障涂层

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2610263A1 (de) * 1974-03-13 1977-06-02 Korel Korrosionsschutz Elektro Elektrisch leitfaehige beschichtung sowie verfahren zur herstellung derselben
EP0164617A1 (de) * 1984-05-28 1985-12-18 Hoechst Aktiengesellschaft Verfahren zur Verbesserung des Benetzungsverhaltens der Oberfläche von Kunststoff-Formteilen für verfahrenstechnische Anwendungen
DE3726372A1 (de) * 1986-08-27 1988-03-03 Toyoda Gosei Kk Nichtmetallischer gegenstand, insbesondere fuer automobile

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE2610263A1 (de) * 1974-03-13 1977-06-02 Korel Korrosionsschutz Elektro Elektrisch leitfaehige beschichtung sowie verfahren zur herstellung derselben
EP0164617A1 (de) * 1984-05-28 1985-12-18 Hoechst Aktiengesellschaft Verfahren zur Verbesserung des Benetzungsverhaltens der Oberfläche von Kunststoff-Formteilen für verfahrenstechnische Anwendungen
DE3726372A1 (de) * 1986-08-27 1988-03-03 Toyoda Gosei Kk Nichtmetallischer gegenstand, insbesondere fuer automobile

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE4443440A1 (de) * 1994-01-26 1995-07-27 Forschungskuratorium Maschinen Verschleißschutzschicht und Verfahren zum Auftragen dieser auf Bauteile
WO1998053140A1 (fr) * 1997-05-22 1998-11-26 Laurent Kropf Lame composite utilisable notamment dans l'industrie papetiere
FR2763603A1 (fr) * 1997-05-22 1998-11-27 Laurent Kropf Lame composite utilisable notamment dans l'industrie papetiere
WO2002004694A1 (de) * 2000-07-07 2002-01-17 Linde Ag Kunststoffoberfläche mit thermisch gespritzter beschichtung und verfahren zu ihrer herstellung
DE102004046111A1 (de) * 2004-09-23 2006-04-06 Elringklinger Ag Verfahren zum Beschichten von Flachdichtungen
US20130309409A1 (en) * 2008-03-04 2013-11-21 Gerhard Johner Coating of a body of steel or carbon fiber reinforced plastic and method for producing such coating
CN112758349A (zh) * 2020-12-29 2021-05-07 成都成发泰达航空科技有限公司 用于超高温环境模拟及考核试验的测试装置与测试方法
CN113234311A (zh) * 2021-05-07 2021-08-10 广州维邦新材料科技有限公司 一种自隔离耐火阻燃pc、pbt复合材料

Also Published As

Publication number Publication date
TW247290B (es) 1995-05-11
EP0549298A3 (es) 1994-01-05
KR930012290A (ko) 1993-07-20
CA2085852A1 (en) 1993-06-24
MX9207501A (es) 1993-11-01
CN1073697A (zh) 1993-06-30
JPH05345966A (ja) 1993-12-27
BR9205092A (pt) 1993-06-29

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