EP3227032B1 - Thermal spray method integrating selected removal of particulates - Google Patents

Thermal spray method integrating selected removal of particulates Download PDF

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Publication number
EP3227032B1
EP3227032B1 EP15864746.1A EP15864746A EP3227032B1 EP 3227032 B1 EP3227032 B1 EP 3227032B1 EP 15864746 A EP15864746 A EP 15864746A EP 3227032 B1 EP3227032 B1 EP 3227032B1
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EP
European Patent Office
Prior art keywords
feedstock
region
liquid
gas stream
column
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Active
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EP15864746.1A
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German (de)
English (en)
French (fr)
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EP3227032A1 (en
EP3227032A4 (en
Inventor
Kent Vanevery
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PROGRESSIVE SURFACE Inc
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PROGRESSIVE SURFACE Inc
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Priority claimed from US14/560,456 external-priority patent/US10279365B2/en
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Publication of EP3227032A4 publication Critical patent/EP3227032A4/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B1/00—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means
    • B05B1/34—Nozzles, spray heads or other outlets, with or without auxiliary devices such as valves, heating means designed to influence the nature of flow of the liquid or other fluent material, e.g. to produce swirl
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/20—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion
    • B05B7/201—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion downstream of the nozzle
    • B05B7/205—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed by flame or combustion downstream of the nozzle the material to be sprayed being originally a particulate material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
    • B05B7/226—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material being originally a particulate material
    • 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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying

Definitions

  • the present invention relates to integrating into a thermal spray system a method for the continuous in-flight reduction of suboptimal feedstock deposition and the in-situ removal of debris, such as less adherent feedstock and surface preparation grit particulates, from the substrate and coating.
  • conventional thermal spraying is a coating method wherein a continuous flow of hot gas 1 generated in chamber 2 is forced to pass through an ejection nozzle 3, forming a divergent gas column 4 having an axis 5.
  • the column 4 is coaxial with the nozzle 3 and extends from the nozzle exit to a substrate surface 6 where the gas column 4 is projected into a surface spot 7.
  • Due to atmospheric air entrainment into the fringes of the gas column the temperature within the gas column follows a Gaussian profile 9 ( Fig. 1 ) where the temperature decreases with distance from axis 5.
  • Air entrainment into the fringes of the gas column also causes the velocity of the gas to decrease with distance from axis 5, following a similar Gaussian profile 9.
  • Peak temperatures in the thermal spray gas column may reach values in excess of 10,000 degrees Celsius, while gas velocities can range from several hundred meters per second to supersonic speeds.
  • Feedstock material is injected into the gas column via one or more injectors 10. It becomes entrained in the gas column which transfers heat and momentum to the feedstock material, causing it to impact with high velocity onto the substrate surface where it adheres to form a coating 11. Thermal spray coatings adhere to the substrate primarily by physical forces. Because of this fact, the substrate surface is typically pretreated prior to the coating process by means of blasting with high velocity abrasive particulates to increase the surface roughness and provide anchoring points onto which the coating can adhere.
  • the particulates impinging on the substrate must be in the optimal temperature and velocity ranges in order to attain a molten status and speed sufficient to deform into a lamellar structure-commonly referred to as a splat-during impact, which increases the ability to bond physically to the underlying surface.
  • a splat-during impact which increases the ability to bond physically to the underlying surface.
  • more than one layer of splats is usually necessary; in this case several overlapping passes are performed.
  • a pass generally consists of the gas column axis moving relative to surface 6 as shown by arrow 8.
  • feedstock materials are generally powders of different coating materials in sizes between several microns to tens of microns.
  • the powder is injected into the hot gas column, typically by using a carrier gas flow.
  • the hot gas stream transfers heat and momentum to the powder, causing it to melt and impact on the substrate surface to form a coating.
  • thermal spray powders Due to technological and economic constraints, thermal spray powders have a relatively wide spread of particle sizes, which is problematic because larger particles require more heat and momentum to form splats during impact than smaller particles.
  • the feedstock material In suspension thermal spraying (STS), the feedstock material consists of particulates suspended in a liquid medium. A flow of this suspension is used to inject the feedstock material into the hot gas column; thus, the liquid medium replaces the carrier gas used in conventional thermal spraying. Compared to conventional thermal spray powders, these particulates are significantly smaller, generally in the submicron to nanometer range. A range of solid particulate sizes is also present in the suspensions, but this range is generally smaller than that of conventional thermal spray powders.
  • the liquid solvent of the suspension Upon injection into the hot gas stream column, the liquid solvent of the suspension is evaporated by the heat of the gas column. Afterwards, heat and momentum continue to be transferred to the particulates, causing them to melt and impact onto the substrate surface to form a coating.
  • particles 13 do not receive enough heat and momentum to form splats upon impacting on the substrate, so they do not adhere well to the substrate and form suboptimal deposits an annular region surrounding the central area of high quality coating.
  • the smallest and lightest feedstock particles 14 likewise form suboptimal deposits in an annular region surrounding the central area of high quality coating, because these particles cannot penetrate into the core of the gas column and travel instead in the fringes where the temperature and velocity are suboptimal. Since a coating is typically produced by overlapping passes to produce multiple deposition layers, the suboptimal deposits can get entrapped in the coating, lowering the coating adhesion and integrity. As a result, the coating strength will be improved by reducing the formation or entrapment in the coating of suboptimal deposits.
  • suboptimal deposits can be reduced by increasing the fraction of particles in the feedstock that are optimally-sized; however, narrowing the particle size range tends to increase significantly the overall cost of the coating process.
  • the entrapment of unwanted suboptimal deposits can be reduced by cleaning these deposits off the surface between coating passes.
  • the techniques commonly used to clean unwanted material off a surface prior to applying a thermal spray coating involve directing a jet of pressurized gas onto the surface. Often times a compressed jet alone does not provide sufficient cleaning; so, solid particulates, such as dry ice or abrasive ceramic grit, are added to the jet to provide a more aggressive cleaning.
  • solid particulates such as dry ice or abrasive ceramic grit
  • coated areas adjacent to the region to be cleaned generally need to be masked or shielded from the grit to prevent damage to the coating. Additionally, the grit blasting process leaves dust particulates on the surface that can become entrapped in the coating and lower the coating adhesion and integrity. With these blasting techniques, equipment separate from what is needed for the thermal spray coating application is used, resulting in additional expenditures for equipment capital, maintenance costs, and coating production time if the thermal spray process is interrupted while the blasting equipment cleans the unwanted material.
  • De Vries teaches using more reactive species to break randomly the existing chemical bonds of undesirable atoms/molecules on the surface, resulting in the more reactive species replacing the undesirable atom/molecules and changing the chemistry of the surface.
  • the technique in De Vries is not transferrable to a thermal spray process where the bonding occurs by physical instead of chemical forces. For example, it is the inventors' belief that even if for some unknown reason one might be motivated to inject water vapors along the substrate surface while thermal spraying a coating as taught in De Vries, it is not obvious to do so since it would likely not result in suboptimal feedstock particles being cooled sufficiently to prevent adherence, nor would the water vapor velocity be able to remove loosely adhered suboptimal deposits.
  • U.S. Patent Application Publication No. 2008/0072790 to Ma et al. teaches a thermal spray system using a combustion chamber and a nozzle to eject a plume towards a substrate.
  • Feedstock material consisting of liquid media, which can include mixtures of organic/inorganic metal salts or suspensions of small-sized solid particles in water or a volatile solvent, is injected into the plume.
  • the water and the solid particles are premixed as a unitary feedstock and are supplied to the plume as a mixture from the same reservoir.
  • the suspension liquid including water is employed by Ma as a carrier for the solid particles solely because of the difficulties to feed fine particles (under 10 micrometers in size) using gas as a carrier (para 0007).
  • Ma does not teach the injection into the plume of a liquid such as water segregated from the solid particulates in the plume, and no provisions to achieve such segregation are disclosed within the description of the embodiments. Furthermore, Ma does not teach liquid injection to modify the deposition characteristics or structure of the coating being formed.
  • U.S. Patent No. 4,770,109 to Schlienger et al. teaches using a plasma torch, not to spray thermally-applied coating, but rather to heat and compact garbage onto a rotating disk located at the bottom of an incinerator chamber. After compaction and incineration, the treated garbage is emptied from the chamber, and the process is restarted.
  • the torch is mounted through the upper lid of the incinerator with the plasma plume directed onto the rotating disk.
  • the garbage to be treated can be in solid as well as liquid form. The solid and liquid garbage are not injected into the plasma plume; they are both fed through one pipe located away from the plasma plume (part 22 in the drawings and col 3 lines 6-7).
  • Schlienger teaches feeding solid and liquid materials into a plasma produced by a plasma torch, the purpose of the process is to destroy the feedstock; therefore, Schlienger provides no provisions to be obviously usable in a thermal spray coating process which seeks to maximize the retention of the desired feedstock. Furthermore, Schlienger provides no provisions for a liquid to be injected directly into the plasma plume for the purpose of affecting the way feedstock particles are treated within the plume.
  • US Patent Application Publication No. 2013/284203 discloses An integrated apparatus and method comprising a plasma gun with a water supply, treatment fluid supply, and controls, the combination of which is adapted for directing a plume onto a surface of a three-dimensional part to treat the surface; and for controlling injection of water into the plume with the plume directed onto an adjacent surface to clean debris and undesired material from the adjacent surface; and for subsequently directing the plume (without water) onto the adjacent surface to treat the adjacent surface.
  • the apparatus and method are particularly useful in suspension plasma spray systems.
  • the present invention relates to integrating into a thermal spray system a method for the continuous in-flight reduction of suboptimal feedstock deposition and the in-situ removal of debris, such as less adherent feedstock and surface preparation grit particulates, from the substrate and coating.
  • a method is used to form a coating on a substrate surface as defined in claim 1.
  • a thermal spray apparatus adapted to form a coating on a substrate surface as defined in claim 13.
  • a thermal spray apparatus/system and a method are provided for the continuous in-flight reduction of suboptimal feedstock deposition and the in-situ removal of debris, such as less adherent feedstock and surface preparation grit particulates, from the substrate and coating.
  • the apparatus ( Figs. 2-2a ) includes a hot gas generator 2 and nozzle 3, which are used to generate a high temperature gas column 4 that projects into a spot onto the substrate surface 6.
  • the hot gas column properties, coating performance requirements, and feedstock characteristics combine to define an optimal feedstock size range; thus, any particle sizes outside this range would be classified as suboptimal, or undesirable.
  • a feedstock size distribution consisting only of particles within the optimal size is impractical.
  • the most efficient scenario is to center the feedstock particle size distribution within the optimal size range, as shown schematically in Fig. 2b . Accordingly, within the gas column 4, the locations of the feedstock particle from each category define two volumetric regions: region 15 and region 16.
  • Region 15 surrounds axis 5 and projects onto the substrate surface 6 in a central spot 17. This region is characterized by the location of the optimal feedstock particles, meaning the particle temperature and velocity conditions generated in region 15 produce an optimal coating on the surface 6.
  • Region 16 surrounds region 15 and projects onto the substrate surface 6 in an annular region 18 that surrounds the central spot 17.
  • Region 16 is characterized by the location of suboptimal feedstock particles; thus, the particle temperature and velocity conditions generated in region 16 are insufficient to produce an optimal coating on the surface 6. Consequently, region 18 is formed by the deposition of suboptimal particles.
  • Figs. 3-3a show an embodiment wherein the system comprises a first injector 19 to inject feedstock 20 into the gas column and a second injector 21 for injecting a liquid 22 into the gas column, with the second injector shown positioned downstream and adjacent to the first injector.
  • the feedstock particle size distribution is skewed, consisting only of particles in the optimal size range and smaller.
  • the size of injector 19 and the speed of feedstock injection produce the penetration of the optimal feedstock particles 23 into region 15, while the suboptimal feedstock particles 25 are confined to the upper portion of region 16.
  • the optimal feedstock particles 23 entrained in region 15 are transferred sufficient heat and momentum from the hot gas stream to impact substrate surface 6 and form an optimal quality coating 24, which is confined to the spot 17.
  • the suboptimal feedstock particles 25 entrained in the upper portion of region 16 are cooled by liquid 22, which is primarily entrained into the upper portion of region 16 by adjusting the size of injector 21 and the speed of liquid injection. As shown in Fig. 3 , the cooling produced by liquid 22 can reduce the degree of suboptimal feedstock particle melting to the point that splat formation is prevented, causing cooled suboptimal feedstock particles 27 to hit surface 6 and bounce off without adhering and forming a coating. Thus, liquid 22 and cooled suboptimal feedstock particles 27 can impact surface 6 and act as abrasive media, removing the weakly-adhered feedstock and grit particles represented by surface debris 26 ahead of the movement of spot 17 and the formation of coating 24.
  • liquid 22 and cooled suboptimal feedstock particles 27 acting as abrasive media on surface 6 may dislodge embedded surface debris such as grit particles 28, removing them from the surface and preventing them from being entrapped in the coating.
  • heating by the hot gas stream and cooling by the impinging liquid may cause the expansion and contraction of surface 6 and weakly-adhered/embedded debris particles 26 and 28, respectively, in a way that aids the removal of these debris particles from the surface.
  • the liquid 22 may contain a suspension of fine abrasive particulates, such as silicon or aluminum oxides. The fine particulates would be entrained in the upper portion of region 16 where they would be accelerated towards surface 6 without achieving the velocity or degree of melting necessary to adhere to surface 6 upon impact. These fine particulates would therefore enhance the removal of debris 26 and 28.
  • Figs. 4-4a depict an embodiment where the feedstock particle size distribution is Gaussian and contains particles below and above the optimal size range.
  • larger than optimal particles 29 injected with the feedstock stream 20 would penetrate through region 15 and become entrained in the lower portion of region 16. Because these particles 29 do not receive sufficient heat and momentum in region 16, they form a suboptimal deposit, represented by surface debris 30, which trails the movement of spot 17 and the formation of coating 24.
  • the smaller than optimal feedstock particulates 25 do not have enough momentum to penetrate into region 15.
  • suboptimal feedstock particles 25 entrain in region 16 where they do not receive enough heat and momentum to form optimal coating 24 upon impacting surface 6, so instead suboptimal feedstock particles 25 add to surface debris 26.
  • the negative situations associated with surface debris 26 and 30 are resolved by incorporating opposing liquid injectors 21 and 31, as shown in the preferred embodiment of Fig. 4 .
  • the size of injector 31 and the speed of injection are adjusted so that the entrainment of liquid 32 occurs substantially within the lower portion of region 16.
  • Some particles 29 are then cooled by liquid 32 to impact the substrate with a degree of melting that is insufficient to adhere to the substrate; these cooled suboptimal feedstock particles 33 hit surface 6 and bounce off without adhering and forming a coating.
  • liquid 32 and suboptimal feedstock particles 33 can impact surface 6 and act as abrasive media, removing weakly-adhered surface debris 30 in the portion of region 18 trailing the motion of the spot 17 and the formation of coating 24.
  • This cleaning mechanism may also remove from surface 6, embedded debris such as grit particle 34.
  • heating by the hot gas stream and cooling by the impinging liquid may cause the expansion and contraction of surface 6 and weakly-adhered/embedded debris particles 30 and 34, respectively, in a way that aids the removal of these debris particles from the surface.
  • liquid 22 and suboptimal feedstock particles 27 acting as abrasive media on surface 6 may dislodge embedded surface debris, such as grit particle 28, removing them from the surface and preventing them from being entrapped into the coating.
  • heating by the hot gas stream and cooling by the impinging liquid may cause the expansion and contraction of surface 6 and weakly-adhered/embedded debris particles 26 and 28, respectively, in a way that aids the removal of these debris particles from the surface.
  • FIG. 5 of the drawings presents another preferred embodiment of the system shown in Fig. 4 with an additional feedstock injector 35 being located opposite to feedstock injector 19.
  • the mechanism of injection and removal of suboptimal particulates and surface debris is a mirror of the mechanisms described for the embodiments shown in Fig. 3 and Fig. 4 .
  • Fig. 6 of the drawings shows a schematic front view of nozzle 3 with a plurality of feedstock injectors 19 and 35 and a plurality of liquid injectors 21 and 31 arranged about axis 5.
  • FIG. 7 Another preferred embodiment of the thermal spray system incorporating the invention is shown schematically in Fig. 7 of the drawings.
  • the gas stream column is shown extending from nozzle 3 to substrate surface 6, the column having a defined core region 15 surrounding axis 5.
  • Feedstock injector 19 is shown having flow control valve 37.
  • liquid injector 21 is shown having flow control valve 38.
  • One of each injector is shown in Fig. 7 ; however, only one injector connected to both control valves 37 and 38 could be incorporated, or a plurality of injectors arranged about axis 5 may be employed as previously described with reference to Fig. 6 .
  • Fig. 7 Another preferred embodiment of the thermal spray system incorporating the invention is shown schematically in Fig. 7 of the drawings.
  • the gas stream column is shown extending from nozzle 3 to substrate surface 6, the column having a defined core region 15 surrounding axis 5.
  • Feedstock injector 19 is shown having flow control valve 37.
  • liquid injector 21 is shown having flow control valve 38.
  • a first step the thermal spray system moves relative to surface 6 parallel to arrow 8 to deposit one or multiple layers of coating 11 or 24 in a manner described here above with reference to Fig. 1 , 3 , 4 , or 5 .
  • feedstock flow is stopped with valve 37, and the liquid velocity is adjusted with valve 38 so that the liquid is entrained substantially within region 15 of the gas stream.
  • the thermal spray system moves relative to surface 6 in the direction(s) of arrow 8 and/or arrow 39 to clean debris particles 26 and 28 from surface 6 and coating 11 or 24 according to the method described here above with reference to Figs. 3, 4 , or 5 .
  • control valve 37 is opened and the feedstock and liquid flows are adjusted to deposit one or multiple layers of coating 11 or 24 in a manner described here above with reference to Figs. 1 , 3 , 4 , or 5 .

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Materials Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Electromagnetism (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Combustion & Propulsion (AREA)
  • Nozzles (AREA)
  • Coating By Spraying Or Casting (AREA)
EP15864746.1A 2014-12-04 2015-07-17 Thermal spray method integrating selected removal of particulates Active EP3227032B1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US14/560,456 US10279365B2 (en) 2012-04-27 2014-12-04 Thermal spray method integrating selected removal of particulates
PCT/US2015/040898 WO2016089452A1 (en) 2014-12-04 2015-07-17 Thermal spray method integrating selected removal of particulates

Publications (3)

Publication Number Publication Date
EP3227032A1 EP3227032A1 (en) 2017-10-11
EP3227032A4 EP3227032A4 (en) 2018-08-22
EP3227032B1 true EP3227032B1 (en) 2022-11-23

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EP15864746.1A Active EP3227032B1 (en) 2014-12-04 2015-07-17 Thermal spray method integrating selected removal of particulates

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EP (1) EP3227032B1 (zh)
JP (1) JP6644070B2 (zh)
KR (1) KR102459847B1 (zh)
CN (1) CN107107097B (zh)
CA (1) CA2967578C (zh)
WO (1) WO2016089452A1 (zh)

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JP6934401B2 (ja) * 2017-11-13 2021-09-15 日本特殊陶業株式会社 溶射部材の製造方法
KR102207933B1 (ko) * 2019-07-17 2021-01-26 주식회사 그린리소스 서스펜션 플라즈마 용사 장치 및 그 제어 방법

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Also Published As

Publication number Publication date
EP3227032A1 (en) 2017-10-11
KR20170091735A (ko) 2017-08-09
CN107107097A (zh) 2017-08-29
EP3227032A4 (en) 2018-08-22
CA2967578C (en) 2021-03-16
JP6644070B2 (ja) 2020-02-12
KR102459847B1 (ko) 2022-10-26
CN107107097B (zh) 2021-04-27
WO2016089452A1 (en) 2016-06-09
JP2018508644A (ja) 2018-03-29
CA2967578A1 (en) 2016-06-09

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