EP3314037A1 - Cold gas spray coating methods and compositions - Google Patents
Cold gas spray coating methods and compositionsInfo
- Publication number
- EP3314037A1 EP3314037A1 EP15897313.1A EP15897313A EP3314037A1 EP 3314037 A1 EP3314037 A1 EP 3314037A1 EP 15897313 A EP15897313 A EP 15897313A EP 3314037 A1 EP3314037 A1 EP 3314037A1
- Authority
- EP
- European Patent Office
- Prior art keywords
- nickel
- alloy
- composition
- ceramic
- powder
- 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- Withdrawn
Links
Classifications
-
- 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
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C1/00—Making non-ferrous alloys
- C22C1/04—Making non-ferrous alloys by powder metallurgy
- C22C1/0433—Nickel- or cobalt-based alloys
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/055—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/14—Treatment of metallic powder
- B22F1/148—Agglomerating
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
- B22F2009/041—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by mechanical alloying, e.g. blending, milling
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
- B22F2998/10—Processes characterised by the sequence of their steps
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/026—Spray drying of solutions or suspensions
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/07—Alloys based on nickel or cobalt based on cobalt
Definitions
- Cold gas spray coating is a coating deposition method which uses powder material accelerated at high speeds through gas jets which adheres to a surface during impact.
- Metals, polymers and ceramics are some representative materials which can be deposited using cold gas spray techniques.
- thermal spraying methods such as plasma spraying, arc spraying, and flame spraying, for example, the powders are not externally melted during spraying.
- the technology has particular utility in the area of parts repair. For example, there have been problems associated with corrosion and wear of metal alloys that are used to fabricate marry different, types of components. This can represent a costly and significant problem associated with large and expensive articles, such as transmission and gearbox housings for rotary aircraft, for example.
- Cold gas spray coating provides one method of repairing soch parts. The process has also been used to repair aircraft engines, gas turbines, and parts used in the oil and gas industry, etc. White the basic technology has been found to be a cost effective and
- compositions and methods described herein meet the challenges described above, including, among other things, achieving more efficient and effective processing.
- a cold gas spray method including spraying a composition containing a primary phase of at least one nickel or iron based material blended with a softer, shear- deformable, secondary phase metal and/or metal alloy, to deposit a dense, or porou coating on a substrate.
- Figure 1 shows representative pressures vs. velocities for particles described herein.
- Figures 2, 3, 4 and 5 show schematic representations of some embodiments of the processes described herein.
- Figures 6, 7, 8, 9, 10 and 11 show micrographs of some of the embodiments of the processes described herein.
- Figure 12 shows some processing parameter embodiments of the processes described herein.
- Figures 13 and 14 show micrographs of some of the embodiments of the processes described herein.
- Powder material mixtures when subjected to impact induced high shock stresses exhibit a variety of dominant and in some cases complimentary effects (see, for example, Eakins DE, Thadhani NN, "Shock Compression of Reactive Powder Mixtures", International Materials Reviews, 2009,Vol:54, ISSN:095()-66()8, Pages:181 -213, hereinafter referred to as the Eakins article; also Boslough M.B., "Shock-induced Chemical Reactions in Ni-Al Powder Mixtures: Radiation Pyrometer Measurements", Chemical Physical Letters, Vol. 150, 5/6, Aug. 1989, p618-622, hereinafter referred to as the Boslough article; and Do, I.P.H., Benson D.J.
- phase changes e.g. phase transformations in iron and metastable steels and metal alloys (see, for example, E. Moin , L. E. Murr, Mater. Sci. Eng., 37 (3) (1979) 249 and C. J. Heathcock , B. E. Protheroe, A. Ball, Wear, 81 (1982) 31 1 - 327), or melting.
- the concept can be altered by using fine, hard ceramic powder particles instead of / or together with the softer metal phase with the theory that the ceramic phases also generate shear mismatch and heat when deposited with a superalloy phase.
- the use of such unique alloy blends reduces the need for development of higher temperature / higher velocity cold gas spray parameters and equipment.
- the result of the aforementioned is deposition of nickel superalloys, (traditionally very difficult to deposit using cold gas spray with typical "best case" deposition efficiencies of around 70%, i.e., 30% of the material sprayed bouncing or falling off) with a minimum of defects and sufficient strength (similar to that attained with air plasma spray coatings, e.g., about 34 MPa or about 5000 psi) using the assistance of a small amount of a ductile or ductile/exothermic second phase that assist with welding of nickel superalloy particles together by hot-deformation (or exothermic) reactions and minimal influence on overall chemistry of the superalloy coating.
- Ni 18Cr 2Ti 1.5Al lSi 0.2Cu 3Fe 1 Mn 2Co 0.1 C 0.15Zr NIMONIC 75, INCONEL 600, INCONEL 617, INCONEL 625, HASTELLOY W, HASTELLOY N, HASTELLOY X, HASTELLOY C, HASTELLOY B, Haynes 214, Haynes 230, CMSX-4 alloy, Cobalt based alloys, STELLITE, CoNiCrAIY and/or NiCrAIY alloys.
- Representative nickel powder useful with the processes described herein can comprise: nickel powder, nickel metal > 97wt.% Ni, and size ranges of about 3 to about 50 micrometers mean diameter.
- silver metal > 97wt.% Ag, and silver alloys
- zinc metal > 97wt.% Zn and zinc alloys
- platinum and palladium metal > 97wt.%
- Figure 2 demonstrates the dynamic impact/ contact between the particles where particle velocity is generally > 500 m/s.
- the particle size ranges A & B generally are ⁇ 50 microns.
- Component 41 can be e.g. INCONEL 718
- Component 42 can be nickel or nickel-5 Al or other soft ailoy.
- the softer shearable second phase material such e.g. Nickel or Ni- 5AI or other soft alloy is introduced and: deforms / shears easily generating heat by friction contact /shear between harder INCONEL 718 particles, and/or generates heat by friction / exothermic reaction, e.g. NiAl. .
- High shear zone 43 indicates friction heating.
- Other approaches which can be used are a combination of powders that either react during spraying or can be diffusion treated post deposition.
- Component 1 (51) can be, e.g.
- INCONEL 718 and Component 2 (52) can be e.g. alumina or YSZ.
- High shear zone 53 indicates friction heating. This zone can also be generated, e.g., by introducing a harder, ceramic, non- shearable second phase material such e.g. alumina or YSZ, which generates heat by friction contact /shear between softer INCONEL 718 particles.
- Figure 13 shows an example of a cold gas sprayed coating microstructure
- Figure 14 shows an example of a cold gas sprayed INCONEL 718 coating (142) deposited onto an INCONEL 718 substrate (141).
- the typical composition of the powder used was INCONEL 718 + 5wt% NiSAl which was cold gas sprayed to a thickness of over 10mm.
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Coating By Spraying Or Casting (AREA)
Abstract
Description
Claims
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
PCT/US2015/038320 WO2017003427A1 (en) | 2015-06-29 | 2015-06-29 | Cold gas spray coating methods and compositions |
Publications (2)
Publication Number | Publication Date |
---|---|
EP3314037A1 true EP3314037A1 (en) | 2018-05-02 |
EP3314037A4 EP3314037A4 (en) | 2019-01-30 |
Family
ID=57608602
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP15897313.1A Withdrawn EP3314037A4 (en) | 2015-06-29 | 2015-06-29 | Cold gas spray coating methods and compositions |
Country Status (6)
Country | Link |
---|---|
US (1) | US20180258539A1 (en) |
EP (1) | EP3314037A4 (en) |
JP (1) | JP2018524466A (en) |
CN (1) | CN107709611A (en) |
CA (1) | CA2984429A1 (en) |
WO (1) | WO2017003427A1 (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11662300B2 (en) | 2019-09-19 | 2023-05-30 | Westinghouse Electric Company Llc | Apparatus for performing in-situ adhesion test of cold spray deposits and method of employing |
US11898986B2 (en) | 2012-10-10 | 2024-02-13 | Westinghouse Electric Company Llc | Systems and methods for steam generator tube analysis for detection of tube degradation |
US11935662B2 (en) | 2019-07-02 | 2024-03-19 | Westinghouse Electric Company Llc | Elongate SiC fuel elements |
Families Citing this family (8)
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WO2018142225A1 (en) * | 2017-02-03 | 2018-08-09 | 日産自動車株式会社 | Sliding member, and sliding member of internal combustion engine |
CA3080622A1 (en) * | 2017-12-15 | 2019-06-20 | Oerlikon Metco (Us) Inc. | Mechanically alloyed metallic thermal spray coating material and thermal spray coating method utilizing the same |
GB2577522B (en) * | 2018-09-27 | 2022-12-28 | 2D Heat Ltd | A heating device, and applications therefore |
CN112996614B (en) | 2018-11-09 | 2024-02-06 | 易福仁科技知产私人有限公司 | Method for forming object by spraying |
JP7074044B2 (en) * | 2018-12-20 | 2022-05-24 | トヨタ自動車株式会社 | Spraying powder |
CN109825827A (en) * | 2019-02-22 | 2019-05-31 | 沈阳富创精密设备有限公司 | A kind of preparation method of IC equipment plasma etch chamber protective coating |
CN109957796A (en) * | 2019-04-11 | 2019-07-02 | 新余学院 | The preparation method of solar selectively absorption WC-Co composite coating |
US11781223B2 (en) * | 2021-06-16 | 2023-10-10 | The Boeing Company | Repair coating and method for repairing a damaged portion of a steel member |
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US5372845A (en) * | 1992-03-06 | 1994-12-13 | Sulzer Plasma Technik, Inc. | Method for preparing binder-free clad powders |
US6915964B2 (en) * | 2001-04-24 | 2005-07-12 | Innovative Technology, Inc. | System and process for solid-state deposition and consolidation of high velocity powder particles using thermal plastic deformation |
US6592935B2 (en) * | 2001-05-30 | 2003-07-15 | Ford Motor Company | Method of manufacturing electromagnetic devices using kinetic spray |
US7201940B1 (en) * | 2001-06-12 | 2007-04-10 | Advanced Cardiovascular Systems, Inc. | Method and apparatus for thermal spray processing of medical devices |
WO2005056879A1 (en) * | 2003-09-29 | 2005-06-23 | General Electric Company | Nano-structured coating systems |
WO2005079209A2 (en) * | 2003-11-26 | 2005-09-01 | The Regents Of The University Of California | Nanocrystalline material layers using cold spray |
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JP5493334B2 (en) * | 2008-11-05 | 2014-05-14 | 国立大学法人東北大学 | Highly efficient adhesion methods and materials in repair of high carbon steel members |
EP2374912A4 (en) * | 2008-12-17 | 2016-03-02 | Master Technology Company Limited | Antibacterial coating, its preparation methods and metalwork containing the coating |
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-
2015
- 2015-06-29 CA CA2984429A patent/CA2984429A1/en not_active Abandoned
- 2015-06-29 WO PCT/US2015/038320 patent/WO2017003427A1/en active Application Filing
- 2015-06-29 CN CN201580080956.XA patent/CN107709611A/en active Pending
- 2015-06-29 JP JP2017564736A patent/JP2018524466A/en active Pending
- 2015-06-29 US US15/568,703 patent/US20180258539A1/en not_active Abandoned
- 2015-06-29 EP EP15897313.1A patent/EP3314037A4/en not_active Withdrawn
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US11898986B2 (en) | 2012-10-10 | 2024-02-13 | Westinghouse Electric Company Llc | Systems and methods for steam generator tube analysis for detection of tube degradation |
US11935662B2 (en) | 2019-07-02 | 2024-03-19 | Westinghouse Electric Company Llc | Elongate SiC fuel elements |
US11662300B2 (en) | 2019-09-19 | 2023-05-30 | Westinghouse Electric Company Llc | Apparatus for performing in-situ adhesion test of cold spray deposits and method of employing |
Also Published As
Publication number | Publication date |
---|---|
CA2984429A1 (en) | 2017-01-05 |
CN107709611A (en) | 2018-02-16 |
WO2017003427A1 (en) | 2017-01-05 |
EP3314037A4 (en) | 2019-01-30 |
JP2018524466A (en) | 2018-08-30 |
US20180258539A1 (en) | 2018-09-13 |
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