JP2009235520A - Cold spray method, and cold spray device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a cold spray method which can securely and easily achieve the reduction in device cost and running cost, and to provide a cold spray device. <P>SOLUTION: In a cold spray method where material powder A is jetted at a high speed from a nozzle 11N together with a working gas H, so as to be deposited on a base material B, as a working gas H accelerating the material powder A, superheated steam H is used. A spray part 10 is provided with a condition sensor 15 measuring the conditions of the superheated steam H. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a cold spray method and a cold spray apparatus.

In recent years, a cold spray method has attracted attention as a new coating method. This cold spray is a technique in which a material powder is jetted from a nozzle at a high speed together with a working gas, and is allowed to collide with a substrate in a solid state to form a coating.
As the material powder, metals, alloys, intermetallic compounds, ceramics, and the like are used. Moreover, as working gas, inert gas, such as nitrogen and argon gas, or helium, hydrogen, etc. are used, and it sets to temperature lower than melting | fusing point of material powder.

  In this cold spray, it is not necessary to heat the material powder to a high temperature as compared with the conventional plasma spraying method, flame spraying method, high-speed flame spraying method and the like. For this reason, there is almost no material change (oxidation and thermal alteration) by heating, and the coating film which has the intended property can be formed. That is, a dense film with high density and good adhesion can be obtained.

In cold spray, in order to improve the adhesion efficiency of the material powder, that is, the ratio of the sprayed material powder to the substrate, the particle size of the material powder is reduced, the spraying speed of the material powder is increased, and the operation is performed. A technique has been proposed in which the temperature of a gas is controlled (for example, 600 to 700 ° C.) and the material powder is heated to such an extent that no material change occurs (see Patent Document 1).
US Pat. No. 7,178,744

However, in the conventional technology, as the gas used as the working gas, an expensive gas such as helium or a gas that requires attention in handling such as hydrogen is used.
For this reason, there is a problem that a working gas recovery device is required to reduce the running cost, the device cost increases, and the device becomes large.

  The present invention has been made in view of the above-described circumstances, and an object thereof is to propose a cold spray method and a cold spray apparatus capable of reliably and easily reducing the apparatus cost and the running cost.

In the cold spray method and the cold spray apparatus according to the present invention, the following means are employed in order to solve the above problems.
According to a first aspect of the present invention, in a cold spray method in which a material powder is sprayed at a high speed together with a working gas from a nozzle and deposited on a substrate, superheated steam is used as the working gas for accelerating the material powder.

The temperature of the superheated steam is 200 ° C. or higher.
Moreover, at least the deposition region of the material powder in the base material is heated to a high temperature of 20 ° C. or higher than the temperature of the superheated steam.

  A second invention is a cold spray apparatus in which material powder is jetted together with a working gas from a nozzle at a high speed and deposited on a substrate, and a superheated steam generator that generates superheated steam as a working gas for accelerating the material powder is provided. It is characterized by providing.

In addition, a state sensor that measures a state of the superheated steam is provided in a spray portion to which the superheated steam and the material powder are injected.
Moreover, the base material heating part which heats the temperature of the deposition area | region of the said material powder at least among the said base materials to 20 degreeC or more higher than the temperature of the said superheated steam is characterized by the above-mentioned.

According to the present invention, the following effects can be obtained.
Compared with the conventional plasma spraying method, flame spraying method, high-speed flame spraying method and the like, the material powder can be adhered to the base material B in a solid state without being heated so much.
The film R thus obtained has excellent properties such as denseness, high density, high thermal conductivity / conductivity, and good adhesion. In particular, since the material powder A is not heated and melted, it has an excellent property that there is almost no oxidation or thermal alteration.

In addition, by using superheated steam as the working gas for accelerating the material powder, the running cost can be kept extremely low. In addition, since a working gas recovery device or the like is not required, the device can be reduced in size and price.
Moreover, since superheated steam has a thermal conductivity four times that of air, it can efficiently heat the powder.

Handling high-pressure gas of 1 MPa or more has legal restrictions. The low-pressure type cold spray increases the temperature to promote the deformation of the powder, and the adhesion does not start unless the powder is brought to a critical speed or more. However, if it is superheated steam, it has good thermal conductivity, so that it can be sufficiently heated in the nozzle to improve the deformability of the powder. Furthermore, since the specific gravity is lighter than air, the powder has better acceleration than air even at the same temperature.
Furthermore, superheated steam is superior to other gases in that it warms the substrate, so that the efficiency of powder deposition is improved by increasing the temperature of the substrate.

Hereinafter, an embodiment of a cold spray method according to the present invention will be described with reference to the drawings.
FIG. 1 is a schematic diagram illustrating a schematic configuration of a cold spray apparatus 1 according to the present embodiment. FIG. 2 is a schematic diagram illustrating a schematic configuration of the cold spray unit 10 according to the present embodiment.
The cold spray device 1 includes a cold spray unit 10 and a base material temperature adjusting unit 50 for placing the base material B and controlling the temperature of the base material B to a constant temperature.

  The cold spray unit 10 is an apparatus for forming a film R by causing the material powder A to collide with the surface of the base material B in a solid state at a sound velocity to a supersonic velocity, and the material powder A together with the high-pressure superheated steam H. A spray gun 11 for spraying, a superheated steam generator 12 for supplying superheated steam H to the spray gun 11, a powder supply unit 13 for supplying material powder A to the spray gun 11, and the like are provided.

  When the superheated steam generator 12 supplies the high-pressure superheated steam H from the rear end of the spray gun 11 toward the spray gun 11, the powder supply unit 13 becomes negative pressure and the material powder A is supplied to the spray gun 11. Is done.

The superheated steam H and the material powder A supplied to the spray gun 11 become a sonic to supersonic flow through the nozzle 11N at the tip of the spray gun 11, and are ejected from the outlet of the nozzle 11N.
In addition, the spraying speed (injection speed) of the material powder A is about 300 to 800 m / s.

As the material powder A, aluminum, an aluminum alloy, a steel material, a nickel-base alloy, or other light metal is used.
As the base material B, aluminum, an aluminum alloy, a steel material, or a nickel-based alloy is used.

For example, when a steel material is used as the material powder A and the base material B, the temperature K1 of the superheated steam H is preferably 300 to 400 ° C. Moreover, when using a nickel base alloy as the powder A and the base material B, it is preferable that the temperature K1 of the superheated steam H is 300-400 degreeC. Since the transformation point of steel is 727 ° C. and the transformation point of Ni-based alloy is 600 ° C., the temperature is lower than that.
For example, when aluminum or an aluminum alloy is used as the material powder A and a steel material or a nickel-based alloy is used as the base material B, the temperature K1 of the superheated steam H is preferably 200 to 300 ° C.
In addition, the heat processing temperature of an aluminum alloy is about 110-180 degreeC. If the heat treatment is continued at this temperature, there is a risk that the original mechanical properties will be lost due to the material design becoming an overaged structure from the intended structure. Since the cold spray method is a local and short-time construction, it does not always have a fatal overaging.
However, the temperature K1 of the superheated steam H (at least the rising temperature of the base material B) is preferably lower than the temperature range of 110 to 180 ° C. Therefore, when aluminum or an aluminum alloy is used as the base material B, the construction with the superheated steam H is not suitable.

FIG. 3 is a state diagram of water.
The superheated steam H sprayed together with the material powder A from the nozzle 11N is preferably a pressure of about 0.27 to 0.69 MPa. In particular, about 0.59-0.69 MPa is suitable.
The temperature K1 of the superheated steam H is a temperature at which the superheated steam state can be maintained, that is, a higher temperature side than the saturated steam curve in FIG. Since the spray gun 11 and the base material B are under atmospheric pressure, the temperature K1 of the superheated steam H is maintained at 100 ° C. or higher throughout. In particular, the temperature is preferably 200 ° C. or higher so that the possibility of condensation is almost eliminated.

  In addition, when the material powder A is injected under reduced pressure, for example, by accommodating the cold spray unit 10 and the base material B in a pressure chamber, the pressure and temperature K1 of the superheated steam H are lower than the above range, It may be at a low temperature, and may be any pressure and temperature K1 at which the superheated steam H can be maintained.

  The material powder A ejected from the outlet of the nozzle 11N collides with the base material B while remaining solid. The material powder A colliding with the base material B at high speed is plastically deformed and adheres to the base material B (forms a coating R). Further, when the material powder A collides with the base material B, the kinetic energy changes to thermal energy, and depending on the material, the material surface exceeds the melting point and can be bonded to obtain a strong adhesion.

  As described above, the cold spray unit 10 forms the coating R by causing the material powder A to collide with the base material B in the solid phase in the sonic to supersonic flow together with the superheated steam H without melting or gasifying the material powder A. Can do.

A state sensor 15 for detecting the state of the superheated steam H is provided on the path (flow path) of the superheated steam H and the inner wall of the nozzle 11N. The state sensor 15 includes a temperature sensor 15a that detects the temperature K1 of the superheated steam H, a pressure sensor 15b that detects pressure, and a condensation sensor 15c that detects the presence or absence of condensation.
The temperature sensor 15a and the pressure sensor 15b are each set as one set and are arranged at a plurality of locations.
For example, an ACM sensor can be used as the dew condensation sensor 15c. The ACM sensor detects a dew condensation state using a potential difference between two kinds of metals. An insulator is placed between two types of metal, and no current flows in the dry state. However, when condensation occurs, water becomes a medium and a current due to the potential difference between the two types of metal flows. By monitoring the ON / OFF state of this current, it is possible to detect whether or not there is a dew condensation state.

From the detection results of the temperature sensor 15a and the pressure sensor 15b, it is possible to indirectly determine whether the superheated steam H is changed from the saturated steam state to the liquid phase state and moisture contained in the superheated steam H is not condensed.
In addition, what is necessary is just to manage temperature as dew condensation monitoring. If necessary, a heater, an induction coil, or the like may be disposed in the nozzle 11N or in the middle of the piping for heating. By heating the superheated steam H, a temperature equal to or higher than the saturated steam temperature curve temperature can be maintained. Thereby, the dew condensation in the cold spray part 10 can be prevented. In particular, since it is predicted that both the pressure and the temperature will decrease at the nozzle 11N, monitoring there is important.
Moreover, it can be directly judged whether the moisture contained in the superheated steam H has dew condensation from the detection result of the dew condensation sensor 15c.
In addition, as the state sensor 15, the case where it consists of the temperature sensor 15a and the pressure sensor 15b may be sufficient, and the case where it consists only of the dew condensation sensor 15c may be sufficient.

Thus, the state of the superheated steam H is detected by the state sensor 15 because when the moisture contained in the superheated steam H is condensed, the material powder A becomes difficult to adhere to the base material B, thereby obtaining a strong adhesion. This is to prevent this from happening.
That is, when the superheated steam H becomes saturated steam by the state sensor 15 and further enters a liquid phase, the temperature K1 and pressure of the superheated steam H to be generated are increased by controlling the superheated steam generator 13 and a gas supply unit (not shown). Let Thereby, dew condensation before the superheated steam H injected from the nozzle 11N reaches the base material B is avoided.

  The base material temperature adjusting unit 50 places the base material B and can heat the base material B. The base plate temperature adjusting unit 50 is embedded in the heating plate 52 and detects the temperature of the heater 54 and the heating plate 52. The sensor 56 includes a temperature control unit 58 that operates the heater 54 based on the detection result of the temperature sensor 56, and the like.

As the heating plate 52, a material having high thermal conductivity, such as copper or aluminum, is preferably used.
As the heater 54, a high frequency coil (high frequency induction heating device) is preferably used. When the heater 54 (high frequency coil) connected to the AC power source is operated, a high-density eddy current is generated near the surface of the heating plate 52, and the heating plate 52 is induction-heated by the Joule heat. .
Thereby, even if the base material B is a non-conductive substance such as ceramics, the base material B is placed on the heating plate 52 and is heated by heat conduction from the heating plate 52.

A thermocouple is preferably used as the temperature sensor 56. The temperature of the heating plate 52 is detected by a temperature sensor 56 (thermocouple) embedded in the heating plate 52. Since the temperature of the heating plate 52 is substantially equal to the heating temperature of the base material B, this temperature can be regarded as the heating temperature of the base material B.
Therefore, the temperature control unit 58 can heat and maintain the base material B at a desired temperature by controlling the heater 54 based on the detection result of the temperature sensor 56.

The heating temperature K2 of the base material B is a temperature at which the superheated steam H injected with the material powder A does not condense on the base material B. That is, the temperature is maintained at a higher temperature than the saturated vapor curve in FIG. Since the base material B is under atmospheric pressure, it is maintained at 100 ° C. or higher throughout. In particular, the temperature is preferably 200 ° C. or higher so that the possibility of condensation is almost eliminated.
Moreover, since it is preferable not to increase the temperature difference between the base material B and the superheated steam H, the base material B is at least as high as the temperature of the superheated steam H. The temperature is set to be at least 20 or higher, preferably 100 ° C. or higher.

  Further, when the base material B is heated, when the material powder A collides with the base material B, heat is conducted from the base material B to the material powder A, and thus the material powder A is easily plastically deformed. At this time, since the base material B is set at a temperature lower than the melting point of the material powder A, the material powder A is not dissolved and no material change (oxidation or thermal alteration) occurs. Furthermore, most of the sprayed material powder A adheres to the base material B, and the adhesion efficiency of the material powder A can be improved.

  Further, when the material powder A is sprayed from the cold spray unit 10, the material powder A is heated by the superheated steam H, so that the temperature difference between the material powder A and the base material B is reduced, and the material powder A is the base material. When it collides with the material B, heat conduction is performed instantaneously and reliably, and the material powder A is easily plastically deformed. That is, the amount of heat conduction from the base material B to the material powder A can be reduced, and the heat conduction from the base material B to the material powder A is ensured.

According to this embodiment, compared with the conventional plasma spraying method, flame spraying method, high-speed flame spraying method, etc., material powder can be made to adhere to the base material B in a solid-phase state, without heating too much.
The film R thus obtained has excellent properties such as denseness, high density, high thermal conductivity / conductivity, and good adhesion. In particular, since the material powder A is not heated and melted, it has an excellent property that there is almost no oxidation or thermal alteration.
Moreover, since the superheated steam H is used as the working gas for accelerating the material powder A, the running cost can be suppressed extremely inexpensively. In addition, since a working gas recovery device or the like is not required, the device can be reduced in size and price.
In addition, the molecular weight of the superheated steam (air) H is 18 g / mol, and the material powder A can be sufficiently accelerated.

  In addition, since the base material B is preliminarily heated, the superheated steam H is not rapidly cooled on the base material B to cause condensation. Thereby, material powder A adheres to base material B satisfactorily, and film R can be formed efficiently.

  The operation procedures shown in the above-described embodiment, or the shapes and combinations of the constituent members are examples, and can be variously changed based on various conditions, design requirements, and the like without departing from the gist of the present invention.

For example, in the above-described embodiment, the case where the heating plate 52 of the substrate temperature adjusting unit 50 is induction-heated and the substrate B placed on the heating plate 52 is heated by heat conduction has been described. Not exclusively.
For example, when the base material B is a conductor, the heating plate 52 may not be used. That is, when the heater 54 (high-frequency coil) is operated, an eddy current is generated in the base material B, and the base material B is induction-heated directly without contact.
That is, in the base material B, at least the region where the material powder A is deposited and the coating R is formed (deposition region) may be heated.

  Further, a laser heating device may be used. In the case of the laser heating apparatus, only the area (deposition area) where the material powder A is sprayed can be locally heated on the surface of the base material B, so that the apparatus can be made compact.

  As the temperature sensor 56, an infrared detection type temperature sensor may be used to detect the surface temperature of the substrate B in a non-contact and direct manner. In particular, an infrared detection type temperature sensor is suitable when an eddy current is generated in the base material B and induction heating is performed without using the heating plate 52.

It is a mimetic diagram showing a schematic structure of a cold spray device concerning an embodiment of the present invention. It is a schematic diagram which shows schematic structure of the cold spray part which concerns on this embodiment. It is a state diagram of water.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Cold spray apparatus 10 ... Cold spray part 11N ... Nozzle 13 ... Superheated steam generator 15 ... State sensor 50 ... Base material temperature adjustment part (base material heating part)
B ... Base material A ... Material powder R ... Film H ... Superheated steam (working gas)
K1 ... temperature of superheated steam K2 ... heating temperature of substrate

Claims (6)

In a cold spray method in which material powder is sprayed at a high speed together with a working gas from a nozzle and deposited on a substrate,
A cold spray method using superheated steam as a working gas for accelerating the material powder.   The cold spray method according to claim 1, wherein the temperature of the superheated steam is 200 ° C or higher.   3. The cold spray method according to claim 1, wherein at least a deposition region of the material powder of the base material is heated to a temperature higher than the temperature of the superheated steam by 20 ° C. or more. In a cold spray device in which material powder is sprayed at high speed from a nozzle together with a working gas and deposited on a substrate,
A cold spray apparatus comprising a superheated steam generator for generating superheated steam as a working gas for accelerating the material powder.   The cold spray device according to claim 4, further comprising: a state sensor that measures a state of the superheated steam in a spray portion to which the superheated steam and the material powder are injected.   The base material heating part which heats the temperature of the deposition area | region of the said material powder of the said base material at least to 20 degreeC or more rather than the temperature of the said superheated steam is provided. The cold spray device according to 1.

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