JP2023532379A - 高温保護用NiCrBSi-ZrB2サーメット粉末、複合コーティング及びその製造方法 - Google Patents
高温保護用NiCrBSi-ZrB2サーメット粉末、複合コーティング及びその製造方法 Download PDFInfo
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- JP2023532379A JP2023532379A JP2023501662A JP2023501662A JP2023532379A JP 2023532379 A JP2023532379 A JP 2023532379A JP 2023501662 A JP2023501662 A JP 2023501662A JP 2023501662 A JP2023501662 A JP 2023501662A JP 2023532379 A JP2023532379 A JP 2023532379A
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- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 1
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- 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
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- C23C4/06—Metallic material
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- C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
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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
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- 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
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- C—CHEMISTRY; METALLURGY
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- 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
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- 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
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- B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
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- Chemical & Material Sciences (AREA)
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- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Metallurgy (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Manufacturing & Machinery (AREA)
- Nanotechnology (AREA)
- Coating By Spraying Or Casting (AREA)
- Powder Metallurgy (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
Abstract
Description
a、NiCrBSi、ZrB2、アルコール及び酸化ジルコニウムボールを割合に応じてボールミル缶に投入し、ボールミリング速度を300~350r/minに設定して30~40h運転してアルコール含有混合粉末溶液を得る機械的ボールミリングステップと、
b、アルコール含有混合粉末溶液を送風定温乾燥器に入れ、加熱温度を50℃に設定し、12h保温する粉末蒸発乾涸ステップと、
c、乾燥後の混合粉末にバインダーのポリビニルアルコール、消泡剤のノルマルオクタノール及び脱イオン水を添加し、撹拌し、静置して水系複合スラリーを得るスラリー配合ステップと、
d、水系複合スラリーを撹拌しながら定流量ポンプによって高速遠心噴霧乾燥機に送入し、噴霧して球形粉末粒子を形成し、遠心噴霧乾燥機の入口温度は200~240℃、出口温度は100~130℃であり、遠心機の噴霧回転盤の周波数は36Hzであり、定流量ポンプの速度は26r/minである噴霧造粒ステップと、
e、真空焼結炉を使用して噴霧後の粉末粒子に対して真空焼結処理を行う真空焼結ステップと、
f、焼結したサーメット粉末に対して振動篩及び超音波発振器を使用して篩分け・分級処理を行い、超音波発振器の周波数を2~3Hzのパルス周波数とし、粒度分布15~45μmのNiCrBSi-ZrB2サーメット粉末を得る篩分け・分級ステップと、を含む。
S1、前記高温保護用NiCrBSi-ZrB2サーメット粉末を製造するステップと、
S2、溶射前、ボイラの鋼基材の表面に対して油抜き浄化処理を行い、次に、表面に対してブラスト処理を行い、ブラスト処理後の基材に対して予熱処理を行うステップと、
S3、酸素-プロパンを燃料とした高速フレーム溶射技術を使用し、酸素ガスを助燃剤、プロパンを燃料、窒素ガスを粉末供給キャリアガス、空気を冷却媒体とし、ステップS1で得たサーメット粉末をボイラの鋼基材の表面に溶射し、NiCrBSi-ZrB2複合コーティングを形成するステップと、を含む。
それぞれ質量%で80%のNiCrBSi及び20%のZrB2粉末を混合してボールミル缶に投入し、ボールミル缶に質量が粉末の質量の2倍となる酸化ジルコニウムボールを投入し、直径15mm、13mm、11mm、10mm、6mmの酸化ジルコニウムボールを選択して割合1:3:3:2:1で配合した。粉末100gあたりに55.5mLのアルコールを添加する割合でボールミル缶にアルコールを投入した。40hボールミリングし、回転速度を320r/minに設定した。
それぞれ質量%で70%のNiCrBSi及び30%のZrB2粉末を混合してボールミル缶に投入し、ボールミル缶に質量が粉末の質量の2倍となる酸化ジルコニウムボールを投入し、直径15mm、13mm、11mm、10mm、6mmの酸化ジルコニウムボールを選択して割合1:3:3:2:1で配合した。粉末100gあたりに55.5mLのアルコールを添加する割合でボールミル缶にアルコールを投入した。30hボールミリングし、回転速度を300r/minに設定した。
それぞれ質量%で60%のNiCrBSi及び40%のZrB2粉末を混合してボールミル缶に投入し、ボールミル缶に質量が粉末の質量の2倍となる酸化ジルコニウムボールを投入し、直径15mm、13mm、11mm、10mm、6mmの酸化ジルコニウムボールを選択して割合1:3:3:2:1で配合した。粉末100gあたりに55.5mLのアルコールを添加する割合でボールミル缶にアルコールを投入した。40hボールミリングし、回転速度を320r/minに設定した。
ホール流速計を用いて粉末の流動性及び嵩密度をテストし、粉末試料の種類ごとに3回テストし、その平均値を該粉末試料の流動性指標及び嵩密度とし、テスト結果は表1に示された。
ビッカース硬度計を用いてコーティングの微小硬度をテストし、荷重は300gf、荷重時間は5sであり、コーティングの種類ごとに10個の点をテストし、その平均値を該コーティングの微小硬度値とし、テスト結果は表2に示された。
Claims (10)
- 高温保護用NiCrBSi-ZrB2サーメット粉末の製造方法であって、
NiCrBSi、ZrB2、アルコール及び酸化ジルコニウムボールを割合に応じてボールミル缶に投入し、ボールミリング速度を300~350r/minに設定して30~40h運転してアルコール含有混合粉末溶液を得る機械的ボールミリングステップaと、
アルコール含有混合粉末溶液を送風定温乾燥器に入れ、加熱温度を50℃に設定し、12h保温する粉末蒸発乾涸ステップbと、
乾燥後の混合粉末にバインダーのポリビニルアルコール、消泡剤のノルマルオクタノール及び脱イオン水を添加し、撹拌し、静置して水系複合スラリーを得るスラリー配合ステップcと、
水系複合スラリーを撹拌しながら定流量ポンプによって高速遠心噴霧乾燥機に送入し、噴霧して球形粉末粒子を形成し、遠心噴霧乾燥機の入口温度は200~240℃、出口温度は100~130℃であり、遠心機の噴霧回転盤の周波数は36Hzであり、定流量ポンプの速度は26r/minである噴霧造粒ステップdと、
真空焼結炉を使用して噴霧後の粉末粒子に対して真空焼結処理を行う真空焼結ステップeと、
焼結したサーメット粉末に対して振動篩及び超音波発振器を使用して篩分け・分級処理を行い、超音波発振器の周波数を2~3Hzのパルス周波数とし、NiCrBSi-ZrB2サーメット粉末を得る篩分け・分級ステップfと、を含む、ことを特徴とする高温保護用NiCrBSi-ZrB2サーメット粉末の製造方法。 - 前記ステップaでは、NiCrBSi粉末の粒径は20~50μmであり、元素の質量%は、C 0.3~1.0%、Cr 8~18%、Si 2.5~5.5%、B 1.8~4.5%、Ni 65~85%、Fe≦5%であり、ZrB2粉末の粒径は1~3μmであり、純度≧99.85%である、ことを特徴とする請求項1に記載の高温保護用NiCrBSi-ZrB2サーメット粉末の製造方法。
- 前記ステップaでは、NiCrBSiとZrB2との質量比は6~8:4~2であり、粉末100gあたりのアルコールの添加量は55.5mlであり、直径15mm、13mm、11mm、10mm、6mmの酸化ジルコニウムボールを選択して割合1:3:3:2:1で配合して混合ボールを得て、ボールと粉末との質量比を2:1にする、ことを特徴とする請求項1に記載の高温保護用NiCrBSi-ZrB2サーメット粉末の製造方法。
- 前記ステップcでは、バインダーのポリビニルアルコールの添加量は粉末の全質量の3~3.5%であり、消泡剤のノルマルオクタノールの添加量は粉末の全質量の0.4~0.5%であり、脱イオン水の添加量はスラリー中の粉末固形分が40%となるように設定される、ことを特徴とする請求項1に記載の高温保護用NiCrBSi-ZrB2サーメット粉末の製造方法。
- 前記ステップeでは、真空焼結は温度傾斜焼結法を使用し、粉末を室温から300℃まで40min加熱し、30min保温し、次に300℃から900~1100℃まで80min加熱し、6h保温し、加熱を停止し、粉末を室温に炉冷する、ことを特徴とする請求項1に記載の高温保護用NiCrBSi-ZrB2サーメット粉末の製造方法。
- 粒径は15~45μm、嵩密度は1.51~2.13g/cm2、流動性は69.8~98.3s/50gである、ことを特徴とする請求項1~5のいずれか一項に記載の製造方法によって製造された高温保護用NiCrBSi-ZrB2サーメット粉末。
- 高温保護用NiCrBSi-ZrB2複合コーティングの製造方法であって、
請求項6に記載の高温保護用NiCrBSi-ZrB2サーメット粉末を製造するステップS1と、
溶射前、ボイラの鋼基材の表面に対して油抜き浄化処理を行い、次に、表面に対してブラスト処理を行い、ブラスト処理後の基材に対して予熱処理を行うステップS2と、
酸素-プロパンを燃料とした高速フレーム溶射技術を使用し、酸素ガスを助燃剤、プロパンを燃料、窒素ガスを粉末供給キャリアガス、空気を冷却媒体とし、ステップS1で得たサーメット粉末をボイラの鋼基材の表面に溶射し、NiCrBSi-ZrB2複合コーティングを形成するステップS3と、を含む、ことを特徴とする高温保護用NiCrBSi-ZrB2複合コーティングの製造方法。 - 前記ステップS2では、ブラスト材料は粒度が25メッシュの金剛砂であり、ブラスト圧力は3~5MPaであり、ブラスト後の基材の表面粗度は2.5~3μmに達し、基材の予熱温度は80~120℃に達する、ことを特徴とする請求項7に記載の高温保護用NiCrBSi-ZrB2複合コーティングの製造方法。
- 前記ステップS3では、プロパンの流速は60~70L/min、酸素ガスの流速は230~250L/min、空気の流速は320~350L/minであり、溶射距離は230~250mm、溶射ステップは3mm、溶射速度は800mm/sであり、粉末供給電圧は5~5.5V、粉末供給率は50~60g/minである、ことを特徴とする請求項7に記載の高温保護用NiCrBSi-ZrB2複合コーティングの製造方法。
- 厚さは200~300μmに達し、硬度は700~1000HVであり、基材との密着強度は75MPaを超え、気孔率は0.4~0.5%に達する、ことを特徴とする請求項7~9のいずれか一項に記載の製造方法によって製造された高温保護用NiCrBSi-ZrB2複合コーティング。
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