JP5538101B2 - Method for reusing sprayed powder, equipment for performing this method, and method for producing coating member - Google Patents

Description

  The present invention relates to a method for reusing spray powder sprayed on an object, equipment for executing the method, and a method for manufacturing a coating member.

Gas turbine rotor blades, stationary blades, combustors, and the like are in direct contact with high-temperature gas and are subjected to severe thermal cycles, erosion, corrosion, and the like. For this reason, members such as blades are often subjected to thermal barrier coating (TCC). As described in Patent Document 1 below, this TBC layer is formed of, for example, a bond coat layer formed by spraying a metal spray powder such as CoNiCrAlY on a target base material, and a ZrO ₂ -based ceramic spray powder. And a top coat layer formed by thermal spraying.

JP 2007-270245 A ([0044])

  The material for forming the base material itself is expensive for members such as moving blades, but since the thermal spray powder for forming a coating layer on the base material is also expensive, the coating member coated with the thermal spray powder such as the moving blades. The manufacturing cost is extremely increased.

  For this reason, reduction of the manufacturing cost of a coating member is desired.

  Therefore, an object of the present invention is to provide a technique capable of reducing the manufacturing cost of a coating member in order to meet such a demand.

The method for reusing sprayed powder according to the invention for achieving the above object is as follows:
In the method of reusing at least one of the metal spray powder and the ceramic spray powder sprayed toward the object,
Of the metal spray powder sprayed toward the object, the metal spray powder not applied to the object and the ceramic spray powder sprayed toward the object do not adhere to the object A ceramic spraying powder, a recovery step of recovering the powder containing the recovered powder as a recovered powder, and the electromagnetic spraying of the recovered powder in the electromagnetic field due to the difference in the electromagnetic properties of the particles constituting the recovered powder. Separation step of separating metal recovery powder into ceramic recovery powder containing ceramic spray powder, and spraying powder of at least one of the metal recovery powder and ceramic recovery powder obtained in the separation step And a thermal spray powder reuse step for thermal spraying on a new object.

  In the reuse method, at least a part of the thermal spray powder sprayed toward the object is reused as the thermal spray powder sprayed on the new object. The manufacturing cost of the coating member on which the coating layer is formed by thermal spraying can be reduced. Further, in the recycling method, even if the metal spray powder and the ceramic spray powder are mixed, both spray powders are separated in the separation step, so that a reusable high-purity spray powder is obtained. be able to.

  Here, in the reuse method of the thermal spray powder, the method has a classification step of extracting powder in a target particle size range from the recovered powder recovered in the recovery step and sending the extracted recovered powder to the separation step It may be.

  In the reuse method, since the reused spray powder falls within the target particle size range, the required performance can be ensured for the coating layer formed of the spray powder.

  In the spraying powder reuse method, the target particle size range of the recovered powder extracted in the classification step is an accumulated particle size of 10% particle size of 30 μm or more, and in the spraying powder reuse step, At least a part of the ceramic recovered powder obtained in the separation step may be sprayed onto the new object as the ceramic spray powder.

  In the recycling method, the required performance, specifically, the required heat resistance performance can be secured for the coating layer formed by spraying the ceramic recovered powder.

  Moreover, in the reuse method of the thermal spray powder, the target particle size range of the recovered powder extracted in the classification step is an integrated particle size 10% particle size of 20 μm or more, and in the thermal spray powder reuse step, At least a part of the metal recovery powder obtained in the separation step may be sprayed onto the new object as the metal spray powder.

  In the recycling method, it is possible to reduce the performance required for the coating layer formed by thermal spraying of the metal recovery powder, specifically, the amount of heat-generated oxide generated.

  The spraying powder recycling method further comprises a ceramic powder classification step of extracting ceramics recovered powder having an accumulated particle size of 10% and a particle size of 30 μm or more from the ceramics recovered powder obtained in the separation step, and the sprayed powder In the reuse process, at least a part of the ceramic recovered powder extracted in the ceramic powder classification process may be sprayed on the new object as the ceramic spray powder.

  In the recycling method, the coating layer formed by spraying the metal recovery powder can suppress the amount of thermally generated oxide, and the heat resistance performance of the coating layer formed by spraying the ceramic recovery powder. Can be secured.

  Moreover, in the reuse method of the thermal spraying powder of the thermal spraying powder, the ceramic recovered powder obtained in the separation step is put into an aqueous solution in which a metal or an amphoteric hydroxide is dissolved, and the metallic powder in the recovered ceramic powder is Alternatively, it has a dissolution and removal step of dissolving amphoteric hydroxide powder and extracting the particulate matter remaining in the aqueous solution, and in the spraying powder reuse step, the particulate extracted from the aqueous solution in the dissolution and removal step An object may be sprayed onto the new object as the ceramic spray powder.

  In the recycling method, the purity of the ceramic spray powder in the ceramic recovered powder can be increased.

  Further, in the thermal spray powder recycling method, in the separation step, the metal recovered powder and the ceramics are generated in an electric field due to a difference in electrical properties of the particles constituting the recovered powder recovered in the recovery step. It may be separated into recovered powder. Further, in the separation step, the metal recovered powder and the ceramic recovered powder may be separated in a magnetic field due to a difference in magnetic properties of each particle constituting the recovered powder recovered in the recovery step. .

A manufacturing method of a coating member according to the invention for achieving the above object
Performing the method of reusing the thermal spray powder, and forming a coating layer on the surface of the target object by using the thermal spray powder sprayed on the target object in the spray powder reuse step to manufacture a coating member. Features.

  In the manufacturing method of the coating member, since at least a part of the thermal spray that has not been applied to the target among the thermal sprays sprayed toward the target is reused as the thermal spray that is sprayed on the new target, The manufacturing cost of the coating member in which the coating layer is formed by thermal spraying of the thermal spray powder can be suppressed.

The thermal spraying equipment according to the invention for achieving the above object is
In thermal spray equipment that sprays metal spray powder and ceramic spray powder on the object,
A first thermal spraying device having a first thermal spraying gun for spraying the metal thermal spraying powder onto the object, a second thermal spraying device having a second thermal spraying gun for spraying the ceramic thermal spraying powder onto the target, and the target Of the metal spray powder sprayed toward the object, the metal spray powder not sprayed on the object, and among the ceramic spray powder sprayed toward the object, the ceramic spray powder not adhered to the object And a recovery device that recovers the powder containing the recovered powder as a recovered powder, and a metal recovered powder containing the metal spray powder in an electromagnetic field due to a difference in electromagnetic properties of the particles constituting the recovered powder. And a separator for separating the recovered ceramic powder containing the ceramic spray powder and extracting at least one recovered powder as a part of the spray powder.

  In the spraying equipment, since at least a part of the thermal spray powder sprayed toward the target object can be reused as the thermal spray powder sprayed on the new target object, The manufacturing cost of the coating member on which the coating layer is formed by thermal spraying can be suppressed. Furthermore, in the said thermal spraying equipment, even if it is a state with which metal spray powder and ceramic spray powder are mixed, since both spray powder can be isolate | separated, the thermal spray powder with the high reusable purity can be obtained.

  Here, in the thermal spraying equipment, the powder in the target particle size range is extracted from the recovered powder recovered by the recovery device, and the recovered powder extracted is provided with the classification device, and the separation device includes the classification device. The recovered powder extracted by may be separated.

  In the said spraying equipment, since the sprayed powder to be reused falls within the target particle size range, the required performance can be ensured for the coating layer formed from the sprayed powder.

  Further, in the thermal spraying equipment, the target particle size range of the recovered powder extracted by the classifier is an accumulated particle size of 10% particle size of 30 μm or more. You may extract as at least one part of a thermal spray powder. In addition, as for the said target particle size range of the said collection | recovery powder which the said classifier extracts, it is more preferable that the integrated particle size 10% particle size is 40 micrometers or more.

  In the said thermal spraying equipment, the performance requested | required with respect to the coating layer formed by the thermal spraying of the said ceramic recovery powder, specifically, the heat-resistant performance calculated | required, can be ensured.

  Further, in the thermal spraying equipment, the target particle size range of the recovered powder extracted by the classifier is an integrated particle size of 10% particle size of 20 μm or more, and the separation device converts the metal recovered powder into the metal You may extract as at least one part of a thermal spray powder.

  In the said thermal spray equipment, the performance calculated | required with respect to the coating layer formed by the thermal spraying of the said metal recovery powder, specifically, suppression of the production amount of a heat generation oxide can be aimed at.

  In the thermal spraying equipment, there is provided a ceramic powder classification device for extracting ceramic recovered powder having an accumulated particle size of 10% particle size of 30 μm or more as at least part of the ceramic sprayed powder from the ceramic recovered powder obtained by the separation device. You may have.

  In the said thermal spraying equipment, while being able to aim at suppression of the production amount of the heat generation oxide of the coating layer formed by the spraying of the metal recovery powder, the heat resistance performance of the coating layer formed by the spraying of the ceramic recovery powder is ensured. can do.

  In the thermal spraying equipment, the first thermal spray gun and the second thermal spray gun are installed in one thermal spray booth, and the recovery device includes a recovery duct having an opening facing the thermal spray booth, And a suction fan for sucking the powder in the thermal spray booth into the recovery duct. The first thermal spray gun is installed in a first thermal spray booth, the second thermal spray gun is installed in a second thermal spray booth different from the first thermal spray booth, and the recovery device has a first opening. A recovery duct that faces the first thermal spraying booth and a second opening faces the second thermal spraying booth, and sucks the powder in the first thermal spraying booth into the recovery duct from the first opening And a suction fan for sucking the powder in the second thermal spray booth into the recovery duct from the second opening.

  According to the present invention, at least a part of the thermal spray powder that has not been applied to the target object among the thermal spray powders sprayed toward the target object can be reused as the thermal spray powder sprayed onto the new target object. The manufacturing cost of the coating member on which the coating layer is formed by thermal spraying can be reduced.

It is explanatory drawing which shows the structure of the thermal spraying installation in 1st embodiment which concerns on this invention. It is explanatory drawing which shows the structure of the flame spraying apparatus in 1st embodiment which concerns on this invention. It is explanatory drawing which shows the structure of the plasma spraying apparatus in 1st embodiment which concerns on this invention. It is explanatory drawing which shows the structure of an example of the classification apparatus in 1st embodiment which concerns on this invention. It is a flowchart which shows the manufacture procedure of the thermal spraying powder and coating member in 1st embodiment which concerns on this invention, The figure (A) is a flowchart which shows the manufacturing procedure of YSZ thermal spraying powder, The figure (B) is manufacture of a coating member. It is a flowchart which shows a procedure. It is a flowchart which shows the procedure of reuse of the thermal spray powder in 1st embodiment which concerns on this invention. The particle size at an integrated particle size of 10% of the YSZ sprayed portion and the temperature difference ΔT that the ceramic layer (coating layer) formed by plasma spraying of the YSZ sprayed powder can withstand without breaking even if the thermal cycle number exceeds 1000 times, It is a graph which shows a relationship. It is a graph which shows the relationship between the particle size of each thermal spraying powder and integrated particle size in 1st embodiment which concerns on this invention. It is explanatory drawing which shows the structure of the thermal spraying installation in 2nd embodiment which concerns on this invention. It is a flowchart which shows the procedure of reuse of the thermal spray powder in 2nd embodiment which concerns on this invention. It is explanatory drawing which shows the structure of the thermal spraying installation in 3rd embodiment which concerns on this invention. It is a flowchart which shows the procedure of reuse of the thermal spray powder in 3rd embodiment which concerns on this invention. It is explanatory drawing which shows the structure of the modification of the thermal spraying equipment of embodiment which concerns on this invention. It is explanatory drawing which shows the structure of the modification of the separation apparatus of embodiment which concerns on this invention. It is sectional drawing of the coating member in one Embodiment which concerns on this invention.

  Hereinafter, various embodiments of the thermal spraying equipment according to the present invention will be described with reference to the drawings.

"Embodiment of coating member"
Before describing the embodiment of the thermal spraying equipment, a coating member manufactured by thermal spraying using the thermal spraying equipment will be described.

  The coating member of this embodiment is formed on the surface of the base material 1 to be coated, the bond coat layer (coating layer) 2 formed on the surface of the target member, and the surface of the bond coat layer 2, as shown in FIG. Ceramic layer (coating layer) 3. The bond coat layer 2 and the ceramic layer 3 constitute a thermal barrier coating (TBC) layer 4.

  The target member 1 is formed of a heat resistant alloy, for example, a Ni-based alloy or a Co-based alloy. Specifically, as the Ni-based alloy, for example, an alloy having the following components is used. Ni-16Cr-8.5Co-1.75Mo-2.6 W-1.75Ta-0.9Nb-3.4Ti-3.4Al (mass%)

  The bond coat layer 2 is provided to alleviate the difference between the thermal expansion amount of the ceramic layer 3 and the thermal expansion amount of the target base material 1. The bond coat layer 2 is formed of an MCrAlY alloy (M is one or two elements selected from the group of Ni, Co, and Fe) excellent in corrosion resistance and oxidation resistance at high temperatures. Specifically, the bond coat layer 2 is formed of, for example, a CoNiCrAlY alloy, and the components thereof are as follows. Co-32Ni-21Cr-8Al-0.5Y (mass%) The bond coat layer 2 is formed by spraying MCrAlY alloy powder on the target base material 1, for example, a high-speed flame (HVOF). The The thickness of the bond coat layer 2 is 10 μm to 500 μm.

The ceramic layer 3 is provided for heat shielding, thermal shock relaxation, and the like on the target base material 1. For this reason, it is formed of stabilized zirconia or the like having low thermal conductivity and high emissivity. Specifically, it is made of yttria-stabilized zirconia (YSZ) having a mass ratio of Yb ₂ O ₃ : ZrO ₂ = 8: 92. This ceramic layer 3 is formed by subjecting YSZ powder to atmospheric pressure plasma spraying (APS) on the target base material 1 on which the bond coat layer 2 is formed. The ceramic layer 3 has a thickness of 0.1 mm to 1 mm.

"First embodiment of thermal spraying equipment"
Next, 1st embodiment of the thermal spraying equipment which concerns on this invention is described using FIGS.

  As shown in FIG. 1, the thermal spraying equipment of the present embodiment includes a high-speed flame spraying apparatus 70 that sprays MCrAlY sprayed powder on the target base material 1 at high speed, and plasma that sprays YSZ sprayed powder on the target base material 1 at atmospheric pressure. Thermal spraying device 10, recovery device 30 that recovers each thermal spray powder not attached to target base material 1, classification device 40 that classifies the powder and the like recovered by recovery device 30, and particles classified by this classification device 40 A separation device 50 that mainly extracts ceramic powder, that is, YSZ powder, from powder having a diameter of 30 μm or more and less than 150 μm, and a dissolution container 61 for dissolving and removing metal powder from the powder extracted by the separation device 50 are provided. ing.

  As shown in FIG. 2, the high-speed flame spraying device 70 includes a flame spraying gun 71, a fuel supply device 81 that supplies fuel to the flame spraying gun 71, an oxygen supply device 82 that supplies oxygen to the flame spraying gun 71, A powder supply device 83 that supplies spray powder to the spray gun, a power supply device 84 that supplies power for igniting fuel to the spray gun 11, and a cooling water supply device 85 that supplies cooling water to the frame spray gun 71. , And a control device 86 for controlling these devices 81 to 85.

  The flame spray gun 71 includes a nozzle 72 in which a flame (frame) F is formed, a spark plug 73 that forms a spark in a chamber 72b on the base side of the nozzle 72, and a gun housing 77 that surrounds the nozzle 72. Have. A fuel inlet 74 and an oxygen inlet 75 are formed in the chamber 72 b of the nozzle 72. A spray powder receiving port 76 is formed between the chamber 72 b of the nozzle 72 and the injection port 72 a of the nozzle 72. The gun housing 77 has a cooling water inlet 78 through which cooling water from the cooling water supply device 85 flows into a cooling space between the inside of the gun housing 77 and the outside of the nozzle 72, and cooling in the cooling space. A cooling water outlet 79 from which water is drained is formed.

  The fuel from the fuel supply device 81 and the oxygen from the oxygen supply device 82 are injected into the chamber 72 b of the nozzle 72. In the chamber 72, the spark plug 73 is ignited by receiving electric power from the power supply device 84, and a spark is formed. As a result, a flame (frame) F is formed in the nozzle 72. Further, spray powder from the powder supply device 83 is supplied into the nozzle 72. The thermal spray powder is sprayed from the spray port 72 a of the nozzle 72 together with the flame F and sprayed onto the target base material 1.

  As shown in FIG. 3, the plasma spraying apparatus 10 includes a plasma spraying gun 11, a working gas supply device 21 that supplies a working gas to the plasma spraying gun 11, and a powder supply device 22 that supplies powder to the spraying gun 11. A power supply device 23 that supplies power for converting the working gas to plasma to the spray gun 11, a cooling water supply device 24 that supplies cooling water to the spray gun 11, and a control that controls these devices 21 to 24. Device 25.

  The plasma spray gun 11 includes a nozzle 12 in which plasma is formed, a tungsten electrode 15 provided in the nozzle 12, and a gun housing 16 surrounding the nozzle 12. The tungsten electrode 15 is fixed inside the nozzle 12 and on the base side thereof. The nozzle 12 has a working gas inlet 13 formed on the base side, and a powder inlet 14 formed on the injection port 12a side. The gun housing 16 has a cooling water inlet 17 through which cooling water from the cooling water supply device 24 flows into a cooling space between the inside of the gun housing 16 and the outside of the nozzle 12, and cooling in the cooling space. A cooling water outlet 18 from which water is drained is formed.

  A working gas such as Ar is supplied from the working gas supply device 21 into the nozzle 12 of the plasma spray gun 11. Further, by driving the power supply device 23, the tungsten electrode 15 becomes a negative electrode, the vicinity of the nozzle 12a of the nozzle 12 becomes a positive electrode, and electrons jump out from the tungsten electrode 15 toward the vicinity of the nozzle outlet 12a. As a result, the working gas is ionized into plasma. Thermal spray powder from the powder supply device 22 is supplied into this plasma. The thermal spray powder is plasma heated and sprayed onto the target base material 1.

  The description will be continued with reference to FIG. The flame spray gun 71 of the high-speed flame spray apparatus 70 and the plasma spray gun 11 of the plasma spray apparatus 10 are both disposed in the spray room B. In the thermal spray booth B, in addition to the thermal spray guns 71 and 11, rotary tables 89 and 29 on which the target base material 1 is placed are also arranged. Of the walls forming the thermal spray booth B, on the walls of the thermal spray guns 71 and 11 on the basis of the rotary tables 89 and 29, intake holes 39 for taking in gas into the booth are formed. Here, the rotary tables 29 and 89 are provided for the respective spray guns 11 and 71. However, only one rotary table is provided, and this single rotary table is used for flame spraying and plasma spraying. Good.

  The recovery device 30 includes a recovery duct 31 for recovering the sprayed powder sprayed from the spray guns 71 and 11, and a suction fan 32 that sucks the powder containing the sprayed powder together with the gas into the recovery duct 31. Yes. The opening 31a of the recovery duct 31 is provided on the wall on the opposite side of the spray guns 71 and 11 with respect to the rotary tables 89 and 29 among the walls forming the spray booth B, and toward the spray guns 71 and 11. It has a large opening. A suction fan 32 is provided at the end of the recovery duct 31. Here, the recovery device 30 is constituted by the recovery duct 31 and the suction fan 32, but a dust collector such as a cyclone may be added to the recovery device 30.

  As shown in FIG. 1, the classifier 40 is connected to the exhaust port of the suction fan 32. The classifier 40 divides the recovered powder collected by the recovery device 30 from the spraying booth B into recovered powder having a particle size of less than 30 μm, recovered powder having a particle size of 30 μm or more and less than 150 μm, and recovered powder of 150 μm or more. Then, the recovered powder having a particle size of 30 μm or more and less than 150 μm is extracted. More precisely, the recovered powder having a 10% cumulative particle size of 30 μm or more and less than 150 μm is extracted.

  As a kind of the classification device 40, there are a centrifugal classification device, a gravity classification device, a sieving device, etc., but any of these devices can be used as long as the recovered powder can be divided into the three particle size ranges as described above. Any type of device may be used, or any two types of devices may be combined.

  In the present embodiment, the recovered powder is classified using a forced vortex centrifugal classifier 45 shown in FIG. The forced vortex centrifugal classifier 45 includes a classification cylinder 46 and a classification rotor 47 that rotates within the classification cylinder 46. Since this forced vortex centrifugal classifier 45 can divide the recovered powder into only two particle size ranges, two forced vortex centrifugal classifiers 45 are connected in series or shown in FIG. Thus, it is good to provide the sieving device 41 downstream of the coarse particle outlet 46a of the single forced vortex centrifugal classifier 45.

  As shown in FIG. 1, the separating device 50 includes a friction charging device 51 that charges each material by transferring charges from one material to the other by rubbing materials having different electrical properties. And an electrostatic sorting device 52 that sorts the material according to the polarity of the material. The frictional charging device 51 has a charging chute that receives powder and the like sent from the classification device 40. In the process of passing through the charging chute, the powder or the like is charged positively or negatively depending on its electrical properties. The electrostatic sorting device 52 includes a negative electrode plate 54 that draws a positively charged substance, a positive electrode plate 53 that draws a negatively charged substance, and a collection container 55 that receives a charged substance of each polarity. Yes. The collection container 55 is provided with a partition 56 for dividing the inside of the container into a positive electrode plate side part 55a, an intermediate part 55b, and a negative electrode plate side part 55c.

  Here, the manufacturing method of the YSZ spraying powder used by this embodiment is demonstrated according to the flowchart shown to FIG. 5 (A).

First, ZrO ₂ powder and Yb ₂ O ₃ powder, which are YSZ production materials, are prepared. Then, put ZrO ₂ powder, _Yb 2 _{O 3} powder, water, a dispersing agent such as a ball mill, these were mixed and slurried (S1).

  Next, the slurry generated in Step 1 is put into a spray dryer and granulated (S2).

Then, the granulated mixture of ZrO ₂ and Yb ₂ O ₃ is subjected to heat treatment (S3). As this heat treatment method, there are the following three methods.

  The first method is a method in which the granulated mixture is placed in an electric furnace, heated to about 1500 to 1600 ° C., and the mixture is sintered. The second method is a method in which the granulated mixture is heated to about 2400 ° C. by using arc discharge to melt the mixture. In this method, after the molten mixture is solidified, the mixture is pulverized and classified. The third method is a method of heating with plasma. As a specific method of performing the plasma heating, for example, there is a method of using the above-described plasma spraying apparatus and putting the granulated mixture into the plasma formed by the plasma spraying apparatus.

By this heat treatment (S3), most of ZrO _{2 in} the mixture changes from monoclinic to tetragonal, and Yb ₂ O ₃ dissolves in the Zr oxide that has changed to tetragonal. It becomes a stable tetragonal Zr oxide powder, that is, YSZ sprayed powder.

Here, Yb ₂ O ₃ powder is used to stabilize the crystal structure of the Zr oxide, but instead of Yb ₂ O ₃ powder, Mg, Ca, Y, La, Sm, Nd, An oxide powder of any one element of Gd, Dy, Er, and Yb may be used. Further, Ce oxide may be used in place of the Zr oxide that is the main component of the thermal spray powder. In this case, oxide powder of one element of La, Nd, and Gd may be used to stabilize the crystal structure of Ce oxide.

  Next, the manufacturing procedure of the thermal barrier coating member described with reference to FIG. 13 will be described according to the flowchart shown in FIG.

  First, the target base material is formed into a target shape (S11). As described above, this target member is made of a Ni alloy or a Co alloy.

  Next, a blast process is performed on the surface of the target base material 1 as a base process of the bond coat layer 2 (FIG. 13) (S12). In this blasting process, alumina (aluminum hydroxide) particles are put into a blasting apparatus, and the alumina particles are sprayed onto the surface of the target base material with a high air pressure. As a result, a large number of alumina particles collide with the surface of the target base material at high speed, and the surface becomes rough.

  Next, using the high-speed flame spraying apparatus 70 of the thermal spraying equipment explained above, MCrAlY spray powder is fast flame-sprayed on the surface of the target base material 1 that has been subjected to the blasting process, and then bonded to the surface of the target base material 1 The coat layer 2 (FIG. 13) is formed (S13). In addition, in order to improve the oxidation resistance of this bond coat layer, aluminum or aluminum and silicon may be diffused and penetrated into the bond coat layer 2 as necessary.

  And using the plasma spraying apparatus 10 of the thermal spraying equipment demonstrated above, the YSZ thermal spraying powder is plasma-sprayed in the direction of the object base material 1 in which the bond coat layer 2 (FIG. 13) was formed, and the bond coat layer 2 The ceramic layer 3 is formed thereon (S14).

  Thus, the thermal barrier coating member in which the TBC layer 4 (FIG. 13) having the bond coat layer 2 and the ceramic layer 3 is formed on the surface of the target base material 1 is completed.

  In this embodiment, the regeneration process (S20) of the YSZ spray powder that was used during plasma spraying (S14) and was not attached to the target base material is executed. The YSZ spraying powder regeneration process (S20) will be described with reference to the flowchart shown in FIG.

  During the plasma spraying (S14), the suction fan 32 of the recovery device 30 is driven. For this reason, among the YSZ spray powder sprayed from the plasma spray gun 11, the YSZ spray powder not attached to the target base material 1 is sucked into the recovery duct 31 and recovered (S21). At this time, various powders floating in the spraying booth B are also sucked into the recovery duct 31. These various powders include alumina particles used in the blasting process (S12), MCrAlY spraying powder used in the formation of the bond coat layer (S13), floating dust in the spraying booth B, and the like. . Note that this recovery process (S21) may be executed only during plasma spraying (S14), but may also be executed during high-speed flame spraying (S13). Furthermore, in order to clean the environment in the welding booth B, this recovery process (S21) may be executed while the thermal spray booth B is used for any process.

  The powder sucked into the collection duct 31, that is, the collected powder, is classified by the classifier 40, the collected powder having a particle size of less than 30 μm, the collected powder having a particle size of 30 μm or more and less than 150 μm, and the collected powder of 150 μm or more. The recovered powder having a particle size of 30 μm or more and less than 150 μm is extracted (S22). More precisely, the recovered powder having a 10% cumulative particle size of 30 μm or more and less than 150 μm is extracted. On the other hand, recovered powder having a particle size of less than 30 μm and recovered powder having a particle size of 150 μm or more are discarded. The recovered powder having a particle size of less than 30 μm contains YSZ spray powder and the like, but is discarded because it has a small particle size and is not suitable as a spray powder for forming a TBC layer. Further, the recovered powder having a particle size of 150 μm or more is discarded because there are few YSZ sprayed powders and conversely there are many dusts such as sand particles.

  The recovered powder extracted by the classification device 40 is separated by the separation device 50 due to the difference in the electrical properties of each substance contained in the recovered powder (S23). Specifically, among the collected powder sent to the separation device 50 by the friction charging device 51 of the separation device 50, the YSZ sprayed powder that is ceramic is charged negatively, and the MCrAlY sprayed powder that is metal is positively charged. Is charged. For this reason, the YSZ spray powder charged to the negative polarity is attracted to the positive electrode plate 53 side of the electrostatic sorting device 52 and falls mainly to the positive electrode plate side portion 55 a in the collection container 55. Further, the MCrAlY spray powder charged to the positive polarity is attracted to the negative electrode plate 54 side and falls mainly to the negative electrode plate side portion 55 c in the collection container 55. The YSZ spray powder charged to the negative polarity and the MCrAlY spray powder charged to the positive polarity fall on the intermediate portion 55b of the collection container 55.

  The recovered powder recovered in the negative electrode plate side portion 55c of the recovery container 55, that is, recovered powder mainly composed of MCrAlY sprayed powder is discarded or reused as the sprayed powder for forming the bond coat layer. Here, the recovered powder collected in the negative electrode plate side portion 55c is discarded because it is assumed that only a relatively small amount of MCrAlY sprayed powder can be recovered with respect to the YSZ sprayed powder. Further, the recovered powder recovered in the intermediate portion 55b of the recovery container 55 is again put into the friction charging device 51 of the separation device 50, and due to the difference in electrical properties of each substance contained in the recovered powder, Re-separated. Further, the collected powder collected on the positive electrode side portion 55a of the collection container 55, that is, the collected powder mainly composed of YSZ sprayed powder is taken out from the collection container 55 and subjected to a dissolution removal process (S24).

  Here, the specific example of the electrostatic separation effect by the separation apparatus 50 of this embodiment is demonstrated. As shown in Table 1 below, the contents of MCrAlY in samples 1 and 2 of the recovered powder obtained in the recovery process (S21) are 5.34 (wt%) and 1.86 (wt%), respectively. In this case, the contents of MCrAlY in samples 1 and 2 of the recovered powder extracted by the classification / separation process (S22, S23) are 0.06 (wt%) and 0.05 (wt%). . That is, in the present embodiment, the recovered powder recovered in the positive electrode plate side portion 55a of the recovery container 55 of the separation device 50, that is, the recovered powder mainly composed of YSZ sprayed powder has a MCrAlY content of 1 (wt%). Less than.

  In the dissolution and removal process (S24), when there is a large amount of metal powder (for example, MCrAlY sprayed powder) in the recovered powder recovered in the positive electrode plate side portion 55a of the recovery container 55, hydrochloric acid, nitric acid, king The recovered powder recovered in the positive electrode plate side 55a of the recovery container 55 is placed in a dissolution container 61 containing an acidic aqueous solution such as water, and the aqueous solution is heated to dissolve the metal powder in the recovered powder. For example, when the recovered powder contains MCrAlY sprayed powder of around 0.5 (wt%), when the recovered powder is heated in aqua regia, unrecovered recovered powder from this aqua regia Is extracted, the amount of the MCrAlY sprayed powder in the recovered powder becomes 0.02 (wt%).

  When the recovered powder recovered in the positive electrode side portion 55a of the recovery container 55 contains a lot of amphoteric hydroxide powder, for example, aluminum hydroxide (alumina) powder, an aqueous solution of 1 to 12 normal sodium hydroxide is used. The recovered powder recovered in the positive electrode plate side portion 55a of the recovery container 55 is placed in the dissolution container 61 containing, and the aqueous solution is heated to dissolve the amphoteric hydroxide powder in the recovered powder. For example, when the recovered powder contains about 0.08 to 0.05 (wt%) of alumina powder, when this recovered powder is heat-treated in an aqueous sodium hydroxide solution, When undissolved recovered powder is extracted, the amount of alumina powder in the recovered powder becomes 0.01 (wt%).

  Further, in the recovered powder recovered in the positive electrode plate side portion 55a of the recovery container 55, when the metal powder and the amphoteric hydroxide powder are relatively large, the heat treatment in the acidic aqueous solution as described above, and Heat treatment in an aqueous sodium hydroxide solution is performed to dissolve the metal powder and amphoteric hydroxide powder in the recovered powder.

  When unnecessary particles are dissolved by the aqueous solution, the aqueous solution and the fine particle solid are separated from the dissolution vessel 61, and the fine particle solid is washed with water and dried to obtain a dry powder.

  The dry powder obtained by this dissolution and removal treatment (S24) has a particle size of 30 μm or more and less than 150 μm, and is a high-purity YSZ powder. Thus, the spraying powder regeneration process (S20) is completed.

  In this embodiment, when this YSZ powder is put into the powder supply device 22 of the thermal spraying apparatus as a YSZ regenerated thermal spraying powder and the input amount of the YSZ thermal spraying powder is small, steps 1 to 3 shown in FIG. Add the virgin spray powder produced in the process. Then, YSZ spray powder is supplied from the powder supply device 22 of the plasma spray apparatus 10 to the plasma spray gun 11, and this YSZ spray powder is plasma sprayed onto the target base material 1. That is, the YSZ regenerated spray powder is reused for plasma spraying (S25, S14 (FIG. 5B)).

  As mentioned above, in this embodiment, after using an unused spraying powder (henceforth a virgin spraying powder) for thermal spraying, since this is collect | recovered and regenerated as a regenerated spraying powder, the virgin spraying used for a thermal spraying is carried out. It is possible to reduce the amount of powder, and as a result, it is possible to reduce the manufacturing cost of the thermal barrier coating member in which the thermal spray powder is sprayed and the thermal barrier coating (TBC) layer is formed on the surface.

  Moreover, in this embodiment, since a ceramic layer is formed with YSZ regenerated spray powder, the possibility of peeling of this ceramic layer can be reduced for the following reasons a and b.

(1) Reason for reducing peelability a
In the process of producing the YSZ virgin spray powder, as described above with reference to FIG. 5A, the mixture of ZrO ₂ and Yb ₂ O ₃ is subjected to heat treatment (S3), and most of the ZrO _{2 in} the mixture is removed. A phase change from monoclinic to tetragonal, and Yb ₂ O ₃ dissolved in the tetragonal Zr oxide to form a solid tetragonal Zr oxide powder, ie, YSZ sprayed powder Is manufacturing.

However, in the heat treatment (S3), when the mixture is heated by an electric furnace or by arc discharge, since the temperature of the mixture does not become so high, even if the heating time is lengthened, all of the ZrO _{2 in} the mixture Does not change from monoclinic to tetragonal, and monoclinic crystals remain. Specifically, although somewhat different depending on the heating conditions, 90 to 95% of the ZrO _{2 in} the mixture becomes tetragonal in the heating as described above, but the rest exists as monoclinic crystals. Furthermore, since the temperature of the mixture does not increase so much, the solid solution amount of Yb ₂ O ₃ is not so much, and the tetragonal Zr oxide is not sufficiently stabilized.

In the heat treatment (S3), when the mixture is plasma-heated, the temperature of the mixture becomes extremely high (for example, about 10,000 ° C.), but since it is instantaneous heating, as in the case described above, All of ZrO ₂ does not change from monoclinic to tetragonal, and the Zr oxide that has become tetragonal does not sufficiently stabilize.

On the other hand, since the YSZ regenerated spray powder is subjected to heat treatment by plasma spraying (S13: second heat treatment) after heat treatment (S3: first heat treatment) performed in the production process of YSZ virgin spray powder, Among them, ZrO ₂ that did not become tetragonal by the first heat treatment, that is, monoclinic crystal, can be phase-shifted to tetragonal crystal, and the solid solution amount of Yb ₂ O ₃ can be increased. Specifically, although slightly different depending on conditions, 99% or more of ZrO _{2 in} the mixture becomes tetragonal by the second heat treatment (S13).

As described above, the YSZ regenerated spray powder has a larger amount of ZrO ₂ in the tetragonal system than the YSZ virgin spray powder, and the amount of solid solution of Yb ₂ O ₃ is larger. The oxide can be further stabilized. For this reason, the peelability of the ceramic layer formed with YSZ regenerated spray powder can be reduced.

(2) Reason for reduction of peelability b
There is a predetermined relationship between the particle size of the YSZ spray powder and the thermal cycle durability of the ceramic layer formed of the YSZ spray powder.

Here, the relationship between the particle size of the thermal spray powder and the thermal cycle durability will be described with reference to FIG. In the figure, the horizontal axis represents the particle size (d ₁₀ ) of the cumulative particle size of YSZ spray powder of 10%, and the vertical axis represents the number of heat cycles of 1000 times by the ceramic layer formed by plasma spraying of YSZ spray powder. The temperature difference ΔT that can be tolerated without breaking even if the temperature exceeds. This temperature difference ΔT is the difference between the highest surface temperature and the highest interface temperature of the ceramic layer. This temperature difference ΔT is an index indicating the thermal cycle durability of the ceramic layer, and it is determined that the thermal cycle durability is higher as the ΔT is larger.

The data shown in FIG. 7 is data obtained in a thermal cycle durability test described below. In this thermal cycle endurance test, a Ni-based alloy (trade name: IN-738LC), which is a heat-resistant alloy having a thickness of 5 (mm), is used as a test piece, and a metal with a film thickness of 100 (μm) is formed by low-pressure plasma spraying. What formed the bond coat layer (Ni: 32 mass%, Cr: 21 mass%, Al: 8 mass%, Y: 0.5 mass%, Co: remainder) was used. A spray gun 11 (F4 gun) manufactured by Sulzer Metco Co., Ltd. was used for spraying the YSZ spray powder on this test piece. The spraying conditions in this spraying are: spraying current: 600 (A), spraying distance: 150 (mm), spray powder supply amount: 60 (g / min), working gas (Ar / H ₂ ) supply amount: 35/7. 4 (l / min). The thickness of the ceramic film formed on the test piece by spraying the YSZ spray powder is 0.5 (mm).

  In this thermal cycle durability test, the laser thermal cycle test method described in Japanese Patent No. 4031631 is adopted, the heating time for the ceramic layer is 3 minutes, the cooling time is 3 minutes, the maximum interface temperature is 900 ° C., The maximum surface temperature was set, the number of thermal cycles until the ceramic layer peeled from the test piece was measured, and ΔT was obtained. The particle size distribution of the thermal spray powder was measured with a laser scattering diffraction type particle size distribution measuring device (manufactured by Cirrus).

  As shown in FIG. 7, when the 10% cumulative particle size of the YSZ sprayed powder reaches 30 μm, ΔT, which is an index of thermal cycle durability, starts to increase rapidly, and its value becomes about 600 ° C. When the cumulative particle size 10% particle size becomes 40 μm, ΔT becomes about 800 ° C., and after that, even if the cumulative particle size 10% particle size becomes larger than 40 μm, it does not change much.

  That is, from the viewpoint of thermal cycle durability, the 10% cumulative particle size of the YSZ sprayed powder is preferably 30 μm or more, and more preferably 40 μm or more.

  By the way, in this embodiment, as shown in FIG. 8, the virgin spray powder (shown by a broken line in the figure) has an accumulated particle size of 10% particle size of 22 to 24 μm or more. When this virgin spray powder is recovered by plasma spraying, the recovered spray powder (indicated by the alternate long and short dash line in the figure) has an accumulated particle size of 10% and a particle size of 20 to 22 μm or more. In this embodiment, regenerated sprayed powder (shown by a solid line in the figure) having an accumulated particle size of 10% and a particle size of 30 μm or more and less than 150 μm is obtained by classification after collection. That is, in this embodiment, regenerated spray powder having a larger average particle size is obtained than virgin spray powder.

  As described above, since the YSZ regenerated spray powder has an average particle size larger than that of the YSZ virgin spray powder, and the accumulated particle size 10% particle size is 30 μm or more and less than 150 μm, the ceramic formed with this YSZ regenerated spray powder The layer has higher thermal cycle durability than the ceramic layer formed of YSZ virgin spray powder. In the present embodiment, the 10% cumulative particle size of the YSZ regenerated spray powder is less than 150 μm because the recovered powder collected by the recovery device 30 has a large amount of garbage in the recovered powder of 150 μm or more. This is because the thermal spraying powder is relatively small, and the thermal spraying powder of 150 μm or more deteriorates the film forming efficiency.

  As described above, in this embodiment, by forming the ceramic layer with the YSZ regenerated spray powder, the possibility of peeling of the ceramic layer can be reduced by the interaction of the reasons a and b described above.

  Specifically, as shown in Table 2 below, in the virgin spray powder (sample 3) heat-treated by plasma heating (sample 3), the relative value of thermal conductivity is 1, and the temperature difference is an index of thermal cycle durability. ΔT was 500 ° C. Moreover, in the virgin spray powder (sample 4) heat-treated (S3) by electric heater heating or arc discharge heating, the relative value of thermal conductivity is 1.2, and the temperature difference ΔT, which is an index of thermal cycle durability, is 500 ° C. Met. The relative value of thermal conductivity is a thermal conductivity ratio based on the thermal conductivity of sample 3 as a reference (1). The lower the thermal conductivity, the better the heat shielding property, which is preferable for the formation of the heat shielding ceramic layer.

  On the other hand, the virgin spray powder heat-treated by plasma heating (S3) was plasma sprayed and then recovered, and the regenerated spray powder (sample 5) classified and separated (S22, S23) was subjected to relative thermal conductivity. The value was 1, and the temperature difference ΔT, which is an index of thermal cycle durability, was 540 ° C. In addition, after the virgin spray powder that has been heat-treated by electric heater heating or arc discharge heating (S3) is plasma sprayed, this is recovered and classified and separated (S22, S23) into the regenerated spray powder (sample 6), The relative value of thermal conductivity was 1.2, and the temperature difference ΔT, which is an index of thermal cycle durability, was 640 ° C.

  That is, the regenerated spray powder has a thermal cycle durability of 1.067 to 1.082 (1.08 = 540/500, 1.067 = 640/600) times higher than the virgin spray powder without increasing the thermal conductivity. can do.

"Second embodiment of thermal spraying equipment"
Next, 2nd embodiment of the thermal spraying equipment which concerns on this invention is described using FIG.9 and FIG.10.

  As shown in FIG. 9, the thermal spraying equipment of this embodiment includes a high-speed flame spraying device 70, a plasma spraying device 10, a recovery device 30, a classification device 40 a, and a separation device 50, as in the first embodiment. Yes. That is, the thermal spraying equipment of this embodiment is basically the same as the thermal spraying equipment of the first embodiment, except that the melting container 61 (FIG. 1) in the first embodiment is not provided.

  In the present embodiment, when only a relatively small amount of YSZ spray powder can be recovered with respect to the MCrAlY spray powder in the recovery step, in other words, a relatively large amount of MCrAlY spray powder is recovered with respect to the YSZ spray powder. This is an embodiment where possible. For this reason, in this embodiment, unlike the first embodiment, the MCrAlY spray powder is reused. That is, in this embodiment, the regeneration process of the MCrAlY spraying powder used in the high-speed flame spraying (S13 (FIG. 5B)) and not attached to the target base material 1 is executed. The MCrAlY spray powder regeneration process (S20a) will be described with reference to the flowchart shown in FIG.

  During the high-speed flame spraying (S13), the suction fan 32 of the recovery device 30 is driven. For this reason, among the MCrAlY spray powder sprayed from the flame spray gun 71, the MCrAlY spray powder not attached to the target base material 1 is sucked into the recovery duct 31 and recovered (S21a). At this time, various powders floating in the spraying booth B are also sucked into the recovery duct 31. These various powders include alumina particles used in the blasting (S12), YSZ sprayed powder used in forming the ceramic layer (S14), floating dust in the spraying booth B, and the like. Note that this recovery process (S21a) may be performed only during flame spraying (S13), but may also be performed during plasma spraying (S14). Furthermore, in order to clean the environment in the welding booth B, this recovery process (S21a) may be executed while the thermal spray booth B is used for any process.

  The powder sucked into the collection duct 31, that is, the collected powder, is classified by the classifier 40a, the collected powder having a particle size of less than 20 μm, the collected powder having a particle size of 20 μm or more and less than 150 μm, and the collected powder of 150 μm or more The recovered powder having a particle size of 20 μm or more and less than 150 μm is extracted (S22a). More precisely, the recovered powder having a 10% cumulative particle size of 20 μm or more and less than 150 μm is extracted. On the other hand, the recovered powder having a particle size of less than 20 μm and the recovered powder having a particle size of 150 μm or more are discarded. The recovered powder having a particle size of less than 20 μm contains MCrAlY spray powder and the like, but is discarded because it has a small particle size and is not suitable as a spray powder for forming a TBC layer. Further, the recovered powder having a particle size of 150 μm or more is discarded because there are few MCrAlY sprayed powders and conversely there are many garbage such as sand grains.

  The recovered powder extracted by the classification device 40a is separated by the separation device 50 by the difference in electrical properties of each substance contained in the recovered powder (S23a), as in the first embodiment. That is, of the collected powder sent to the separation device 50, the collected powder mainly composed of YSZ sprayed powder that is ceramic falls mainly on the positive plate side portion 55 a in the collection container 55. Further, the recovered powder mainly composed of the metal MCrAlY spray powder falls mainly on the negative electrode plate side portion 55 c in the recovery container 55. Further, the YSZ spray powder and the MCrAlY spray powder fall on the intermediate portion 55b of the collection container 55.

  The recovered powder recovered in the positive electrode plate side 55a of the recovery container 55, that is, recovered powder mainly composed of YSZ sprayed powder is discarded. This is because, in the present embodiment, as described above, relatively little YSZ sprayed powder can be recovered with respect to the MCrAlY sprayed powder. Further, the recovered powder recovered in the intermediate portion 55b of the recovery container 55 is again put into the friction charging device 51 of the separation device 50, and due to the difference in electrical properties of each substance contained in the recovered powder, Re-separated. Further, the recovered powder recovered in the negative electrode plate side portion 55c of the recovery container 55, that is, the recovered powder mainly composed of MCrAlY sprayed powder is taken out from the recovery container 55 and reused as MCrAlY regenerated sprayed powder (S25a). ).

  That is, in the present embodiment, upon completion of the separation process (S23a), the MCrAlY sprayed powder regeneration process (S20a) is completed.

  Here, the specific example of the electrostatic separation effect by the separation apparatus 50 of this embodiment is demonstrated. As shown in Table 3 below, when the YSZ content in the sample 7 of the recovered powder obtained in the recovery process (S21a) was 7.52 (wt%), classification / separation process (S22a, The YSZ content in the sample 7 of the recovered powder extracted in S23a) is 0.08 (wt%). That is, in the present embodiment, the recovered powder recovered in the negative electrode plate side 55c of the recovery container 55 of the separation device 50, that is, the recovered powder mainly composed of MCrAlY sprayed powder has a YSZ content of 1 (wt%). Less than.

  In the reuse of the MCrAlY spray powder (S25a), the MCrAlY regenerated spray powder obtained by the regeneration process of the MCrAlY spray powder (S20a) is charged into the powder supply device 83 of the frame spray device 70, and the amount of MCrAlY spray powder charged. If there is little, add MCrAlY virgin spray powder. Then, the MCrAlY spray powder is supplied from the powder supply device 83 of the flame spraying apparatus 70 to the frame spray gun 71, and the MCrAlY spray powder is sprayed onto the target base material 1. That is, the MCrAlY regenerated spray powder is reused for flame spraying.

  As described above, in the present embodiment, after the MCrAlY virgin spray powder is used for spraying, it is recovered and regenerated as the regenerated spray powder, so the amount of virgin spray powder used for spraying can be reduced, As a result, it is possible to reduce the manufacturing cost of the thermal barrier coating member in which the thermal spray powder is sprayed and the thermal barrier coating (TBC) layer is formed on the surface.

  Further, in this embodiment, although the bond coat layer is formed with the MCrAlY regenerated spray powder, the performance deterioration of the bond coat layer can be suppressed as compared with the case where the bond coat layer is formed with the MCrAlY virgin spray powder.

  Specifically, as shown in Table 4 below, when the bond coat layer formed with the virgin spray powder (sample 8) is maintained at 1000 ° C. for 300 hours, it is generated on the surface of the bond coat layer. The thickness of the oxide (thermally generated oxide, TGO) was 5 μm. Further, after flame spraying the virgin spray powder, the bond coat layer formed with the spray powder (sample 9) obtained by collecting (S21a) this was heated at 1000 ° C. for 300 hours as described above. When maintained, the thickness of TGO produced on the surface of this bond coat layer was 12 μm. When GTO is generated on the surface of the bond coat layer, internal stress in the peeling direction acts on the ceramic layer. For this reason, it is preferable that the thickness of this GTO is thin.

  On the other hand, after flame spraying the virgin spray powder, this was recovered (S21a), and the same as described above for the bond coat layer formed with the regenerated spray powder (sample 10) subjected to classification / separation processing (S22a, S23a) When the temperature was maintained at 1000 ° C. for 300 hours, the thickness of TGO generated on the surface of the bond coat layer was 5 μm, as in the case of Sample 8.

  That is, after flame spraying the virgin spray powder, the recovered powder having a particle size of 20 μm or more and less than 150 μm is extracted from the recovered powder in the classification process (S22a), and the recovered powder is subjected to a separation process (S23a). The obtained MCrAlY regenerated spray powder (sample 10) has the same TGO thickness as the virgin spray powder (sample 8), and the bond coat layer does not deteriorate in performance.

  In this way, if the cumulative particle size 10% particle size of the MCrAlY regenerated spray powder is 20 μm or more, the performance deterioration of the bond coat layer can be suppressed. In this embodiment, in the classification process (S22a), from the recovered powder. The recovered powder having a particle size of 20 μm or more is extracted. Furthermore, in the present embodiment, in consideration of film formation efficiency, the recovered powder having an accumulated particle size of 10% and a particle size of less than 150 μm is extracted.

  The thickness of TGO is closely related to the amount of oxygen element adhering to each particle constituting the MCrAlY spray powder. As the particle size decreases, the surface area per unit volume increases, so that the metal particles constituting the thermal spray powder increase the amount of attached oxygen element per unit volume as the particle size decreases. Accordingly, the MCrAlY spray powder has a larger TGO thickness when the diameter is smaller than when the diameter of the particles constituting the MCrAlY spray powder is larger.

  In addition, if the cumulative particle size 10% particle size of the MCrAlY regenerated spray powder is larger than 20 μm, for example, 30 μm, the thickness of TGO will be thinner than when virgin spray powder is used, so in the classification process (S22a) The recovered powder having a particle size of 30 μm or more may be extracted from the recovered powder.

"Third embodiment of thermal spraying equipment"
Next, a third embodiment of the thermal spraying equipment according to the present invention will be described with reference to FIGS. 11 and 12.

  As shown in FIG. 11, the thermal spraying equipment of this embodiment is a high-speed flame spraying device 70, a plasma spraying device 10, a recovery device 30, a classification device 40 a, a separation device 50, and a melting container, as in the first embodiment. 61 is provided. Furthermore, the thermal spraying equipment of this embodiment includes a suction fan 65 that sucks the collected powder collected on the positive electrode plate side portion 55a of the collection container 55 of the separation device 50, a classification device 66 sucked by the suction fan 65, It has.

  The present embodiment is an embodiment in which each of the YSZ spray powder and the MCrAlY spray powder can be recovered as much as worthy of recovery in the recovery process. For this reason, in this embodiment, YSZ spray powder and MCrAlY spray powder are reused. Therefore, hereinafter, the regeneration process (S20b) of the YSZ spray powder and the MCrAlY spray powder will be described according to the flowchart shown in FIG.

  During high-speed flame spraying (S13) and plasma spraying (S14), the suction fan 32 of the recovery device 30 is driven. For this reason, among the MCrAlY spray powder sprayed from the flame spray gun 71, the MCrAlY spray powder not attached to the target base material 1, and among the YSZ spray powder sprayed from the plasma spray gun 11, the target base material 1. The YSZ spray powder not attached is sucked into the recovery duct 31 and recovered (S21b). At this time, various powders floating in the spraying booth B are also sucked into the recovery duct 31. These various powders include alumina particles used in the blasting process (S12), floating dust in the spraying booth B, and the like. Note that this recovery process (S21b) may be executed only during flame spraying (S13) and plasma spraying (S14), but in order to keep the environment in the welding booth B always clean, The collection process (S21b) may be executed during use from any process.

  The powder sucked into the collection duct 31, that is, the collected powder, is classified by the classifier 40a, the collected powder having a particle size of less than 20 μm, the collected powder having a particle size of 20 μm or more and less than 150 μm, and the collected powder of 150 μm or more. The recovered powder having a particle size of 20 μm or more and less than 150 μm is extracted (S22b). More precisely, the recovered powder having a 10% cumulative particle size of 20 μm or more and less than 150 μm is extracted. On the other hand, recovered powder having a particle size of less than 20 μm and recovered powder having a particle size of 150 μm or more are discarded. The recovered powder having a particle size of less than 20 μm contains MCrAlY spray powder and YSZ spray powder. However, since the particle size is small, it is not suitable as a spray powder for forming the TBC layer, and is discarded. Further, the recovered powder having a particle size of 150 μm or more is discarded because there are few MCrAlY spray powder and YSZ spray powder, and conversely, there are many dusts such as sand grains.

  The recovered powder extracted by the classification device 40a is separated by the separation device 50 according to the difference in electrical properties of each substance contained in the recovered powder (S23b), as in each of the above-described embodiments. That is, of the collected powder sent to the separation device 50, the collected powder mainly composed of YSZ sprayed powder that is ceramic falls mainly on the positive plate side portion 55 a in the collection container 55. Further, the recovered powder mainly composed of the metal MCrAlY spray powder falls mainly on the negative electrode plate side portion 55 c in the recovery container 55. Further, the YSZ spray powder and the MCrAlY spray powder fall on the intermediate portion 55b of the collection container 55.

  The recovered powder collected on the negative electrode plate side portion 55c of the recovery container 55, that is, the recovered powder mainly composed of MCrAlY spray powder, is taken out from the recovery container 55 and re-used as MCrAlY regenerated spray powder as in the second embodiment. Used (S25c). Further, the recovered powder recovered in the intermediate portion 55b of the recovery container 55 is again put into the friction charging device 51 of the separation device 50, and due to the difference in electrical properties of each substance contained in the recovered powder, Re-separated.

  Further, the collected powder collected on the positive electrode side portion 55a of the collection container 55, that is, the collected powder mainly composed of YSZ sprayed powder is sucked from the positive electrode plate side portion 55a of the collection container 55 by the suction fan 65, It is sent to the classifier 66. The classifier 66 separates the recovered powder having a particle size of less than 30 μm and the recovered powder having a particle size of 30 μm or more, and extracts the recovered powder having a particle size of 30 μm or more (S22c). The recovered powder sent to the classifier 66 has already been classified into particles having a particle size of less than 150 μm in the previous stage. Therefore, the recovered powder extracted by the classifier 66 has a particle size of 30 μm or more. The recovered powder is less than 150 μm.

  The recovered powder mainly made of YSZ sprayed powder that has been classified by the classifying device 66 is reused as YSZ regenerated sprayed powder after being subjected to dissolution removal processing (S24b), as in the first embodiment. (S25b).

  As described above, the regeneration process of the YSZ spray powder is completed by the processes of Step 21b to Step 24b, and the regeneration process of the MCrAlY spray powder is completed by the processes of Steps 21b, 22b, and 23b.

  As described above, in this embodiment, after each of the virgin MCrAlY spray powder and the virgin YSZ spray powder is used for spraying, these are recovered and regenerated as the regenerated spray powder, respectively. Therefore, the virgin MCrAlY spray powder used for spraying is used. And the amount of virgin YSZ spray powder can be reduced. For this reason, according to this embodiment, the manufacturing cost of a thermal-insulation coating member can be reduced rather than 1st embodiment and 2nd embodiment.

  In this embodiment, in order to obtain an MCrAlY regenerated spray powder having an accumulated particle size of 10% and a particle size of 20 μm or more and less than 150 μm, and a YSZ regenerated spray powder having an accumulated particle size of 10% and a particle size of 30 μm to less than 150 μm, Although two classifiers 40 and 66 are provided, in order to obtain a MCrAlY regenerated spray powder and a YSZ regenerated spray powder having an accumulated particle size of 10% and a particle size of 30 μm or more and less than 150 μm, a subsequent classifier 66, And the suction fan 65 which guides the recovered powder to the classifier 66 is not necessary.

“Variation of spraying equipment”
First, the 1st modification of a thermal spraying installation is demonstrated using FIG.

  The thermal spray equipment of each of the above embodiments performs flame spraying and plasma spraying in one thermal spray booth B. On the other hand, the spraying equipment of this modification is provided with a spraying booth B1 dedicated to flame spraying and a spraying booth B2 dedicated to plasma spraying.

  The recovery duct 30b of the present modification has openings 31c and 31d provided in a flame spraying booth B1 dedicated to flame spraying and a spraying booth B2 dedicated to plasma spraying, and then integrated as one duct. In the present modification, a suction fan 32 is provided in a portion integrated with this one duct. The equipment after the suction fan 32 is the same as in the above embodiments. In the thermal spraying equipment shown in FIG. 13, the equipment after the suction fan 32 is the same as the thermal spraying equipment of the third embodiment.

  As described above, even when a thermal spray booth is provided for each thermal spray type as in this modification, the thermal spray powder used in each thermal spray booth can be regenerated.

  Next, a second modification of the thermal spray equipment will be described.

  In each of the thermal spraying equipment of each of the embodiments described above, the electrostatic separation device 50 is used as the separation device, but instead of this, a magnetic separation device that selectively separates the magnetic material with a magnet may be used. In this magnetic separation device, MCrAlY spray powder, which is a metal, is adsorbed to the magnet from the recovered powder sucked into the recovery duct. When a magnetic separator is used as the separator, it is preferable to use a high gradient magnetic separator 50a as shown in FIG. The high gradient magnetic separation device 50a includes, for example, a cylinder 52a formed of a magnetically permeable material in a magnetic field formed by a strong electromagnet 51a such as a superconducting magnet, and the cylinder 52a is made of ferromagnetic stainless steel. This is a device for placing a wool material 53a, forming a large magnetic gradient between the wool and the periphery of the wool, and causing the fool material 53a to function as a magnetic filter to adsorb and separate the magnetic material.

  In the high gradient magnetic separation device 50a, the MCrAlY spray powder as a metal adsorbs the wool material 53a as a magnetic filter, and the YSZ spray powder as a ceramic passes through the wool material 53a. Therefore, while the suction fan 40 is driven to collect the spray powder, the electromagnet 51a is magnetized by the control device 54a, and the metal MCrAlY spray powder or the like is adsorbed to the wool material 53a as a magnetic filter. Then, the YSZ sprayed powder that is not adsorbed to the wool material 53a is discharged from the cylinder 52a. When the suction fan 40 is stopped and the spray powder is no longer supplied to the high gradient magnetic separation device 50a, the controller 54a demagnetizes the electromagnet 51a, and the MCrAlY spray powder adsorbed on the wool material 53a is removed from the wool material. The MCrAlY sprayed powder is discharged from the cylinder 52a.

  Thus, in this high gradient magnetic separation apparatus 50a, MCrAlY spray powder and YSZ spray powder are discharged from the same cylinder 52a at different timings. Therefore, in order to change the discharge destination of these spray powders, it is preferable to provide a switching valve 58 at the tip of the cylinder 52a.

  Here, a specific example of the magnetic separation effect of the high gradient magnetic separation device 50a of the present modification will be described. As shown in Table 5 below, the MCrAlY contents in the recovered powder samples 11 and 12 obtained in the recovery process (S21) are 5.34 (wt%) and 1.86 (wt%), respectively. In this case, the contents of MCrAlY in the recovered powder samples 11 and 12 extracted by the classification process and the magnetic separation process are 0.09 (wt%) and 0.06 (wt%). That is, in this modification, the recovered powder mainly composed of YSZ sprayed powder has a MCrAlY content of less than 1 (wt%).

  1: target base material, 2: bond coat layer, 3: ceramic layer, 4: TBC layer, 10: plasma spray device, 11: plasma spray gun, 22: powder supply device, 23: power supply device, 30: recovery device, 31: Recovery duct, 32: Suction fan, 40, 40a: Classification device, 50, 50a: Separation device, 61: Melting container, 70: Flame spraying device, 71: Flame spraying gun, 83: Powder supply device, 84: Power supply

Claims (16)

In the method of reusing at least one of the metal spray powder and the ceramic spray powder sprayed toward the object,
Of the metal spray powder sprayed toward the object, the metal spray powder not applied to the object and the ceramic spray powder sprayed toward the object do not adhere to the object A ceramic spraying powder, and a recovery step of recovering a powder containing the recovered powder as a recovered powder;
Separation of separating the recovered powder into a metal recovered powder containing the metal spray powder and a ceramic recovered powder including the ceramic spray powder in an electromagnetic field due to a difference in electromagnetic properties of the particles constituting the recovered powder. Process,
Of the metal recovery powder obtained in the separation step and the ceramic recovery powder, at least one of the recovered powder as a thermal spray powder, a thermal spray powder reuse step of spraying a new object,
A method for reusing thermal spraying powder characterized by comprising: In the reuse method of the thermal spraying powder of Claim 1,
From the recovered powder recovered in the recovery step, a powder having a target particle size range is extracted, and the extracted recovered powder is sent to the separation step.
A method for reusing spraying powder characterized by the above. In the reuse method of the thermal spraying powder of Claim 2,
The target particle size range of the recovered powder extracted in the classification step is a cumulative particle size 10% particle size of 30 μm or more,
In the spraying powder reuse step, at least a part of the ceramic recovered powder obtained in the separation step is sprayed on the new object as the ceramic spraying powder.
A method for reusing spraying powder characterized by the above. In the reuse method of the thermal spraying powder of Claim 2,
The target particle size range of the recovered powder extracted in the classification step is a cumulative particle size 10% particle size of 20 μm or more,
In the spraying powder reuse step, at least a part of the metal recovery powder obtained in the separation step is sprayed on the new object as the metal spraying powder.
A method for reusing spraying powder characterized by the above. In the reuse method of the thermal spraying powder of Claim 4,
From the ceramics recovered powder obtained in the separation step, there is a ceramic powder classification step of extracting ceramics recovered powder having a cumulative particle size of 10% particle size of 30 μm or more,
In the spraying powder reuse step, at least a part of the ceramic recovered powder extracted in the ceramic powder classification step is sprayed onto the new object as the ceramic spraying powder.
A method for reusing spraying powder characterized by the above. In the reuse method of the thermal spray powder as described in any one of Claim 1 to 5,
The ceramic recovered powder obtained in the separation step is placed in an aqueous solution that dissolves metal or amphoteric hydroxide, and the metal powder or amphoteric hydroxide powder in the ceramic recovered powder is dissolved in the aqueous solution. Having a dissolution and removal step of extracting the remaining particulate matter;
In the thermal spray powder reuse step, the granular material extracted from the aqueous solution in the dissolution removal step is sprayed onto the new object as the ceramic spray powder,
A method for reusing spraying powder characterized by the above. In the reuse method of the thermal spraying powder as described in any one of Claim 1 to 6,
In the separation step, due to the difference in electrical properties of each particle constituting the recovered powder recovered in the recovery step, the metal recovered powder and the ceramic recovered powder are separated in an electric field.
A method for reusing spraying powder characterized by the above. In the reuse method of the thermal spraying powder as described in any one of Claim 1 to 6,
In the separation step, due to the difference in magnetic properties of each particle constituting the recovered powder recovered in the recovery step, the metal recovered powder and the ceramic recovered powder are separated in a magnetic field.
A method for reusing spraying powder characterized by the above. The method for reusing thermal spray powder according to any one of claims 1 to 8,
In the spraying powder reuse step, a coating member is manufactured by forming a coating layer on the surface of the object with the sprayed powder sprayed on the object.
The manufacturing method of the coating member characterized by the above-mentioned. In thermal spray equipment that sprays metal spray powder and ceramic spray powder on the object,
A first thermal spraying device having a first thermal spray gun for spraying the metal thermal spray powder on the object;
A second spraying device having a second spray gun for spraying the ceramic spray powder on the object;
Of the metal spray powder sprayed toward the object, the metal spray powder not applied to the object and the ceramic spray powder sprayed toward the object do not adhere to the object A ceramic spraying powder, and a recovery device for recovering powder containing the recovered powder as recovered powder;
Due to the difference in electromagnetic properties of the particles constituting the recovered powder, the recovered powder is separated into a metal recovered powder containing the metal spray powder and a ceramic recovered powder including the ceramic spray powder in an electromagnetic field, A separator for extracting at least one of the recovered powders as a part of the thermal spray powder;
Thermal spraying equipment characterized by comprising. The thermal spray equipment according to claim 10,
From the recovered powder recovered by the recovery device, extract the powder of the target particle size range, the extracted recovered powder is equipped with the classification device,
The separation device separates the recovered powder extracted by the classification device;
Thermal spraying equipment characterized by that. The thermal spray equipment according to claim 11,
The target particle size range of the recovered powder extracted by the classifier is an integrated particle size 10% particle size of 30 μm or more,
The separation device extracts the ceramic recovered powder as at least a part of the ceramic spray powder.
Thermal spraying equipment characterized by that. The thermal spray equipment according to claim 11,
The target particle size range of the recovered powder extracted by the classifier is an integrated particle size 10% particle size of 20 μm or more,
The separation device extracts the metal recovery powder as at least a part of the metal spray powder.
Thermal spraying equipment characterized by that. The thermal spray equipment according to claim 13,
A ceramic powder classification device for extracting ceramic recovered powder having an accumulated particle size of 10% particle size of 30 μm or more as at least part of the ceramic spray powder from the ceramic recovered powder obtained by the separator;
Thermal spraying equipment characterized by that. In the thermal spray equipment as described in any one of Claim 10 to 14,
The first spray gun and the second spray gun are installed in one spray booth,
The recovery device has a recovery duct whose opening faces the spraying booth, and a suction fan for sucking powder in the spraying booth into the recovery duct,
Thermal spraying equipment characterized by that. In the thermal spray equipment as described in any one of Claim 10 to 14,
The first thermal spray gun is installed in a first thermal spray booth, and the second thermal spray gun is installed in a second thermal spray booth different from the first thermal spray booth;
The recovery device includes a recovery duct having a first opening facing the first thermal spraying booth and a second opening facing the second thermal spraying booth, and powders in the first thermal spraying booth. A suction fan for sucking into the recovery duct from one opening and sucking the powder in the second thermal spray booth into the recovery duct from the second opening;
Thermal spraying equipment characterized by that.

Images