US20180002815A1 - Cold spray process using treated metal powder - Google Patents

Cold spray process using treated metal powder Download PDF

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Publication number
US20180002815A1
US20180002815A1 US15/544,700 US201615544700A US2018002815A1 US 20180002815 A1 US20180002815 A1 US 20180002815A1 US 201615544700 A US201615544700 A US 201615544700A US 2018002815 A1 US2018002815 A1 US 2018002815A1
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United States
Prior art keywords
gas
nitrogen
metal powder
titanium
powder particles
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Abandoned
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US15/544,700
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English (en)
Inventor
Randolph Carlton McGee
Zissis A. Dardas
Ying She
Aaron T. Nardi
Michael A. Klecka
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Sikorsky Aircraft Corp
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Sikorsky Aircraft Corp
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Priority to US15/544,700 priority Critical patent/US20180002815A1/en
Assigned to SIKORSKY AIRCRAFT CORPORATION reassignment SIKORSKY AIRCRAFT CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DARDAS, ZISSIS A., NARDI, AARON T., MCGEE, Randolph Carlton, SHE, YING, KLECKA, Michael A.
Publication of US20180002815A1 publication Critical patent/US20180002815A1/en
Abandoned legal-status Critical Current

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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
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • B22F1/0088—
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
    • B22F1/14—Treatment of metallic powder
    • B22F1/145—Chemical treatment, e.g. passivation or decarburisation
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
    • C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
    • C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
    • C23C8/24—Nitriding
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
    • C23C8/80—After-treatment
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
    • C22C29/16—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on nitrides

Definitions

  • Thermal spray technologies such as the cold spray process can be used for various applications such as applying metal layers to non-metallic substrates to make metal layer-containing composite articles, applying metal outer layers to substrates of a different material, for example to obtain corrosion benefits of the outer layer metal with the processability of the substrate metal, field repair of metal components, and various other additive manufacturing technology applications.
  • Titanium and titanium alloys are widely used for various applications such as aircraft, motor vehicles, and countless other applications, where they provide beneficial properties including but not limited to strength, strength:weight ratio, corrosion resistance, high specific heat, and tolerance of extreme temperatures.
  • the use of titanium alloys as metal powder used in the cold spray process has been limited by factors such as degradation of the nozzles used in the cold gas spray process and a tendency of the titanium alloys to clog nozzles used in the cold spray process.
  • Conventional approaches for dealing with such nozzle problems typically involve the use of exotic (and expensive) materials such as quartz for the cold spray nozzles, or modification of cold spray process parameters to lower temperatures or other process modifications that can cause adverse impacts to the properties of cold spray-applied material.
  • a method of applying a metal comprising titanium to a substrate comprises nitriding the surface of metal powder particles comprising titanium by contacting the particles with a first gas comprising nitrogen in a fluidized bed reactor, and depositing the nitrided metal powder particles onto the substrate with cold spray deposition using a second gas.
  • the metal powder particles comprise titanium or titanium alloys Ti—6Al—4V, Ti—3Al—2.5V, Ti—5Al—2.5Sn, Ti—8Al—1Mo—1V, Ti—6Al—2Sn—4Zr—2Mo, ⁇ + ⁇ Ti—6Al—4V, or near ⁇ Ti—10V—2Fe—3Al.
  • the metal powder particles comprises titanium or titanium alloy grades 5 (Ti—6Al—4V) or 23 (Ti—6Al—4V) according to ASTM B861-10.
  • the metal powder particles after nitriding comprise elemental nitrogen at the particle surface and also comprise an internal particle portion that is free of elemental nitrogen.
  • the metal powder particles after nitriding have a surface nitrogen content ranging from 5.96 wt. % to 12.22 wt. % as determined by x-ray photoelectron spectroscopy.
  • the metal powder particles after nitriding have a nitrogen:oxygen surface wt. % ratio of from 5.96:26.20 to 12.22:16.75 as determined by x-ray photoelectron spectroscopy.
  • the first gas comprises at least 1 vol. % nitrogen.
  • the first gas consists essentially of nitrogen.
  • the fluidized bed reactor is operated at a temperature of 500° C. to 850° C.
  • the first gas is at a pressure of 0.11 to 0.12 MPa.
  • the space velocity of the first gas in the fluidized bed reactor is from 1 min ⁇ 1 to 30 min ⁇ 1 .
  • the metal powder particles are contacted with the first gas in the fluidized bed reactor for at least 1 minute.
  • the second gas comprises helium or argon.
  • the second gas comprises helium or argon and nitrogen.
  • the second gas consists essentially of helium or argon.
  • the second gas is at a temperature of 20° C. to 850° C.
  • FIG. 1 is a schematic depiction of a fluidized bed reactor assembly
  • FIG. 2 is a schematic depiction of a cold spray system
  • FIG. 3 is a bar chart showing the results of surface elemental analysis of titanium alloy powders processed as described herein.
  • FIG. 1 An exemplary fluidized bed reactor assembly for nitriding titanium alloys is depicted in FIG. 1 .
  • the assembly includes a fluidized bed reactor 12 having inlet openings 14 disposed at one end of the reactor 12 and an outlet opening 16 disposed at the opposite end of the reactor 12 .
  • the fluidized bed reactor 12 is disposed inside of an outer tubing 18 , with outlet 16 extending to the outside of outer tubing 18 .
  • the fluidized bed assembly is disposed in a furnace (not shown) to provide heat.
  • Thermocouples 17 and 19 are disposed to monitor temperature in the reactor 12 and outer tubing 18 , respectively.
  • An inlet 20 is connected to a gas feed line 22 .
  • a gas source 24 such as a storage tank or a gas-generating reactor is connected to gas feed line 22 to supply a gas feed to the fluidized bed reactor 12 .
  • Other components such as mass flow controller 26 , pressure regulating valve 28 , pressure sensor 30 , and shut-off valves 32 and 34 are also disposed in the gas feed line 22 for monitoring and controlling the flow rate and pressure of the gas delivered to the reactor 12 .
  • Reactor outlet 16 is connected to outlet line 36 , which is connected to a water or other liquid bubbler 38 .
  • a bleed line 40 with shut-off valve 42 also connects feed line 22 to the bubbler 38 , which is vented to atmosphere through exhaust port 44 .
  • a gas comprising nitrogen from gas source 24 is fed through feed line 22 , with the flow rate and gas pressure controlled by mass flow controller 26 and pressure regulating valve 28 .
  • the nitrogen-containing gas enters the outer tubing 18 through inlet 20 .
  • the gas is heated as it passes through the space between fluidized bed 12 and outer tubing 18 to enter the fluidized bed reactor 12 through inlet 14 .
  • the fluidized bed reactor 12 has metal particles 46 comprising titanium disposed therein, and the upward gas flow rate through the reactor applies sufficient upward force to the particles 46 to counteract the force of gravity acting on the particles so that they are suspended in a fluid configuration in the reactor space.
  • the gas flow is generally maintained below levels that would carry entrained particles out of the reactor 16 through outlet 16 , and outlet 16 can also be fitted with a filter or screen to further assist in keeping metal powder particles 46 from exiting the reactor 12 .
  • Nitrogen-containing gas exits the reactor 12 through outlet 16 and flows via outlet line 36 to the bubbler 38 , from which it is exhausted to the atmosphere through exhaust port 44 .
  • the invention can utilize any titanium metal or titanium metal alloy, including any of the grades of titanium alloys specified in ASTM B861-10.
  • the titanium alloy comprises from 0 to 10 wt. % aluminum and from 0 to 10 wt. % vanadium.
  • the titanium alloy is an alpha-beta titanium alloy such as Ti—6Al—4V (e.g., grades 5 or 23 according to ASTM B861-10), Ti—Al—Sn, Ti—Al—V—Sn, Ti—Al—Mo, Ti—Al—Nb, Ti—V—Fe—Al, Ti—8Al—1Mo—1V, Ti—6Al—2Sn—4Zr—2Mo, ⁇ + ⁇ Ti—6Al—4V or near ⁇ Ti—10V—2Fe—3Al.
  • the titanium alloy is a Ti—6Al—4V alloy such as grade 5 or grade 23 according to ASTM B861-10.
  • the nitrogen-containing gas can contain from 1 vol. % to 100 vol. % nitrogen, more specifically from 5 vol. % to 100 vol. % nitrogen, and more specifically from 25 vol. % to 75 vol. % nitrogen. In some embodiments, the nitrogen-containing gas consists essentially of nitrogen, and in some embodiments the nitrogen-containing gas is pure.
  • the nitriding reaction conducted in the fluidized bed reactor is typically conducted at elevated temperature, compared to ambient conditions. The reaction temperature in the reactor can range from 500° C. to 800° C., more specifically from 600° C. to 750° C., and even more specifically from 600° C. to 700° C.
  • Pressures in the reactor can range from 0.11 MPa to 0.13 MPa, more specifically from 0.11 MPa to 0.12 MPa, and even more specifically from 0.11 MPa to 0.115 MPa.
  • the flow rate of nitrogen to the reactor can vary based on factors such as reactor dimension, with exemplary flow rates of 0.0069 m/min to 0.013 m/min, more specifically from 0.0097 m/min to 0.011 m/min, and even more specifically from 0.010 m/min to 0.0105 m/min.
  • the metal powder particles can be nitrided for periods (i.e., contact time with the nitrogen-containing gas) of at least 1 minute, for example, time periods ranging from 1 minute to 30 minutes, more specifically from 1 minute to 10 minutes, and even more specifically from 1 minute to 5 minutes.
  • the reactor In batch mode, such as depicted in the reaction scheme shown in FIG. 1 , the reactor is operated for the specified amount of time to achieve the desired contact time. In a continuous mode, throughput of the particles through the reactor can be adjusted to achieve an average residence time equal to the desired contact time.
  • the particles After processing the titanium-containing metal particles in the nitrogen-containing fluidized bed reactor, the particles can have a surface nitrogen content ranging from 5.96 wt. % to 12.22 wt. %, more specifically from 5.96 wt. % to 7.90 wt. %, or from 7.90 wt. % to 9.77 wt. %, or from 9.77 wt. % to 12.22 wt. %, as determined by x-ray photoelectron spectroscopy. As used herein, x-ray photoelectron spectroscopy and the values specified herein are according to the protocols of according to ASTM E2735-14, Standard
  • the metal powder particles can have a nitrogen:oxygen surface wt. % ratio of from 5.96:26.20 to 7.90:21.83 as determined by x-ray photoelectron spectroscopy, and more specifically can have a nitrogen:oxygen surface wt.
  • the nitriding reaction is conducted under conditions (e.g., contact time, temperature, space velocity) so that nitriding occurs on the surface of the metal particles but not throughout the interior of the particles, resulting in particles with a surface layer comprising nitrogen and at least a portion of the particles' interior being free of nitrogen.
  • the nitride titanium or titanium alloy metal powder is applied to a substrate with a cold spray deposition process.
  • a cold spray process unmelted metal particles are introduced into a high velocity gas stream being projected out of a high velocity (e.g., supersonic) nozzle toward the coating substrate target.
  • the particles' kinetic energy provides sufficient heat on impact with the coating substrate such that the particles plastically deform and fuse with the substrate and surrounding deposited metal material.
  • the particles impact the substrate they rapidly cool even as the particles are deforming. The particles change shape dramatically from relatively round to very thin flat splats on the surface.
  • FIG. 2 An exemplary system is depicted in FIG. 2 .
  • metal powder is fed from powder feeder 48 through conduit 49 to spray gun 50 , which includes nozzle 52 and gun heater 54 .
  • Powder particle diameter sizes can range from 1 to 120 microns, more specifically from 5 to 75 microns.
  • Pressurized gas is fed from gas pre-heater 56 to gun heater 54 through conduit 55 .
  • Exemplary gases for use in the system include helium, nitrogen, or a mixture of helium and nitrogen. Helium can provide greater gas velocities than nitrogen and has the additional technical effect of being benefited by the nitriding process because unlike a nitrogen-based gas stream, helium does not provide any opportunity for nitriding to occur in the spray gun 50 .
  • the powder and the gas streams are mixed in the gun and accelerated to supersonic speeds as the gas/powder mixture exits the nozzle 52 .
  • the system also includes a controller or control console 58 , which receives input from gun pressure sensor 60 and gun temperature sensor 62 and provides control signals to the gas pre-heater and powder feeder.
  • the term “cold” in “cold spray deposition” refers to the fact that the gas is maintained at a temperature below the melting point of the metal powder; however, as described above the gas is heated in both the gas pre-heater 56 and the gun heater 54 .
  • the temperature of the gas used in the process can range from 0° C. to 1200° C., more specifically from 200° C. to 1000° C., and even more specifically from 200° C. to 800° C.
  • Gas pressure can range from 5 bar to 60 bar, more specifically from 15 bar to 45 bar, and even more specifically from 20 bar to 40 bar.
  • Ti—6Al—4V alloy powder materials were nitrided in a fluidized bed reactor as shown in FIG. 1 .
  • a fluidized bed reactor as shown in FIG. 1 .
  • the reactor was then placed in a Model K-3-18 reactor furnace (CM Furnaces, Inc.).
  • argon gas Pierair
  • the furnace temperature was increased at a rate of about 4.5° C./min to the target nitridation temperature as shown in Table 1.
  • a control sample was also prepared in which argon gas was used for the entire process without any nitrogen gas.
  • the gas flow was switched to nitrogen (Matheson) and the temperature was held for the times indicated in Table 1.
  • the gas flow was switched to argon and the reactor was allowed to cool down. This was done primarily to isolate the soak time and to prevent any further nitridation that might occur at the higher temperatures during the slow cooling process.
  • the powder temperature reached a low enough temperature (about 300° C.)
  • the gas flow was switched again, back to nitrogen and the furnace continued to cool down to ambient temperature.
  • the resulting metal powders, along with samples of the untreated powder were characterized using scanning electron microscopy (SEM) and energy dispersive X-ray micro-analysis (EDX).
  • nitridation at 700° C. and 800° C. each resulted in an increase in surface nitrogen on the particles and a decrease in surface oxygen for the particles, with nitridation at 800° C. producing a greater effect than nitridation at 700° C.
  • Surface carbon detected by XPS is believed to result from surface contamination during preparation of the metal powders.
  • the metal powders were used in a system as shown in FIG. 2 using helium at 700° and 30 bar as the gas or a 50/50 blend of helium and nitrogen at 800° C. and 40 bar.
  • the nitrided titanium alloy powders exhibited significantly reduced nozzle clogging (and resulting higher quality metal deposits) than either the untreated powder or the control powder.

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  • Chemical & Material Sciences (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Chemical & Material Sciences (AREA)
  • Solid-Phase Diffusion Into Metallic Material Surfaces (AREA)
US15/544,700 2015-01-21 2016-01-20 Cold spray process using treated metal powder Abandoned US20180002815A1 (en)

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US201562106140P 2015-01-21 2015-01-21
PCT/US2016/013995 WO2016118551A1 (fr) 2015-01-21 2016-01-20 Procédé de pulvérisation à froid mettant en œuvre une poudre métallique traitée
US15/544,700 US20180002815A1 (en) 2015-01-21 2016-01-20 Cold spray process using treated metal powder

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20190160528A1 (en) * 2017-11-27 2019-05-30 Hamilton Sundstrand Corporation Method and apparatus for improving powder flowability
CN111992715A (zh) * 2020-08-21 2020-11-27 浙江工业大学 一种激光诱导界面原位反应增强的钛合金增材制造方法
US11097340B2 (en) 2018-11-19 2021-08-24 Hamilton Sundstrand Corporation Powder cleaning systems and methods

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CN109843422A (zh) * 2016-09-07 2019-06-04 泰斯索尼克股份有限公司 用于低压冷喷涂的带有微型反应器和盒的料斗
CN107377968A (zh) * 2017-09-08 2017-11-24 安徽工业大学 一种基于喷吹流化的异质复合粉末的制备装置及制备方法
CN109935533B (zh) * 2017-12-18 2021-09-21 无锡华润安盛科技有限公司 封装体的反应层去除装置及去除方法

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CA2289200C (fr) * 1997-05-13 2009-08-25 Richard Edmund Toth Poudres dures a revetement resistant et articles frittes produits a partir de ces poudres
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Cited By (4)

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Publication number Priority date Publication date Assignee Title
US20190160528A1 (en) * 2017-11-27 2019-05-30 Hamilton Sundstrand Corporation Method and apparatus for improving powder flowability
US11097340B2 (en) 2018-11-19 2021-08-24 Hamilton Sundstrand Corporation Powder cleaning systems and methods
US11980880B2 (en) 2018-11-19 2024-05-14 Hamilton Sundstrand Corporation Powder cleaning systems and methods
CN111992715A (zh) * 2020-08-21 2020-11-27 浙江工业大学 一种激光诱导界面原位反应增强的钛合金增材制造方法

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EP3247516A1 (fr) 2017-11-29
EP3247516A4 (fr) 2018-08-22
EP3247516B1 (fr) 2019-08-28
WO2016118551A1 (fr) 2016-07-28

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