US3254970A - Flame spray clad powder composed of a refractory material and nickel or cobalt - Google Patents

Flame spray clad powder composed of a refractory material and nickel or cobalt Download PDF

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Publication number
US3254970A
US3254970A US134544A US13454461A US3254970A US 3254970 A US3254970 A US 3254970A US 134544 A US134544 A US 134544A US 13454461 A US13454461 A US 13454461A US 3254970 A US3254970 A US 3254970A
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United States
Prior art keywords
powder
nickel
coating
flame
mesh
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US134544A
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English (en)
Inventor
Ferdinand J Dittrich
Arthur P Shepard
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Metco Inc
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Metco Inc
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Priority to US134544A priority Critical patent/US3254970A/en
Priority to GB33002/61A priority patent/GB1000353A/en
Priority to ES270818A priority patent/ES270818A1/es
Priority to DE1961M0050689 priority patent/DE1446207B2/de
Priority to SE10687/61A priority patent/SE302712B/xx
Priority to CH1256661A priority patent/CH439909A/de
Priority to FR879239A priority patent/FR1313303A/fr
Priority to CH230766A priority patent/CH503123A/de
Priority to FR54773A priority patent/FR90386E/fr
Application granted granted Critical
Publication of US3254970A publication Critical patent/US3254970A/en
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • 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
    • B22F1/18—Non-metallic particles coated with metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
    • 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
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/31—Coating with metals
    • C23C18/32—Coating with nickel, cobalt or mixtures thereof with phosphorus or boron
    • C23C18/34—Coating with nickel, cobalt or mixtures thereof with phosphorus or boron using reducing agents
    • 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
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
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    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/923—Physical dimension
    • Y10S428/924—Composite
    • Y10S428/926—Thickness of individual layer specified
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    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/9335—Product by special process
    • Y10S428/936—Chemical deposition, e.g. electroless plating
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    • Y10S428/922—Static electricity metal bleed-off metallic stock
    • Y10S428/9335—Product by special process
    • Y10S428/937—Sprayed metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10S428/938—Vapor deposition or gas diffusion
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12181—Composite powder [e.g., coated, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/12535—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12576—Boride, carbide or nitride component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/12625—Free carbon containing component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/1266—O, S, or organic compound in metal component
    • Y10T428/12667—Oxide of transition metal or Al
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/12736—Al-base component
    • Y10T428/12743—Next to refractory [Group IVB, VB, or VIB] metal-base component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/12806—Refractory [Group IVB, VB, or VIB] metal-base component
    • Y10T428/12812—Diverse refractory group metal-base components: alternative to or next to each other
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    • Y10T428/12861—Group VIII or IB metal-base component
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    • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913—Rod, strand, filament or fiber
    • Y10T428/2918—Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
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    • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
    • Y10T428/2991—Coated
    • Y10T428/2993—Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]

Definitions

  • This invention relates to the flame spraying of synergistic composites.
  • the invention more particularly relates to the flame spraying of synergistically-clad flame spray powders, to a novel group of flame spray materials comprising such synergistically-clad flame spray powders, and more broadly to the spraying of other synergistic composites wherein the synergistic action involves the generation of heat.
  • Flame spraying involves the feeding of a heat-fusible material into a heating zone, wherein the same is melted or at least heat-softened and then propelled from the heating zone in a finely divided form, generally onto a surface to be coated.
  • the material being sprayed is generally fed into the heating zone in the form of either a powder or a wire (the latter term designating both rods and wires).
  • the spraying is effected in a device known as a heat-fusible material spray gun or a flame spray gun.
  • the rod or wire of the material to be sprayed is fed into the heating zone formed by a flame of some type, where it is melted or at least heat-softened and atomized, usually by blast gas, and thence propelledin finely divided form onto the surface to be coated.
  • the rod or wire may be a conventionally formed rod or wire of a metal, or may be formed by sintering together finely divided material or by bonding together finely divided material by means of a plastic binder or other suitable binder which disintegrates in the heat of the heating zone, thereby releasing the material to be spray-ed in finely divided form.
  • a powder type flame spray gun For spraying finely divided, i.e., powdered material, a powder type flame spray gun is used in which the powder, usually entrained in a carrier gas, is fed into the heating zone of the gun formed by a flame of some type. The powder is either melted or at least the surface of the grains heat-softened in this zone, and the thus thermally conditioned particles propelled onto a surface to provide a coating.
  • a separate blast gas is often dispensed with, though the same may be supplied in order to aid in accelerating the particles and propelling them toward the surface to be coated.
  • the blast gas may be provided for both the wire type and powder guns to perform the additional function of cooling the workpiece and the coating being formed thereon.
  • the heat for the heating zone is most commonly produced from a flame caused by the combustion of a fuel, such as acetylene, propane, natural gas or the like, using oxygen or air as the oxidizing agent.
  • a fuel such as acetylene, propane, natural gas or the like
  • the heat may, however, also be produced by an electrical arc flame or in the newer type of guns, by a plasma flame.
  • the plasma flame may in itself constitute part of an electric are or, in accordance with a newer development, may be in the form of a free plasma stream, i.e., a stream of plasma which may be considered independent of the are as it does not contribute to the electric flow between electrodes.
  • Heat-fusible material spray guns utilizing electric resistance heating or induction heating as the heat source have also been proposed but have not proven commercially successful except in connection with the spraying of low melting point metals, such as solders, lead and zinc.
  • Flame spraying in the initial stages of its commercial development was used mostly for the spraying of various metals and was often referred to as metallizing.
  • the art of flame spraying extends to the spraying of a much wider group of materials, including higher melting point or refractory metals, ceramic, cermets and the like, and such materials are of increasing commercial interest.
  • the rod or wire In the case of spraying heat-fusible materials in the initial form of a rod or wire, the rod or wire is generally of a single composition, i.e., in the form of a specific metal, alloy, ceramic or the like. While it is true that rods or wires formed from finely divided material bound together with a binder. of plastic or the like, as mentioned above, were known, the binder did not take part in the spraying or contribute to the coating and merely served the purpose of maintaining the rod or wire in shape until fed into the heating zone.
  • One object of this invention is the spraying of the heat-fusible material in a novel form, which allows the I obtaining of superior results.
  • a further object of this invention is a novel group of flame spraying materials.
  • FIG. 1 diagrammatically shows a cross-section of a grain of a novel flame spray powder in accordance with the invention
  • FIG. 2 is a diagrammatic cross-section of a further embodiment of a grain of a novel flame spray powder in accordance with the invention
  • FIG. 3 is a diagrammatic cross-section of an embodiment of a novel flame spray rod or wire in accordance with the invent-ion.
  • FIG. 4 shows an elevation of a further embodiment of a novel flame spray rod or wire in accordance with the invention.
  • the flame spraying is effected with the material being sprayed in the form of a powder, the individual grains of which are in the form of a clad composite consisting of nuclei and at least one coating layer of a different material which will synergistically act with the nuclei in the process.
  • Each grain of the synergistically clad composite powders may also be in the form of a nucleus with two or more diiferent coating layers which will synergistically act with each other and/ or with the nucleus.
  • the synergistic action of the coating layer with the nucleus and the coating layers with each other may manifest itself as a chemical or physical action or both, and may appear in the heating zone and/ or along the path of travel to the surface to be coated, or at the sprayed coating as sprayed, or after a subsequent treatment such as a heatingor fusing operation.
  • the synergistic action between the nuclei and/ or the coating layer or layers may, for example, involve the physical or chemical generation of heat by exothermic reaction in the heating zone, along the path of travel to the target, or on the coated surface itself, so as to increase the thermal efliciency of the process, aid in the bonding of the coating and/or produce results and effects by this in situ generated heat which cannot be achieved by the externally supplied heat.
  • the synergism resulting in the exothermic reaction may be caused by the utilization of two components which will combine at the temperatures involved to form a material with a melting point higher than that of either of the constituents, with a considerable release of heat, by the use of components which will chemically combine in exothermic reaction, as for example where one acts as an oxidizing and the other a reducing agent, or by the use of components which will dissolve together in generation of heat or the like.
  • one of the components may be a nickel-containing component and the other an aluminumcontaining component which will combine under the spraying conditions to form a nickel-aluminum inter-metallic compound with an exothermic reaction.
  • one of the components may contain the aluminum and the other antimony, calcium, cobalt, lanthanum, lithium, manganese, nickel, palladium, praseodymium, dysprosium, or a combination thereof which, upon combining during the spraying, form a higher melting point compound with the generation of heat.
  • the clad-composite powder may be a combination of nickel with elemental phosphorus, silver, copper, aluminum or the like, which will combine in exothermic reaction.
  • the synergistic action may also involve a protective effect of the coating material on the nuclei or a lower coating layer in order to prevent loss or destruction of this under-material and allow the spraying of the combination.
  • nickel may be coated on nickel-phosphorus, nickel-boron, or the like in order to prevent loss or destruction of the fiuxing agent and allow the formation of a self-fiuxing coating, as for example in the spray-weld process.
  • the synergism may also involve a bonding effect in order to allow a satisfactory bonding on a base of sprayed materials which normally present bonding difiiculties, as for example the synergism of a matrix metal, such as nickel or cobalt, with a hard or refractory material, such as tungsten carbide, A1 diamonds or other hard gems or the like.
  • a matrix metal such as nickel or cobalt
  • a hard or refractory material such as tungsten carbide, A1 diamonds or other hard gems or the like.
  • Bonding to the base or substrate being coated may also be aided by the synergistic action of exothermic reaction, as for example in the case of nickel-coated aluminum powder.
  • the synergistic effect may also involves the combining of the components to form a third component, such as a compound or alloy or inter-metallic compound desired as the coating constituent. This may involve a dissolving together of the components, alloying the components, or a chemical reaction between components which may be endothermic in nature if sufficient heat is available for the process.
  • the powder particles may be in the form of a nucleus with a single coating layer, or may be in the form of a nucleus with a multiple number of layers of the same or different materials.
  • the clad powders in accordance with the invention may be formed in any known or desired manner and preferably by the known chemical plating processes in which a coating material is deposited on a seed or nucleus of another material, or in which multiple layers of various materials are built up on the seed material, or in which various materials are co-deposited in a single layer on the seed material.
  • a preferred mode of forming the clad powders involves the depositing of a metal from a solution by reduction on a seed or nucleus, such as the hydrogen reduction of ammoniacal solutions of nickel and ammonium sulphate on a seed powder catalyzed by the addition of anthraquinone. It is also possible to form the coating by the use of other known coating processes, such as coating by vapor deposition, by the thermal decomposition of metal carbonyls, by hydrogen reduction of metal halide vapors, by thermal decomposition of halides, hydrides, carbonyls, organometals or other volatile compounds, or by displacement gas plating and the like.
  • the clad powders for this invention should have the general over-all shape and size of conventional, flamespray powders, and thus for example should have a size between 60 mesh and +3 microns and preferably l40 and +10'microns (U.S. standard screen mesh size). Most preferably the powder should be as uniform as possible in grain size, with the individual grains not varying by more than 250 microns and preferably microns.
  • the clad powders may be sprayed per se or in combination with other different clad powders, or in combination with other conventional flame spray powders or powder components.
  • FIG. 1 diagrammatically shows an embodiment of a clad powder having a nucleus of aluminum and a coating of nickel.
  • the powders are preferably sprayed, as such, in a powder-type of flame spray gun, it is also possible to combine the same in the form of a wire or rod, using a plastic or similar binder which decomposes in the heating zone of the gun, or, in certain cases the powders may be compacted and/ or sintered together in the form of a rod or wire.
  • the spray material may assume a form other than the clad powder and may, for example, be in the form of a suitable aggregate or a composite wire, such as a wire having a coating sheath of one material, such as nickel, with a core of the other material, such as aluminum, as shown in FIG. 3, or wire formed by twisting together and rolling separate wires of components, such as nickel and aluminum, as shown in FIG. 4.
  • a suitable aggregate or a composite wire such as a wire having a coating sheath of one material, such as nickel, with a core of the other material, such as aluminum, as shown in FIG. 3, or wire formed by twisting together and rolling separate wires of components, such as nickel and aluminum, as shown in FIG. 4.
  • Various combinations of other exothermically-reacting components may of course be used in the formation of such Wire, which exothermic reaction will substantially contribute to the heat economy of the flame spraying and may even show self-ignition characteristics when fed through the spray gun.
  • EXAMPLE 1 An aluminum powder having a particle size between mesh and +325 mesh (U.S. standard screen size) is coated with nickel in the known manner by the hydrogen reduction of an ammoniacal solution of nickel and ammonium sulphate, using anthraquinone as the coating catalyst. The reduction is effected at a temperature between about 300 and 350 F. in a mechanically agitated autoclave using solutions containing 40-50 grams per liter of nickel and 10-400 grams per liter of (NH SO and 2030 grams per liter of NH About .2 gram per liter of anthraquinone is used as the catalyst and the autoclave is pressurized with hydrogen at a pressure of about 300 lbs. p.s.i.g.
  • the solution is discharged from the autoclave and replenished with a fresh solution which need not contain further amounts of the anthraquinone coating catalyst, as the initially formed nickel coating in itself acts as a catalyst.
  • the cycle is continuously repeated until a composite powder is formed containing about 16 to 18% by weight aluminum and 84 to 82% by weight of nickel, and a size of l00 to +270 mesh.
  • the powder thus formed is flame-sprayed on a mild steel plate which has been surface-cleaned with emery cloth.
  • the spraying is effected at about 7 inches from the plate, using a powder-type flame-spray gun as described in US. Patent 2,961,335, issuing November 22, 1960 and sold by Metco, Inc. of Westbury, Long Island, N.Y., under the trade name of Thermospray powder gun.
  • the spraying is efiected at a rate of 6 to 9 lbs. of powder per hour, using acetylene gas as the fuel at a pressure of 10 p.s.i. and a flow rate of 17 to 25 cu. ft./hr. and oxygen as the oxidizing gas at a pressure of 12 p.s.i. and a flow rate of 29 to 35 cu. ft./hr.
  • the nickel coating and the aluminum base combine in the heat of the flame with a strong exothermic action, forming a nickel aluminum inter-metallic compound which deposits on the base as a dense, high quality coating which exhibits self-bonding characteristics.
  • a coating layer of .002-.004 thickness is built up in this manner.
  • the coating may be used as a base material for spraying of further layers of different metals or the like and serves as an excellent intermediate bonding layer.
  • the coated rod When the example is repeated on a molybdenum rod of diameter, with a coating between .008.010 thick, the coated rod may be repeatedly heated to approximately 2000 F. in air, with a welding torch, and cooled to room temperature with no visible oxidation occurring.
  • the composite powder contains -45% by weight of aluminum and 55-90% by weight of nickel.
  • Low alloy steels and stainless steels smooth-ground to remove surface contamination; copper .and copper base alloys, rough-ground or light-grit-blasted; aluminum and aluminum base alloys, rough-ground or light-grit-blasted; magnesium, rough ground or light-grit-blasted; and titanium, rough-ground or light-grit-blasted.
  • Example 3 The nickel-clad powder of Example 1 is mixed with an A1 0 powder having a particle size between 62 microns and 10 microns, in the ratio of about 40% of the nickelclad powder with 60% by weight of the ceramic. The powder is sprayed, using the gun described in Example 1,
  • EXAMPLE 5 may be subsequently fused by a welding torch or furnace heated to form a homogenous-pore-free coating welded to the base material.
  • EXAMPLE 6 A nickel-boron powder is coated with nickel to form a composite flame-spray powder having a size between 120 and 325 mesh and containing 70 to nickel, based on the nickel boron. The powder was sprayed in the manner described in Example 1 and a high quality of self-fluxing coating was formed.
  • the coating is mechanically bonded to the base and may be subsequently fused with a welding torch or in a furnace to form a dense homogenous, non-porous coating.
  • a reactive base material such as molybdenum
  • the coating can be fused to the base material by a torch or furnace without atmosphere control and below the recrystallization temperature of pure molybdenum, and .will protect the molybdenum base from an oxidizing atmosphere at elevated temperatures up to the melting point of the nickel-boron coating.
  • EXAMPLE 7 Metallic cobalt is deposited as a coating on zirconia powder by the reduction of a cobalt ammonium sulphate solution with hydrogen so as to form a cobalt-clad zirconia flame-spray powder having a size between 140 mesh and 15 microns and containing 25 to cobalt, based on the zirconia.
  • the material is sprayed in the manner described in Example 1 on a grit-blasted base and a cermet coating is formed which shows excellent adhesion to the base and which willretard oxidation of the base.
  • the coating furthermore has a high degree of hardness even at elevated temperatures, excellentshock-resistance and abrasion-resistance, and the metal matrix material is evenly distributed throughout the applied coating.
  • the percentages of the ceramic in the composition between about 5 and 75% by weight in order to vary the properties of the coating.
  • the hardness and wear-resistant properties of the coating are correspondingly increased and the thermal conductivity decreased.
  • the bonding and shock-resistant properties are increased.
  • EXAMPLE 8 A1 powder of a mesh size betweenSOrnicrons and 10 microns 'is' coated with nickel in the manner I I described :in Example 1 to produce a composite powder 7 containing 25 to 95% of the nickel based on the alu mesh andilS microns. The powderis sprayed in the manner described in Example 1 on a gritblasted b ase,
  • cermet' coating which shows excellent minurn oxide and having a particle size between 140 I I adhesion to the base, a high degree of hardness e ven at elevated temperatures, and excellent thermal shock and abrasion-resistant characteristics.
  • I I Industrial diamond powder having a size between I 120 and +140 mesh was coated with nickel in the manner described in Example 1 so that the nickel-clad composite powder formed contained. about 25 to- 50% an excellent bone or lap in which the diamonds were'firmly bonded in place.
  • Cobalt-bonded tungsten carbide particles of sharp, an- I 'gular shape were coated with I nickel in the I manner de scribed in Example 1 so. as to produce a nickel-clad I flame'spray powder having a particle sizebetween. 100 I and 325 mesh and containing 20 to 50% nickel based on I I the tungsten carbidcr The powder was sprayed in the manner described in Example 9, with the formation of I an excellent cutting hone or lap. The sharp angular I edges of the initial tungsten carbide were retained in the coating.
  • EXAMPLE 11 A nickel boron powder is coated with copper and the copper-coated composite further coated with nickel to form a composite-clad flame spray powder having a particle size between 100 and 325 mesh containing 63 to 67% nickel and 26 to 32% copper and 2 to boron by weight.
  • the powder is sprayed in a powdertype flame spray gun on a lightly grit-blasted steel base with the flame spray gun and method as described in Example 1.
  • An excellent self-fluxing alloy is formed, which when fused in place by heating with an acetylene torch, forms a dense coating which corresponds in characteristics to Monel.
  • the metal matrix 8 EXAMPLE 13 A nickel boron powder is coated with chromium and t the resulting coated powderinturn coated with nickel so as to form a, flame spray composite-clad powder having, amesh, size between 100 and 3,25 and containing 170 t Wm 80% nickel and 18 to 20%: chrome I and :2 to 1'0%' I I boron by weight, Thepowder is sprayedin the manner described in Example 12, resulting in ,a self-fluxing alloy coating which,when fused inplace in the manner described: in Example 12, produces a high grade coating having characteristics similar to Nichrome V,
  • the material is'sprayediin the/ manner described in Example 1 on a base with surface roughened by grit-blasting, and a high grade, bonded titanium carbide coating is formed in which the nickel acts as a r'natrix'binding' material.
  • composite flame spray powder having a particle size be- I I tween IOOand 325 mesh and containing to nickel based on the. copper.
  • a base roughened by I grit-blasting or other'means an excellent, corrosion and 1oxidation-resistantcoating is formed.
  • a similar coating ' is formed it the copper is replaoed withchr-omium in an amount of 15 to-25% chromium based on the nickel.
  • Molybdenum disilicide powder is coated with nickel in the manner described in Example 1 so as to form a composite-clad flame spray powder having a particle size between 140 mesh and 10 microns, and containing 15 to 40% nickel by weight based on the disilicide.
  • the powder is sprayed with the flame spray gun described in Example 1 on a base material roughened by grit-blasting.
  • the resultant oxidation-resistant coating is very dense, but may be further improved by subsequent heat treatment in a neutral to reducing atmosphere.
  • EXAMPLE 18 Silver solder powder is coated with nickel in the manner described in Example 1 so as to produce a nickelclad composite powder having a size between and 325 mesh and containing 25 to 50% nickel based on the Upon spraying in the manner described silver solder.
  • the fused coating may be suitably finished by grinding for use as a wear-resisting coating or used, as .fused, where the coated article is to be used as a hone or lap, the sharp edges of the carbide inclusions constituting the abrading or cutting edges.
  • the nickel protects the titanium from oxidation during storage and when spraying.
  • the nickel protects the niobium from oxidation during storage and when spraying.
  • EXAMPLE 22 A molybdenum powder was coated with nickel in the manner described in Example 1 so as toproduce a nickelclad flame spray powder having a particle size between 100 and 325 mesh and containing 5 .to 40% nickel based on the molybdenum.
  • the nickel protects the molybdenum from oxidation during storage and when spraying.
  • the nickel protects the titanium boride during the spray.
  • EXAMPLE 24 A silver powder is coated with nickel so as to form a nickel-clad flame spray powder having a particle size between 100 and 325 mesh and containing 30 to 70% nickel based on the silver.
  • EXAMPLE 25 An aluminum powder is copper-plated so as to form a copper-clad flame spray powder having a particle size be tween 100- and 325 mesh and containing to 98% or 8 to 20% copper based on the aluminum.
  • Example .1 Upon spraying in the manner described in Example .1, on a base material prepared by grit-blasting, the copper and aluminum combined in the flame to form a harder, corrosion resistant alloy.
  • EXAMPLE 26 A silicon powder was coated with copper so as to form a copper-clad flame spray powder having a particle size between 100 and 325 mesh and containing 50 to 80% by weight of copper based on the silicon.
  • Example 2 Upon spraying in the manner described in Example 1, on a base material prepared by grit blasting, the copper and silicon combine in the flame to form coatings of a material considerably more inert than copper.
  • EXAMPLE 27 Tin powder is coated with copper so as to form a copper-clad composite flame spray powder having a mesh size between 100 and 325 mesh and containing 75 to copper-based on the tin.
  • Example 2 Upon spraying in the manner described in Example 1, upon a base material prepared by grit-blasting, the copper and tin combined in the flame to produce a ductile, corrosion-resistant coating.
  • EXAMPLE 29 Lead powder is coated with copper so as to form composite flame spray powder having a particle size between and 325 mesh and containing 50 to 90% copper based on the lead.
  • Example 2 Upon spraying in the manner described in Example 1, upon a base material prepared by grit-blasting, an excel lent, leaded copper material is deposited which is suitable for use as a bearing.
  • EXAMPLE 30 The nickel-clad flame spray powder of Example 1 is mixed with about 20% by weight of low pressure polyethylene powder and molded at a temperature of about 212 F. into the form of a rod of /s" diameter.
  • the rod is sprayed, using a conventional wire-type flame spray gun sold by Metco, Inc. of Westbury, Long Island, N.Y., as the Metco-type 4E Gun.
  • the spraying is effected with acetylene at a pressure of 15 p.s.i. and a flow rate of 37 cu. ft./hr. with oxygen as oxidizing gas at a pressure of 38 p.s.i. and a flow rate of 75 cu. ft./hr.; with air as a blast gas at a pressure of 40 p.s.i. and a flow rate of 25 cu. ft./min.
  • the end coating produced is similar to the coating produced in Example 1.
  • EXAMPLE 31 at a pressure of 15 p.s.i. and a flow rate of 37 cu. ft./hr. with oxygen as the oxidizing gas at a pressure of 38 p.s.i. and a flow rate of 75 cu. ft./hr. Air is used as a blast gas at a pressure of 55 p.s.i. and a flow rate of 30 cu. ft./min.
  • the end coating produced is similar to the coating produced in Example 10.
  • EXAMPLE 32 A wire is formed by encasing a core of aluminum in a tube of nickel and drawing to a size of .125 in diameter plus or minus .002. The wire contains 82 to 84% by weight of nickel based on the aluminum.
  • the wire is sprayed, using a conventional wire type flame spray gun sold by Metco, Inc. of Westbury, Long Island, N.Y., as the Metco-type 4E Gun.
  • Spraying is effected with acetylene at a pressure of 15 p.s.i. and a flow rate of 37 cu. ft./hr. with oxygen as the oxidizing gas at a pressure of 38 p.s.i. and a flow rate of 75 cu.t ft./hr.
  • Air is used as a blast gas at a pressure of 55 p.s.i. and a flow rate of 30 cu. ft./ min.
  • the end coating produced is similar to the coating produced in Example 1.
  • EXAMPLE 33 A composite wire is formed by winding individual wires of nickel and aluminum and drawing the same to a thickness of .125" plus or minus .002". The wire contains 82 to 84% by weight of nickel based on the aluminum. The wire is sprayed in the manner described in Example 32, with identical conditions and coating resulting.
  • EXAMPLE 34 A self-fluxing silver-solder powder containing 15% silver, 5% phosphorus and 80% copper, is coated with copper so as to form a composite flame spray powder having a particle size between 100 and 325 mesh and containing to 50% copper based on the silver-solder.
  • Example 2 Upon spraying in the manner described in Example 1, on a base material prepared by light grit-blasting, an excellent, low melting point, self-fluxing alloy is deposited.
  • EXAMPLE 36 A simple mixture of powders containing 10 to of the composite nickel-nickel phosphorus powder described in Example 5 and 75 to 90% of copper or copper alloy powder of the kind known as Everdur is sprayed with the gun and spray conditions described in Example 1.
  • the coating as described is mechanically bonded to the base material and slightly porous by nature. It may be subsequently fused by torch or furnace heating to form a homogenous, pore-free coating welded to the base material. After fusion the coating is a fairly hard, corrosionresistant, welded bronze overlay.
  • Example 36 is repeated, using, however, the composite nickel-phosphorus powder described in Example 11 in place of the nickelnickel phosphorus powder.
  • EXAMPLE 38 A simple mixture of powders containing 69% of the composite powder as described in Example 6 and 31% pure copper powder in the particle size range 140 and +325 mesh is sprayed with the gun as described in Example 1.
  • the coating as applied may be subsequently fused without atmosphere control, to form a homogenous alloy fused to the base material, which corresponds in characteristics to Monel.
  • EXAMPLE 39 A simple mixture of powders containing 81% of the composite powder as described in Example 6 and 19% of pure chromium powder in the particle size range -140 and +325 mesh is sprayed with the gun as described in Example 1.
  • the coating as applied may be subsequently fused without atmosphere control, to form a homogenous alloy fused to the base material, which corresponds in characteristics to Nichrome V.
  • Example 9 is repeated except in place of the nickel, nickel phosphorus was used containing 6 to 12% of phosphorus. A similar coating resulted upon spraying, which however, was self-fiuxing. Fusion bonding of particles to each other and to the base was accomplished by fusing the applied coating.
  • EXAMPLE 41 The coated diamond powder of Example 9 is mixed with nickel-coated silver solder powder of Example 19 in the proportion of 50 to 75% diamond to 25 to 50% materix material.
  • Example 2 The mixture was sprayed in the manner described in Example 1 and the deposit subsequently fused.
  • the resultant coating was a dense, pore-free coating fused to the base material in which the diamonds were securely anchored by the low melting point, self-fluxing matrix metal.
  • Example 14 is repeated except in place of the nickel, nickel phosphorus is used containing 4 to 12% of phosphorus. A similar coating resulted which, however, was self-fluxing.
  • EXAMPLE 43 A silicon powder having a particle size between 140 and 325 mesh is coated with molybdenum in the known manner and a composite powder is formed containing about 35 to 39% by weight of silicon and about 61 to 65%;1 by weight of molybdenum, and a size of to 270 mes The powder thus formed is flame-sprayed on a base material which has been prepared by light grit-blasting, in the manner described in Example 1.
  • the molybdenum coating and the silicon base combine in the heat of the flame, forming a molybdenum silicon inter-metallic which deposits on the base as a dense, high quality coating which exhibits excellent resistance to oxidation at elevated temperatures and will protect the base material from oxidation.
  • EXAMPLE 44 A molybdenum powder having a particle size range between 140 and 325 mesh is coated with silicon in the known manner and a composite powder is formed containing about 35 to 39% by weight of silicon and about 61 to 65% by weight of molybdenum, and a size of 100 to 270 mesh.
  • the powder thus formed is flame-sprayed on a base material which has been prepared by light grit-blasting.
  • the spraying is elfected at about five inches from the plate, using a powder type plasma flame-spray gun sold by Metco, Inc. of Westbury, Long Island, N.Y., under the trade name of Type MB Plasma Flame Gun.
  • the spraying is efiected at a rate of six to nine lbs. of powder per hour, using argon gas as the plasma gas at a pressure of 100 p.s.i. and a flow rate of cu. ft./hr., using argon as the powder carrier gas at 100 p.s.i. and a flow rate of 11.5 cu. ft./hr., using a No. 3 (pointed) electrode and rial from oxidation.
  • the molybdenum base and silicon coating combine in the heat of the flame, forming a molybdenum silicon inter-metallic which deposits on the base as a dense, high quality coating which exhibits excellent resistance to oxidation at high temperatures and willprotect the base material from oxidation.
  • EXAMPLE 45 p A silicon powder having a particle size between 140 and 325 mesh is coated with chromium in the known manner, and a composite powder is formed containing about 48 to 85% chromium and 15 to 52% silicon by Weight and a size of 100 to 270 mesh.
  • the powder thus formed is flame-sprayed on a base material which has been prepared by light grit-blasting in the manner described in Example 1.
  • the chromium coating and the silicon base combine in the heat of the flame, forming a chromium-silicon intermetallic which deposits on the base as a dense, high quality coating which exhibits excellent resistance to oxidation at elevated temperatures and will protect the base material from oxidation.
  • EXAMPLE 46 A chromium powder having a particle size between 140 and 325 mesh is coated with silicon in the known manner, and a composite powder is formed containing about 48 to 85% chromium and 15 to 52% silicon by weight and a size of 100 to 270 mesh.
  • the chromium base and silicon coating combine in the heat of the flame, forming a chromium silicon intermetallic which deposits on the base as a dense, high quality coating which exhibits excellent resistance to oxidation at high temperatures and will protect the base mate- EXAMPLE 47
  • a zirconium powder having a particle size between 140 and 325v mesh is coated with chromium in the known manner and a composite powder is formed containing about 47%, zirconium and 53% chromium by weight and a size of 100 to 270 mesh.
  • the powder thus formed is flame-sprayed on a base material in the manner described in Example 1.
  • the chromium coating and the zirconium base combine in the heat of the flame, forming a chromium zirconium inter-metallic which deposits on the base as a dense, high quality coating which exhibits excellent resistance to oxidation at high temperatures.
  • EXAMPLE 48 A titanium powder having a particle size range betwen 140 and 325 mesh is coated with chromium in the known manner and a composite powder is formed containing about 35% chromium and 65% titanium by weight and a size of 100 to 270 mesh.
  • the chromium coating and the titanium base combine in the heat of the flame, forming a chromium titanium inter-metallic which deposits on the base as a dense, high quality coating which exhibits excellent resistance to oxidation at high temperatures.
  • EXAMPLE 49 A titanium powder having a particle size range between 140 and 325 mesh is coated with silicon in the known manner and a composite powder is formed containing about 35 to 65% titanium and 35 to 65 silicon by weight and a size of to 270 mesh.
  • the powder thus formed is flame-sprayed on a base material which has been prepared by light grit-blasting.
  • the spraying is effected at about five inches from the plate, using a powder type plasma flame-spray gun sold by Metco, Inc. of Westbury, Long Island, N.Y., under the trade name of Type MB Plasma Flame Gun.
  • the spraying is effected at a rate of six to nine lbs. of powder per hour, using argon gas as the plasma gas at a pressure of 100 p.s.i. and a flow rate of cu. ft./hr., using argon as the powder carrier gas at 100 p.s.i. and a fiow rate of 11.5 cu. ft./hr., using a No. 3 (pointed) electrode and No. 3R argon nozzle, and using arc current of 550 amperes at 45 volts.
  • the titanium base and silicon coating combine in the heat of the flame, forming a titanium silicon inter-metallic which deposits on the base as a dense, high quality coating which exhibits excellent resistance to oxidation at high temperatures and will protect the base material from oxidation.
  • EXAMPLE 50 A dysprosium powder having a particle size between and 325 mesh is coated with aluminum in the known manner and a composite powder is formed containing 60 to 75% dysprosium and 25 to 40% aluminum by weight and a size of 100 to 270 mesh.
  • the powder thus formed is flame-sprayed on a base material which has been prepared' by light grit-blasting in the manner described in Example 1.
  • the aluminum'coating and the dysprosium base combine in the heat of the flame with a strong exothermic action, forming a dysprosium aluminum inter-metallic compound which deposits on the base as a dense, high .quality coating which exhibits excellent properties at high temperatures.
  • EXAMPLE 51 A lanthanum powder having a particle size between 140 and 325 mesh is coated with aluminum in the A chromium powder having a particle size between 140 and 325 mesh is coated with aluminum in the known' manner and a composite powder is formed consisting of 60 to 62% chromium and 38 to 40% aluminum by weight and a size of 100 to 270 mesh.
  • the powder thus formed is flame-sprayed on a base material which has been prepared by grit-blasting in the manner described in Example 1.
  • the aluminum coating and the chromium base combine in the heat of the flame with a strong exothermic 15 action, forming a chromium aluminum inter-metallic compound which deposits on the base as a dense, high quality coating of very high melting point and excellent oxidation-resistance.
  • Example 52 is repeated except that the composite powder is formed with an aluminum core and chromium coating. Identical results are obtained.
  • EXAMPLE 54 The nickel-clad aluminum composite powder of Example 1 is mixed with cobalt bonded tungsten carbide particle powder having a particle size range of l40 mesh microns, and preferably 140 +325 mesh in proportions of:
  • (c) preferably 50 weight percent each of the tungsten carbide and composite.
  • the powder mixtures are each flame-sprayed on a mild steel plate which has been surface cleaned by grinding or very light sand-blast cleaning.
  • the spraying is effected at about 8-9 inches from the plate, using a powder-type flame-spray gun as described in US. Patent 2,961,335, issuing November 22, 1960, and sold by Metco, Inc. of Westbury, Long Island, N.Y., under the trade name of Thermo-Spray powder gun.
  • the spraying is effected at a rate of 6 to 10 lbs. per hour using acetylene gas as the fuel at a pressure of 12 p.s.i. and a flow rate of 20 to cubic feet per hour and oxygen as the oxidizing gas at a pressure of 14 p.s.i. and a flow rate of 30 to cubic feet per hour.
  • the nickel-aluminum composite powder in the mixture reacts exothermically in the flame to provide the selfbonding properties of the mixture and, being fully molten on impact with the subtrate, becomes the matrix which securely binds the tungsten carbide particles together in the coating.
  • the resultant coating is of a highly wear-resistant coating material, applicable to virtually any base material and not subject to the limitations of the previously used self-fluxing alloy matrix materials which must be fused at approximately 1900 F.
  • EXAMPLE Example 54 is repeated except that in place of the grade of tungsten carbide cobalt powder grains used, cobalt-bonded tungsten carbide grains with lower cobalt content and sharp, angular shape are used.
  • Example 54 The powder was sprayed in the manner described in Example 54. The sharp, angular edges of the initial tungsten carbide particles were retained in the coating.
  • the deposited coating may be suitably finished by grinding for use as a wear-resisting coating or used as deposited where the coated article is to be used as a hone or lap, the sharp edges of the carbide inclusions constituting the abrading or cutting edges.
  • Example 55 is repeated except that in place of the cobalt-bonded tungsten carbide grains described, the nickel-clad tungsten carbide grains described in Example 10 were substituted.
  • EXAMPLE 57 The nickel-clad aluminum composite described in Example 1 is mixed with a columbium (niobium) powder of size between l20 mesh and +10 microns and preferably 140 +325 mesh in the proportions of 60 Weight percent of the nickel-aluminum composite.
  • the powder mixture is sprayed in the manner described in Example 54.
  • the resultant coating is self-bonding to a wide variety of substrate materials and when properly finished, by grinding or other means is a highly wearresistant, hard coating.
  • EXAMPLE 58 The nickel-clad aluminum composite described in Ex ample 1 is mixed with a molybdenum powder of a size between 120 mesh and +10 microns and preferably -140 +325 mesh in the proportions of 65 weight percent molybdenum to 35 weight percent of the nickel-aluminum composite.
  • Example 54 The powder mixture is sprayed in the manner described in Example 54.
  • the resultant coating is selfbonding to a wide variety of substrate materials and when properly finished by grinding or other means presents a highly wear-resistant, hard surface.
  • Example 54 is repeated except in place of the tungsten carbide, other carbides such as titanium carbide, tantalum carbide, columbium carbide, chromium carbide and mixtures of the various carbides are used.
  • other carbides such as titanium carbide, tantalum carbide, columbium carbide, chromium carbide and mixtures of the various carbides are used.
  • EXAMPLE 60 The nickel-clad aluminum core composite from Example 54 is mixed with aluminum powder in the mesh size range +100 +325 mesh, and preferably in the 170 +325 mesh size range in the proportions of weight percent nickel aluminum composite to 20 weight percent aluminum.
  • the mixture was sprayed in the manner described in Example 54.
  • the coating as deposited consists of an intimate mixture of the flame-reacted nickel aluminide and aluminum securely bonded to the base and particle to particle within the coating.
  • the nickel aluminide and aluminum combine to form a dense, homogenous coating fused to the base material which can be used for cathodic protection of iron and steel subject to water and salt water corrosion.
  • EXAMPLE 61 The nickel-clad aluminum composite powder of Example 54 is mixed with Monel powder of a size between mesh and +10 microns, and preferably between and +325 mesh in the proportions 35 weight percent composite to 65 weight percent Monel.
  • the powder mixture was sprayed in the manner described in Example 54.
  • the resultant coating is selfbonding to a wide variety of substrate materials and the inclusion of the nickel-aluminum composite, the components of which combine exothermically in the flame to provide the self-bonding ability of the mixture, considerably increase the particle to particle bonds within the coating and decrease the permeability of the coating.
  • EXAMPLE 62 Example 61 is repeated except that nickel and stainless steel powders are substituted for the Monel.
  • Example 61 is repeated except that chromium is substituted for the Monel.
  • the resultant coating when properly finished by grinding or other means shows high resistance to abrasion, wear, and galling by other metals, and is an excellent bearing surface.
  • the flame spraymg of synergistically-acting composites in accordance with the invention is effected in the conventional manner, using the conventional flame spray equipment and utilizing conventional surface-preparation, though in certain instances wherein the spray coating has self-bonding characteristics,
  • synergistic composites in accordance with the invention may be sprayed in conjunction with or in addition to other flame-spray materials conventionally used in the art, or may be sprayed in combination with or in conjunction with each other.
  • synergistically clad powders in accordance with the invention may be sprayed in admixture with other conventional spray powders or mixtures of two or more of the composite powders in accordance with the invention may be sprayed.
  • composite powders such as nickelcoated aluminum particles
  • the use of these composite powders, such as nickelcoated aluminum particles will generally improve the bond of the total sprayed mixture and thus of the other component or components to the substrate making the mixture self-bonding.
  • the particle bond will also be improved so that the porosity of the coating may be decreased.
  • the use of the composites in admixture with conventional spray powders may thus be used to improve the characteristics and properties of the materials or, conversely, the properties of the composites, such as the nickelaluminum deposits may be enhanced or other new or better properties may be obtained.
  • Example 1 When, for example, using a mixture of a nickel clad aluminum powder as for instance, is shown in Example 1, with tungsten carbide, titanium carbide, tantalum carbide, chromium carbide, molybdenum, niobium and tantalum amounts of 20% to 80%, and preferably 25% to 50% by weight of the composite may be used.
  • the mixtures are self-bonding as sprayed and form abrasion and wear-resistant coatings.
  • the same composite is sprayed in mixture with Monel, stainless steel, nickel, chormium, etc., amounts of 25 to 75% by weight of the composite, and preferably 30% to 40% by weight of the composite are used.
  • a flame spray powder in the form of individual, synergistically clad particles of a size between about 60 mesh and plus 3 microns comprising a nucleus and at least one coating layer of a material differing from said nucleus, one of said coating layer and nucleus comprising a refractory selected from the group consisting of refractory oxides, refractory carbides, and diamond, the other a bonding matrix for said refractory material selected from the group consisting of nickel and cobalt matrices.
  • a flame spray powder according which said carbide is tungsten carbide.
  • a flame spray powder according which said coating layer is nickel and aluminum oxide.
  • a flame spray powder according to claim 1 in which said powder is bonded in the form of a wire.
  • a flame spray powder according to claim 1 including at least one additional coating layer differing from said nucleus and first mentioned coating layer and synergistically active with at least one of said nucleus and first mentioned coating layer in flame spraying.

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  • Agricultural Chemicals And Associated Chemicals (AREA)
US134544A 1960-11-22 1961-08-16 Flame spray clad powder composed of a refractory material and nickel or cobalt Expired - Lifetime US3254970A (en)

Priority Applications (9)

Application Number Priority Date Filing Date Title
US134544A US3254970A (en) 1960-11-22 1961-08-16 Flame spray clad powder composed of a refractory material and nickel or cobalt
GB33002/61A GB1000353A (en) 1960-11-22 1961-09-14 Improvements relating to flame spraying
ES270818A ES270818A1 (es) 1960-11-22 1961-09-29 Un perfeccionamiento en el procedimiento de proyección en llama de preparados sinergéticos
DE1961M0050689 DE1446207B2 (de) 1960-11-22 1961-10-26 Aus mehreren bestandteilen bestehendes flammspritzmaterial
SE10687/61A SE302712B (en)) 1960-11-22 1961-10-27
CH1256661A CH439909A (de) 1960-11-22 1961-10-31 Verfahren zum Flammspritzen
FR879239A FR1313303A (fr) 1960-11-22 1961-11-17 Perfectionnement à la projection à l'aide d'une flamme de composés synergiques pulvérisés
CH230766A CH503123A (de) 1960-11-22 1966-02-17 Verfahren zum Flammspritzen
FR54773A FR90386E (fr) 1960-11-22 1966-03-24 Perfectionnement à la projection à l'aide d'une flamme de composés synergiques pulvérisés

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US7254360A 1960-11-22 1960-11-22
US134544A US3254970A (en) 1960-11-22 1961-08-16 Flame spray clad powder composed of a refractory material and nickel or cobalt

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Cited By (59)

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US3332753A (en) * 1963-10-10 1967-07-25 Raybestos Manhattan Inc Flame spraying
US3338688A (en) * 1964-10-06 1967-08-29 Metco Inc Low smoking nickel aluminum flame spray powder
US3342626A (en) * 1963-10-02 1967-09-19 Avco Corp Flame spray metallizing
US3361560A (en) * 1966-04-19 1968-01-02 Du Pont Nickel silicon and refractory metal alloy
US3378392A (en) * 1963-07-24 1968-04-16 Metco Inc High temperature flame spray powder and process
US3410714A (en) * 1965-10-18 1968-11-12 Gen Electric Metallizing and bonding non-metallic bodies
US3413136A (en) * 1965-03-10 1968-11-26 United Aircraft Corp Abradable coating
US3419415A (en) * 1964-09-29 1968-12-31 Metco Inc Composite carbide flame spray material
US3428442A (en) * 1966-09-22 1969-02-18 Eutectic Welding Alloys Coated spray-weld alloy powders
US3479231A (en) * 1965-11-12 1969-11-18 Eutectic Welding Alloys Welding product and process
US3482502A (en) * 1965-06-18 1969-12-09 Balke & Co Developer for automatically operated photographic device
FR2048433A5 (en)) * 1969-07-01 1971-03-19 Metco Inc
US3607343A (en) * 1965-10-04 1971-09-21 Metco Inc Flame spray powders and process with alumina having titanium dioxide bonded to the surface thereof
US3636242A (en) * 1968-12-09 1972-01-18 Ericsson Telefon Ab L M An electric conductor wire
US3721870A (en) * 1971-06-25 1973-03-20 Welwyn Electric Ltd Capacitor
US3760143A (en) * 1972-01-03 1973-09-18 Warren Fastener Corp Welding stud
DE2432125A1 (de) * 1973-07-06 1975-01-23 Metco Inc Flammspritzwerkstoffe
US3892882A (en) * 1973-05-25 1975-07-01 Union Carbide Corp Process for plasma flame spray coating in a sub-atmospheric pressure environment
US3910734A (en) * 1973-08-20 1975-10-07 Ford Motor Co Composite apex seal
US3953193A (en) * 1973-04-23 1976-04-27 General Electric Company Coating powder mixture
US3960545A (en) * 1975-03-24 1976-06-01 Gte Sylvania Incorporated Cermet plasma flame spray powder, method for producing same and articles produced therefrom
US4004042A (en) * 1975-03-07 1977-01-18 Sirius Corporation Method for applying a wear and impact resistant coating
US4019875A (en) * 1973-07-06 1977-04-26 Metco, Inc. Aluminum-coated nickel or cobalt core flame spray materials
EP0028475A1 (en) * 1979-11-06 1981-05-13 Sherritt Gordon Mines Limited Thermal spray powder and method of forming abradable seals therewith
FR2478677A1 (fr) * 1980-03-22 1981-09-25 Rolls Royce Poudre pour la formation de couches protectrices sur pieces de machines
US4389251A (en) * 1980-01-17 1983-06-21 Castolin S.A. Powder mixture for thermal spraying
US4507151A (en) * 1980-12-05 1985-03-26 Castolin S.A. Coating material for the formation of abrasion-resistant and impact-resistant coatings on workpieces
US4678511A (en) * 1984-09-08 1987-07-07 Awamura Metal Industry Co., Ltd. Spray micropellets
US4725508A (en) * 1986-10-23 1988-02-16 The Perkin-Elmer Corporation Composite hard chromium compounds for thermal spraying
EP0282310A3 (en) * 1987-03-11 1989-07-12 James A. Browning High power extended arc plasma spray method and apparatus
US4928879A (en) * 1988-12-22 1990-05-29 The Perkin-Elmer Corporation Wire and power thermal spray gun
US4987003A (en) * 1988-03-04 1991-01-22 Alcan International Limited Production of aluminum matrix composite coatings on metal structures
US4999225A (en) * 1989-01-05 1991-03-12 The Perkin-Elmer Corporation High velocity powder thermal spray method for spraying non-meltable materials
RU2200208C2 (ru) * 2001-04-23 2003-03-10 Институт физики прочности и материаловедения СО РАН Способ нанесения плазменного покрытия
US6613452B2 (en) 2001-01-16 2003-09-02 Northrop Grumman Corporation Corrosion resistant coating system and method
US20050029808A1 (en) * 2003-08-05 2005-02-10 Heany Industries, Inc. Surface coated spherical slip joint for forming a sealed interface and method of fabrication
RU2279495C2 (ru) * 2004-08-24 2006-07-10 Государственное учреждение "Институт химии твердого тела" Уральского отделения Российской академии наук Композиционный порошок для газотермических покрытий
US20060236887A1 (en) * 2005-02-08 2006-10-26 John Childs Delay units and methods of making the same
US20060283622A1 (en) * 2005-02-10 2006-12-21 Francis Debladis Electric wire having a core of aluminum or aluminum alloy
US20070243406A1 (en) * 2006-04-17 2007-10-18 Federal-Mogul World Wide, Inc. Sliding bearing and method of manufacture
RU2385211C2 (ru) * 2008-04-29 2010-03-27 Открытое Акционерное Общество "Российские Железные Дороги" Способ восстановления шеек стальных коленчатых валов
CN103691938A (zh) * 2014-01-01 2014-04-02 北京矿冶研究总院 金属包覆粉末表面合金化方法
CN103748254A (zh) * 2011-03-28 2014-04-23 Vtt科技研究中心 热喷涂涂层
US8794152B2 (en) 2010-03-09 2014-08-05 Dyno Nobel Inc. Sealer elements, detonators containing the same, and methods of making
RU2532738C1 (ru) * 2013-09-26 2014-11-10 Андрей Николаевич Пурехов Способ восстановления изношенных поверхностей стальных деталей
WO2017011503A1 (en) * 2015-07-15 2017-01-19 Siqing Song-Destro Method of manufacture and applications for fire retardant, heat, fungi, and insect resistant, and strength enhancing additive
EP3137643A4 (en) * 2014-04-30 2017-09-06 Sulzer Metco (US) Inc. Titanium carbide overlay and method of making
US9856546B2 (en) 2006-09-22 2018-01-02 H. C. Starck Gmbh Metal powder
CN108326463A (zh) * 2018-01-31 2018-07-27 华中科技大学 一种利用缆式焊丝制备金属间化合物零件的方法
US20180333775A1 (en) * 2016-12-26 2018-11-22 Technology Research Association For Future Additive Manufacturing Metal laminating and shaping powder and method of manufacturing the same
CN109915342A (zh) * 2019-01-02 2019-06-21 武汉钢铁有限公司 一种基于复合式密封涂层的煤气压缩机级间密封装置
CN111636021A (zh) * 2020-05-29 2020-09-08 中国铁道科学研究院集团有限公司金属及化学研究所 一种热喷涂用稀土锌铝镍钛合金丝材及其制备方法和应用
CN113293372A (zh) * 2021-05-31 2021-08-24 内蒙古联晟新能源材料有限公司 一种二次处理轧制铝卷表面的加工工艺
RU2760138C1 (ru) * 2021-01-15 2021-11-22 Иван Андреевич Безбородов Способ восстановления шатунной шейки коленчатого вала двигателя внутреннего сгорания
RU2766395C1 (ru) * 2021-07-20 2022-03-15 федеральное государственное бюджетное образовательное учреждение высшего образования «Вологодская государственная молочнохозяйственная академия имени Н.В. Верещагина» (ФГБОУ ВО Вологодская ГМХА) Способ восстановления шеек коленчатых валов путем приклеивания полукольцевых накладок
US11292088B2 (en) * 2013-10-02 2022-04-05 Oerlikon Metco (Us) Inc. Wear resistant coating
CN115710683A (zh) * 2022-11-16 2023-02-24 西安石油大学 一种基于表面包覆技术和火焰喷涂技术的Mo-Cu合金制备方法
RU2791718C1 (ru) * 2022-05-23 2023-03-13 федеральное государственное бюджетное образовательное учреждение высшего образования "Вологодская государственная молочнохозяйственная академия имени Н.В. Верещагина" (ФГБОУ ВО Вологодская ГМХА) Способ восстановления цилиндрических поверхностей деталей путем приклеивания полукольцевых накладок
US12128375B2 (en) 2019-08-02 2024-10-29 Hydromecanique Et Frottement Method for preparing a metal powder for an additive manufacturing process and use of such powder

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US3322515A (en) * 1965-03-25 1967-05-30 Metco Inc Flame spraying exothermically reacting intermetallic compound forming composites
GB1558762A (en) * 1975-07-04 1980-01-09 Johnson Matthey Co Ltd Metal or alloy coated powders
US4027367A (en) * 1975-07-24 1977-06-07 Rondeau Henry S Spray bonding of nickel aluminum and nickel titanium alloys
CH622452A5 (en)) * 1977-07-13 1981-04-15 Castolin Sa
US4181525A (en) * 1978-07-19 1980-01-01 Metco, Inc. Self-bonding flame spray powders for producing readily machinable coatings
US4276353A (en) * 1978-08-23 1981-06-30 Metco, Inc. Self-bonding flame spray wire for producing a readily grindable coating
DE2841552C2 (de) * 1978-09-23 1982-12-23 Goetze Ag, 5093 Burscheid Spritzpulver für die Herstellung verschleißfester Beschichtungen auf den Laufflächen gleitender Reibung ausgesetzter Maschinenteile
US4421799A (en) * 1982-02-16 1983-12-20 Metco, Inc. Aluminum clad refractory oxide flame spraying powder
FR2532954A1 (fr) * 1982-09-14 1984-03-16 Cetehor Procede de traitement de pieces pour ameliorer les proprietes de durete et de frottement desdites pieces, par depot d'un revetement metallique sur lesdites pieces; et pieces metalliques ainsi traitees
CN103174624B (zh) * 2013-03-11 2015-08-26 戴亚洲 一种纳米金属陶瓷涂层活塞杆及其制造方法
CN109306426A (zh) * 2017-07-28 2019-02-05 宜兴市韦德同机械科技有限公司 一种电力杆用盖板材料
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CN110056598B (zh) * 2019-04-11 2020-10-09 宁波顺达粉末冶金工业有限公司 一种导向器及其制备方法
DE102023000899A1 (de) * 2023-03-10 2024-09-12 Wieland-Werke Aktiengesellschaft Verfahren zur Herstellung einer Widerstandsanordnung

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Cited By (71)

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US3378392A (en) * 1963-07-24 1968-04-16 Metco Inc High temperature flame spray powder and process
US3342626A (en) * 1963-10-02 1967-09-19 Avco Corp Flame spray metallizing
US3332753A (en) * 1963-10-10 1967-07-25 Raybestos Manhattan Inc Flame spraying
US3419415A (en) * 1964-09-29 1968-12-31 Metco Inc Composite carbide flame spray material
US3338688A (en) * 1964-10-06 1967-08-29 Metco Inc Low smoking nickel aluminum flame spray powder
US3413136A (en) * 1965-03-10 1968-11-26 United Aircraft Corp Abradable coating
US3482502A (en) * 1965-06-18 1969-12-09 Balke & Co Developer for automatically operated photographic device
US3607343A (en) * 1965-10-04 1971-09-21 Metco Inc Flame spray powders and process with alumina having titanium dioxide bonded to the surface thereof
US3410714A (en) * 1965-10-18 1968-11-12 Gen Electric Metallizing and bonding non-metallic bodies
US3479231A (en) * 1965-11-12 1969-11-18 Eutectic Welding Alloys Welding product and process
US3361560A (en) * 1966-04-19 1968-01-02 Du Pont Nickel silicon and refractory metal alloy
USRE29547E (en) * 1966-04-19 1978-02-21 E. I. Du Pont De Nemours And Company Nickel silicon and refractory metal alloy
US3428442A (en) * 1966-09-22 1969-02-18 Eutectic Welding Alloys Coated spray-weld alloy powders
US3636242A (en) * 1968-12-09 1972-01-18 Ericsson Telefon Ab L M An electric conductor wire
FR2048433A5 (en)) * 1969-07-01 1971-03-19 Metco Inc
US3721870A (en) * 1971-06-25 1973-03-20 Welwyn Electric Ltd Capacitor
US3760143A (en) * 1972-01-03 1973-09-18 Warren Fastener Corp Welding stud
US3953193A (en) * 1973-04-23 1976-04-27 General Electric Company Coating powder mixture
US3892882A (en) * 1973-05-25 1975-07-01 Union Carbide Corp Process for plasma flame spray coating in a sub-atmospheric pressure environment
DE2432125A1 (de) * 1973-07-06 1975-01-23 Metco Inc Flammspritzwerkstoffe
US4019875A (en) * 1973-07-06 1977-04-26 Metco, Inc. Aluminum-coated nickel or cobalt core flame spray materials
US3910734A (en) * 1973-08-20 1975-10-07 Ford Motor Co Composite apex seal
US4004042A (en) * 1975-03-07 1977-01-18 Sirius Corporation Method for applying a wear and impact resistant coating
US3960545A (en) * 1975-03-24 1976-06-01 Gte Sylvania Incorporated Cermet plasma flame spray powder, method for producing same and articles produced therefrom
EP0028475A1 (en) * 1979-11-06 1981-05-13 Sherritt Gordon Mines Limited Thermal spray powder and method of forming abradable seals therewith
US4389251A (en) * 1980-01-17 1983-06-21 Castolin S.A. Powder mixture for thermal spraying
FR2478677A1 (fr) * 1980-03-22 1981-09-25 Rolls Royce Poudre pour la formation de couches protectrices sur pieces de machines
US4507151A (en) * 1980-12-05 1985-03-26 Castolin S.A. Coating material for the formation of abrasion-resistant and impact-resistant coatings on workpieces
US4678511A (en) * 1984-09-08 1987-07-07 Awamura Metal Industry Co., Ltd. Spray micropellets
US4725508A (en) * 1986-10-23 1988-02-16 The Perkin-Elmer Corporation Composite hard chromium compounds for thermal spraying
EP0265800A1 (en) * 1986-10-23 1988-05-04 The Perkin-Elmer Corporation Composite hard chromium compounds for thermal spraying
EP0282310A3 (en) * 1987-03-11 1989-07-12 James A. Browning High power extended arc plasma spray method and apparatus
US4987003A (en) * 1988-03-04 1991-01-22 Alcan International Limited Production of aluminum matrix composite coatings on metal structures
US4928879A (en) * 1988-12-22 1990-05-29 The Perkin-Elmer Corporation Wire and power thermal spray gun
US4999225A (en) * 1989-01-05 1991-03-12 The Perkin-Elmer Corporation High velocity powder thermal spray method for spraying non-meltable materials
US6613452B2 (en) 2001-01-16 2003-09-02 Northrop Grumman Corporation Corrosion resistant coating system and method
RU2200208C2 (ru) * 2001-04-23 2003-03-10 Институт физики прочности и материаловедения СО РАН Способ нанесения плазменного покрытия
US20050029808A1 (en) * 2003-08-05 2005-02-10 Heany Industries, Inc. Surface coated spherical slip joint for forming a sealed interface and method of fabrication
US6904661B2 (en) 2003-08-05 2005-06-14 Heany Industries, Inc. Method of fabricating surface coated spherical slip joint for forming a sealed interface
RU2279495C2 (ru) * 2004-08-24 2006-07-10 Государственное учреждение "Институт химии твердого тела" Уральского отделения Российской академии наук Композиционный порошок для газотермических покрытий
US7650840B2 (en) 2005-02-08 2010-01-26 Dyno Nobel Inc. Delay units and methods of making the same
US20100064924A1 (en) * 2005-02-08 2010-03-18 John Childs Delay units and methods of making the same
US8245643B2 (en) 2005-02-08 2012-08-21 Dyno Nobel Inc. Delay units and methods of making the same
US20060236887A1 (en) * 2005-02-08 2006-10-26 John Childs Delay units and methods of making the same
US20060283622A1 (en) * 2005-02-10 2006-12-21 Francis Debladis Electric wire having a core of aluminum or aluminum alloy
US7491890B2 (en) * 2005-02-10 2009-02-17 Nexans Electric wire having a core of aluminum or aluminum alloy
US20070243406A1 (en) * 2006-04-17 2007-10-18 Federal-Mogul World Wide, Inc. Sliding bearing and method of manufacture
US9856546B2 (en) 2006-09-22 2018-01-02 H. C. Starck Gmbh Metal powder
RU2385211C2 (ru) * 2008-04-29 2010-03-27 Открытое Акционерное Общество "Российские Железные Дороги" Способ восстановления шеек стальных коленчатых валов
US8794152B2 (en) 2010-03-09 2014-08-05 Dyno Nobel Inc. Sealer elements, detonators containing the same, and methods of making
EP2691554A4 (en) * 2011-03-28 2015-03-18 Teknologian Tutkimuskeskus Vtt Oy THERMAL SPRAY COATING
CN103748254A (zh) * 2011-03-28 2014-04-23 Vtt科技研究中心 热喷涂涂层
US9562280B2 (en) 2011-03-28 2017-02-07 Teknologian Tutkimuskeskus Vtt Thermally sprayed coating
KR101878900B1 (ko) * 2011-03-28 2018-07-16 테크놀로지안 투트키무스케스쿠스 브이티티 오와이 용사처리된 코팅
KR20140052986A (ko) * 2011-03-28 2014-05-07 테크놀로지안 투트키무스케스쿠스 브이티티 용사처리된 코팅
RU2532738C1 (ru) * 2013-09-26 2014-11-10 Андрей Николаевич Пурехов Способ восстановления изношенных поверхностей стальных деталей
US11292088B2 (en) * 2013-10-02 2022-04-05 Oerlikon Metco (Us) Inc. Wear resistant coating
CN103691938A (zh) * 2014-01-01 2014-04-02 北京矿冶研究总院 金属包覆粉末表面合金化方法
EP3137643A4 (en) * 2014-04-30 2017-09-06 Sulzer Metco (US) Inc. Titanium carbide overlay and method of making
WO2017011503A1 (en) * 2015-07-15 2017-01-19 Siqing Song-Destro Method of manufacture and applications for fire retardant, heat, fungi, and insect resistant, and strength enhancing additive
US20180333775A1 (en) * 2016-12-26 2018-11-22 Technology Research Association For Future Additive Manufacturing Metal laminating and shaping powder and method of manufacturing the same
CN108326463A (zh) * 2018-01-31 2018-07-27 华中科技大学 一种利用缆式焊丝制备金属间化合物零件的方法
CN109915342A (zh) * 2019-01-02 2019-06-21 武汉钢铁有限公司 一种基于复合式密封涂层的煤气压缩机级间密封装置
US12128375B2 (en) 2019-08-02 2024-10-29 Hydromecanique Et Frottement Method for preparing a metal powder for an additive manufacturing process and use of such powder
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CN111636021A (zh) * 2020-05-29 2020-09-08 中国铁道科学研究院集团有限公司金属及化学研究所 一种热喷涂用稀土锌铝镍钛合金丝材及其制备方法和应用
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RU2766395C1 (ru) * 2021-07-20 2022-03-15 федеральное государственное бюджетное образовательное учреждение высшего образования «Вологодская государственная молочнохозяйственная академия имени Н.В. Верещагина» (ФГБОУ ВО Вологодская ГМХА) Способ восстановления шеек коленчатых валов путем приклеивания полукольцевых накладок
RU2791718C1 (ru) * 2022-05-23 2023-03-13 федеральное государственное бюджетное образовательное учреждение высшего образования "Вологодская государственная молочнохозяйственная академия имени Н.В. Верещагина" (ФГБОУ ВО Вологодская ГМХА) Способ восстановления цилиндрических поверхностей деталей путем приклеивания полукольцевых накладок
CN115710683A (zh) * 2022-11-16 2023-02-24 西安石油大学 一种基于表面包覆技术和火焰喷涂技术的Mo-Cu合金制备方法

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FR1313303A (fr) 1962-12-28
SE302712B (en)) 1968-07-29
ES270818A1 (es) 1962-03-01
DE1446207B2 (de) 1977-06-08
DE1446207A1 (de) 1969-02-20
CH439909A (de) 1967-07-15
GB1000353A (en) 1965-08-04

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