WO1997003776A1 - Poudres composites - Google Patents

Poudres composites Download PDF

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Publication number
WO1997003776A1
WO1997003776A1 PCT/CA1996/000474 CA9600474W WO9703776A1 WO 1997003776 A1 WO1997003776 A1 WO 1997003776A1 CA 9600474 W CA9600474 W CA 9600474W WO 9703776 A1 WO9703776 A1 WO 9703776A1
Authority
WO
WIPO (PCT)
Prior art keywords
metallic phase
metallic
composite powder
phase
powders
Prior art date
Application number
PCT/CA1996/000474
Other languages
English (en)
Inventor
Montasser Wael
Original Assignee
Westaim Technologies Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Westaim Technologies Inc. filed Critical Westaim Technologies Inc.
Priority to AU63508/96A priority Critical patent/AU6350896A/en
Publication of WO1997003776A1 publication Critical patent/WO1997003776A1/fr

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Classifications

    • 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
    • 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

Definitions

  • the present invention relates to novel composite powders exhibiting exceptional mechanical properties and to a process for the production thereof.
  • Composite powders are broadly defined as any powder wherein each particle comprises an intimate mixture of metal and ceramic or polymeric particles. These powders may be engineered to attain particular properties for specific applications.
  • Composite powders are commonly utilized to form protective coatings having good wear, anti-seizing, corrosion resistant and scuffing resistant properties. Typically, the coatings are applied using thermal spray techniques. Other applications for composite powders include the fabrication of powder metallurgy parts, such parts being produced using powder injection moulding, hot isostatic pressing or other powder consolidation techniques.
  • Examples of composite powders known in the prior art for the thermal spray applications described supra generally comprise mechanical blends of molybdenum - nickel - chromium - chromium carbide powders, or nickel - chromium clad chromium carbide or spray dried and sintered molybdenum - nickel - chromium - chromium carbide powders.
  • the current commercial processes for the production of such composite powders utilize mechanical blending or spray drying techniques. Mechanical blending is a process wherein the constituents remain as separate particles. In spray drying methods, there may be some agglomeration of the constituents into a single form, however the metallic phase does not become fully alloyed.
  • U. S. patent 2,853,398 issued to V. N. Mackiw et al., and assigned to Sherritt Gordon Mines Ltd. discloses a method of producing composite powders comprising a non - metallic core encapsulated by a metal coating.
  • U. S. patent 3,914,504 to D. A. W. Fustukian describes the production of composite alloy coated particles, such as nickel coated graphite or cobalt coated tungsten carbide, with finely divided particles of at least one metal.
  • U. S. patents 4,291,089 and 4, 374,173 are illustrative of composite powders sprayable by thermal spraying onto a substrate to thereby form an abradable seal coating.
  • a more modern process contemplates the preparation of composite powders which involves melting the metal component and subjecting the molten metal to gas atomization with the injection of a second phase taking place at the point of atomization.
  • An exemplary process is described in Japanese Patent SHOU 64-56810 assigned to Daido Special Steel Company, Aichi.
  • the composite powders formed by this process typically comprise a central metal alloy core with some peripheral second phase particles on the outer surface.
  • the present invention encompasses two types of composite powders wherein the commonality therebetween resides in the existence of a fully alloyed metallic phase and a uniformly dispersed non - metallic phase in each discrete particle which is attained by the use of starting materials which are in the powder form.
  • the non-metallic phase is formed during the preparation thereof. Furthermore, the composite powders are derived from the elemental constituents being in a well mixed powder form. It has been determined that when the mixture is subjected to heating, so that one of the metal constituents reaches its melting temperature, other metals present which have higher melting points dissolve in the molten metal. The molten alloy then reacts with the non-metallic constituents to form the non-metallic phase. As a result it is possible to attain a uniform, fully alloyed composition in the metallic phase with discrete aggregates of the non- metallic phase being uniformly dispersed in the melt. The melt is then atomized to form the composite powder. The atomized composite powders exhibit exceptional hardness, wear resistance and other beneficial mechanical properties.
  • the second class of composite powders are those wherein preformed non - metallic aggregates are uniformly dispersed in a metallic phase or vice versa and wherein the non-metallic phase is a constituent of the feed mixture and does not change during processing.
  • the first class of composite powders is formed of particles wherein each particle comprises a metallic phase, formed by the dissolution of one or more metals within another metal, at the melting temperature of the latter, said metallic phase comprising one or more alloys; and a second non- metallic phase, said second phase being substantially uniformly dispersed within said metallic phase.
  • This first class of composite powders finds particular utility as coatings sprayable by thermal spraying but it is to be understood that the utility of the powders is not limited to this single application.
  • Preferred composite powders would be selected from MoNiCr/Cr 3 C2 or NiCr/Cr3C2 or the like.
  • the products formed exhibit uniformity of the fine non - metallic phase, for example the carbide phase in the preferred powders above, in the powder particles thereby providing a uniform composition when utilized as coatings.
  • the invention also extends to a second class of composite powders wherein in each particle, a non - metallic phase is trapped inside a metal alloy matrix, or vice versa without any reaction or dissolution between the metal constituents having taken place.
  • Such powders as aluminum-silicon-silicon carbide typically find use in the powder metallurgy parts market.
  • each particle comprises an alloyed metallic matrix; and a non - metallic phase, said non- metallic phase being uniformly dispersed within said metallic matrix or wherein each particle comprises a non - metallic matrix having an alloyed metallic phase uniformly dispersed therein.
  • a homogenous composition results because no segregation can take place during the filling of molds, as occurs in the case of mechanically mixed powders, during the manufacture of the parts in powder injection and other powder consolidation processes.
  • the invention involves: admixing the powders to be utilized in predetermined quantities; optionally, compacting said powders into forms; melting the powder mixture; and atomizing the molten feed to thereby break down the feed melt with gas jets into particles having a pre-engineered composition and microstructure.
  • Figure 1 is a photomicrograph showing a perspective view a MoNiCr/Cr3C2 atomized powder particle
  • Figure 2 is a photomicrograph showing a cross- sectional view of a NiCr/Cr3C2 composite powder particle
  • Figure 3 is a photomicrograph showing a cross- sectional view of an AlSi/SiC composite powder particle; .
  • Figure 4 is a photomicrograph showing a cross- sectional view of an AlMg/A ⁇ O composite powder particle
  • Figure 5 is a photomicrograph showing a cross- sectional view of a MoNiCr/Cr3C2 composite powder particle wherein the carbide has been formed in- situ from a carbon-containing feed material.
  • Suitable powders functional to form the metallic phase are selected from molybdenum, chromium, nickel, zinc, aluminium, copper, silicon or cobalt.
  • the particle size ranges from 5 to 200 microns.
  • one metal having a lower melting temperature would be used in conjunction with at least one metal which is soluble in the lower melting temperature metal.
  • the quantity/quantities of metal powder would be selected to provide the desired composition.
  • the non - metallic phase of the composite powder is selected from a ceramic or a preformed carbide, or from a carbide formed in situ.
  • the second phase should be particulate and may be either reactive or non-reactive. Suitable compounds would include such ceramics as alumina or aluminium nitride or zirconia or silicon carbide. Alternatively, a stoichiometric amount of carbon may be added to form the carbide.
  • a metallic matrix having a non - metallic second phase or a non - metallic matrix having a metallic phase therein The starting material powders are admixed in the desired amounts using a "V" type blender for a time in the range of about 3 to 4h.
  • the mixed powders may be compacted into shaped forms using a press at a pressure in the range of about 50,000 psi. at ambient temperature.
  • the blended powder mixture is then heated to its melting point, the temperature varying with the component powders.
  • the powders will melt at about the lowest melting point of the powders contained therein.
  • nickel containing powders will melt at between about 1440 ⁇ C - 1450 ⁇ C irrespective of the fact that they may contain molybdenum which melts at 2760 ⁇ C.
  • the heating stage is conducted in a furnace with an atmosphere of argon at atmospheric pressure for times ranging between 2 to 4h.
  • the molten mixture is atomized in a conventional gas atomizer and broken down using gas jets into particles having a particle size ranging from between 10 - 150 microns and having the desired composition and microstructure, and is then cooled.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Powder Metallurgy (AREA)

Abstract

L'invention concerne des poudres composites. Ces poudres sont utilisées pour les revêtements par pulvérisation thermique ou pour la fabrication de pièces selon les techniques de métallurgie des poudres. Les particules de poudre sphériques sont caractérisées par la présence d'une phase métallique entièrement alliée et d'une deuxième phase non métallique dispersée uniformément dans cette dernière.
PCT/CA1996/000474 1995-07-17 1996-07-15 Poudres composites WO1997003776A1 (fr)

Priority Applications (1)

Application Number Priority Date Filing Date Title
AU63508/96A AU6350896A (en) 1995-07-17 1996-07-15 Composite powders

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US50321995A 1995-07-17 1995-07-17
US08/503,219 1995-07-17

Publications (1)

Publication Number Publication Date
WO1997003776A1 true WO1997003776A1 (fr) 1997-02-06

Family

ID=24001202

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/CA1996/000474 WO1997003776A1 (fr) 1995-07-17 1996-07-15 Poudres composites

Country Status (2)

Country Link
AU (1) AU6350896A (fr)
WO (1) WO1997003776A1 (fr)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009026655B3 (de) * 2009-06-03 2011-06-30 Linde Aktiengesellschaft, 80331 Verfahren zur Herstellung eines Metallmatrix-Verbundwerkstoffs, Metallmatrix-Verbundwerkstoff und seine Verwendung
EP2650398A1 (fr) * 2012-04-11 2013-10-16 Sulzer Metco AG Poudre mouillable avec liaison à base de fer super-ferritique, ainsi qu'un substrat, notamment un disque de frein avec une couche de diffusion thermique
US10646412B1 (en) 2019-04-09 2020-05-12 Micro Powders, Inc. Micronized composite powder additive
US11091641B2 (en) 2019-04-09 2021-08-17 Micro Powders, Inc. Liquid composite emulsions

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2853398A (en) * 1956-04-11 1958-09-23 Sherritt Gordon Mines Ltd Method of producing composite nonmetallic metal powders
US3732091A (en) * 1969-07-04 1973-05-08 Anvar Method for preparing mutual dispersions of carbides and metals or alloys and novel products thereof
EP0240251A2 (fr) * 1986-04-02 1987-10-07 The British Petroleum Company p.l.c. Fabrication de matériaux composites
EP0345795A1 (fr) * 1988-06-09 1989-12-13 Nisshin Steel Co., Ltd. Procédé et dispositif de revêtement de poudres fines
US4985202A (en) * 1984-10-19 1991-01-15 Martin Marietta Corporation Process for forming porous metal-second phase composites
US5122182A (en) * 1990-05-02 1992-06-16 The Perkin-Elmer Corporation Composite thermal spray powder of metal and non-metal
EP0499392A2 (fr) * 1991-02-14 1992-08-19 Nissan Motor Company, Ltd. Procédé pour la préparation d'alliages frittés à base de fer résistant à l'usure
EP0515944A1 (fr) * 1991-05-27 1992-12-02 Daido Tokushuko Kabushiki Kaisha Procédé pour la production d'une poudre en alliage contenant en dispersion des particules dures
US5338330A (en) * 1987-05-22 1994-08-16 Exxon Research & Engineering Company Multiphase composite particle containing a distribution of nonmetallic compound particles

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2853398A (en) * 1956-04-11 1958-09-23 Sherritt Gordon Mines Ltd Method of producing composite nonmetallic metal powders
US3732091A (en) * 1969-07-04 1973-05-08 Anvar Method for preparing mutual dispersions of carbides and metals or alloys and novel products thereof
US4985202A (en) * 1984-10-19 1991-01-15 Martin Marietta Corporation Process for forming porous metal-second phase composites
EP0240251A2 (fr) * 1986-04-02 1987-10-07 The British Petroleum Company p.l.c. Fabrication de matériaux composites
US5338330A (en) * 1987-05-22 1994-08-16 Exxon Research & Engineering Company Multiphase composite particle containing a distribution of nonmetallic compound particles
EP0345795A1 (fr) * 1988-06-09 1989-12-13 Nisshin Steel Co., Ltd. Procédé et dispositif de revêtement de poudres fines
US5122182A (en) * 1990-05-02 1992-06-16 The Perkin-Elmer Corporation Composite thermal spray powder of metal and non-metal
EP0499392A2 (fr) * 1991-02-14 1992-08-19 Nissan Motor Company, Ltd. Procédé pour la préparation d'alliages frittés à base de fer résistant à l'usure
EP0515944A1 (fr) * 1991-05-27 1992-12-02 Daido Tokushuko Kabushiki Kaisha Procédé pour la production d'une poudre en alliage contenant en dispersion des particules dures

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102009026655B3 (de) * 2009-06-03 2011-06-30 Linde Aktiengesellschaft, 80331 Verfahren zur Herstellung eines Metallmatrix-Verbundwerkstoffs, Metallmatrix-Verbundwerkstoff und seine Verwendung
EP2650398A1 (fr) * 2012-04-11 2013-10-16 Sulzer Metco AG Poudre mouillable avec liaison à base de fer super-ferritique, ainsi qu'un substrat, notamment un disque de frein avec une couche de diffusion thermique
US9752632B2 (en) 2012-04-11 2017-09-05 Oerlikon Metco Ag, Wohlen Spray powder with a superferritic iron-based compound as well as a substrate, in particular a brake disk with a thermal spray layer
KR102057131B1 (ko) 2012-04-11 2019-12-18 오엘리콘 멧코 아게, 볼렌 슈퍼페라이트 철계 화합물을 함유하는 분무 분말 및 기판, 특히 열적 분무층을 가진 브레이크 디스크
US10646412B1 (en) 2019-04-09 2020-05-12 Micro Powders, Inc. Micronized composite powder additive
US11091641B2 (en) 2019-04-09 2021-08-17 Micro Powders, Inc. Liquid composite emulsions

Also Published As

Publication number Publication date
AU6350896A (en) 1997-02-18

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