WO2011094222A1 - Abradable composition and method of manufacture - Google Patents
Abradable composition and method of manufacture Download PDFInfo
- Publication number
- WO2011094222A1 WO2011094222A1 PCT/US2011/022445 US2011022445W WO2011094222A1 WO 2011094222 A1 WO2011094222 A1 WO 2011094222A1 US 2011022445 W US2011022445 W US 2011022445W WO 2011094222 A1 WO2011094222 A1 WO 2011094222A1
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- WO
- WIPO (PCT)
- Prior art keywords
- component
- thermal spray
- clad
- powder
- spray powder
- Prior art date
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Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- 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
-
- 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
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/103—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing an organic binding agent comprising a mixture of, or obtained by reaction of, two or more components other than a solvent or a lubricating agent
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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
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
- B22F1/105—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material containing inorganic lubricating or binding agents, e.g. metal salts
-
- 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
- B22F1/12—Metallic powder containing non-metallic particles
-
- 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
- B22F1/17—Metallic particles coated with metal
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- 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
- C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
- C22C32/0068—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only nitrides
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/10—Metal compounds
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08K—Use of inorganic or non-macromolecular organic substances as compounding ingredients
- C08K3/00—Use of inorganic substances as compounding ingredients
- C08K3/38—Boron-containing compounds
Definitions
- CA2639732 (A1), US7582365, US7267889, US 7763573, US6887530, US7179507, US7008462, US7135240, US7052527, US6808756, US5976695, US5434210, US5196471 , US5506055, US5122182 and US5049450.
- This patent teaches the use of the spray drying process for making the composites, involving the spraying of a slurry of very fine powdered constituents with a binder to form droplets, and drying the droplets into a powder.
- a slurry of very fine powdered constituents with a binder to form droplets, and drying the droplets into a powder.
- constituents may be incorporated, for example in a cermet powder of a metal and a non-metal.
- bentonite is useful for producing thermal sprayed abradable seal coatings for gas turbine engines. Cladding of metal core particles with finer particles of ceramic is taught in U.S. Pat. No. 3,655,425 (Longo and Patel) for similar purpose.
- a composite means two or more particles in physical contact. These composites usually include a binder, however a binder is not always included. Additionally, cladding may occur mechanically or chemically as known in the art.
- An object of the invention is to create a novel form of a composite powder that forms an abradable by thermal spraying a first component A that is mechanically blended with a second component B.
- a thermal spray powder blend comprising a first component powder and a second component powder.
- the component powders are in the form of composite particles each of which comprises pluralities of sub-particles of metal and non-metal, the latter typically being a ceramic or a polymer.
- the composite particles of the second powder have a substantially different morphology than the composite particles of the first powder.
- component A is a metal particle
- component B is a mechanically clad composite
- components A and B are each either mechanically clad composites or chemically clad composites.
- component A is a composite with polymer that is
- component B is a composite without polymer that is
- a first component is a composite that includes an organic binder, a metal phase, and a solid lubricant; and a second component is a composite having an organic binder, a metal phase and a polymer phase; wherein the apparent density difference between each component is less than the apparent density when compared to blending the individual components; wherein the first and second components are manufactured as either spray dried or mechanically clad material and the material are sprayed either with combustion or plasma spraying, preferably plasma spraying; and wherein the thermal spray powder has an overall particle size of about 10 to about 150 microns, preferably about 44 to about 150 microns.
- the metal phase is NiCr or 316 stainless steel and the solid lubricant is hexagonal boron nitride (HBN).
- the blend ratio for the second component into the first component is 0-40 wt%, preferably 5-30 wt%, more preferably about 7-15wt%, more preferably about 8-12 wt%, and more preferably about 10 wt%.
- the blend ratio of the metal component to the solid lubricant and or polymer metal clad component is about 10-90 wt%, preferably 25-75 wt%, and more preferably 40- 60 wt%.
- the result is improved entrapments of solid lubricant and/or polymer phase through mechanical cladding and/or spray drying. This also results in more reproducible and consistent coating microstructures compared to co-spray or mechanical blends of various components with different densities.
- Higher temperature organic binders are used for improved mechanical integrity. The binders, in combination with the metal phase, help to minimize decomposition of the polymer phase.
- FIG. 1 shows a first aspect of the invention.
- FIG. 2 shows another aspect of the invention
- FIG. 3 shows another aspect of the invention
- FIG. 4 shows another aspect of the invention
- FIG. 5 shows another aspect of the invention
- FIG. 6 shows another aspect of the invention
- component A is a metal particle
- component B is a mechanically clad composite
- components A and B are each either mechanically clad composites or chemically clad composites.
- component A is a composite with polymer that is mechanically clad while component B is a composite without polymer that is mechanically clad.
- a first component is a composite that includes an organic binder, a metal phase, and a solid lubricant; and a second component is a composite that has an organic binder, a metal phase and a polymer phase; wherein the apparent density difference between each component is less than the apparent density when compared to blending the individual components; wherein the first and second components are manufactured as either spray dried or mechanically clad material and the material are sprayed either with combustion or plasma spraying, preferably plasma spraying; and wherein the thermal spray powder has an overall particle size of about 10 to about 150 microns, preferably about 44 to about 150 microns.
- the metal phase is NiCr or 316 stainless steel, or a metal powder, for example but not limited to iron, nickel or cobalt based or combinations of the three.
- Metal powders may also contain chromium between about 0-40 wt%, aluminum between about 0-15 wt%, and additional additives of key elements such as, but not limited to, yttrium, hafnium, silicon, rhenium, tantalum and tungsten.
- MCrAIY's and intermetallics, such as Fe 3 AI, iron aluminide, nickel aluminide, may also be used.
- the solid lubricant is HBN.
- the blend ratio for the second component into the first component is 0-40 wt%, preferably 5-30 wt%, more preferably about 7-15wt%, more preferably about 8-12 wt%, and more preferably about 10 wt%.
- the blend ratio of the metal component to the solid lubricant and or polymer metal clad component is about 10-90 wt%, preferably 25-75 wt%, and more preferably 40-60 wt%.
- This embodiment results in improved entrapment ⁇ of solid lubricant and/or polymer phase through mechanical cladding and/or spray drying. This also results in more reproducible and consistent coating microstructures compared to co- spray or mechanical blends of various components with different densities. Higher temperature organic binders are added for improved mechanical integrity. The binder in combination with metal phase also helps to minimize decomposition of the polymer phase.
- the thermal spray powder has an overall particle size of about 10 to about 150 microns, preferably about 44 to about 150 microns.
- the overall powder is a composite of one or two constituents.
- a first component has an organic binder, a metal phase, and a solid lubricant.
- the metal phase may be, for example, NiCr or 316 stainless steel, or a metal powder, for example but not limited to iron, nickel or cobalt based or combinations of the three.
- Metal powders may also contain chromium between about 0-40 wt%, aluminum between about 0-15 wt%, and additional additives of key elements such as, but not limited to, yttrium, hafnium, silicon, rhenium, tantalum and tungsten.
- MCrAIY's and intermetallics such as Fe 3 AI, iron aluminide, nickel aluminide, may also be used.
- the solid lubricant may be, for example, agglomerated hexagonal boron nitride (ABN), HBN.
- a second component has an organic binder, a metal phase and a polymer phase.
- the blend ratio for the second component constituent 2 into constituent 1 is 0-40 wt%, preferably 5-30 wt%, more preferably about 7- 15wt%, more preferably 8-12 wt%, and more preferably about 10 wt%.
- a first component is a metal as defined above and the second component is a mechanically clad solid lubricant with an organic binder.
- the cladding may be the same as the metal used in the first component.
- the solid lubricant and the binder may be as listed above.
- a polymer can be substituted for the solid lubricant.
- the blend ratio of the metal component to the solid lubricant clad component is about 10-90 wt%, preferably 25- 75 wt%, and more preferably 40-60 wt%. When the polymer is substituted for the solid lubricant, the preferred blend ratio is about 10-20 wt.%.
- the first and second components can be
- the first and second components are sprayed either with combustion or plasma spraying, preferably plasma spraying, forming a coating, preferably an abradable coating.
- a polymer when a coating is made, a polymer is used to control porosity, and solid lubricant reduces frictional heating by a blade tip when the blade tip cuts the coating at different incursions and speeds. Together or separately, polymer and/or lubricant reduces inter-particle cohesive strength of the thermal spray coating. In some cases polymers are composited with solid lubricant to achieve many of the advantages.
- Blending or Co-spraying Two approaches of manufacturing these abradable coatings are: Blending or Co-spraying.
- the benefit of co-spraying is more control of process since density differences in blends may lead to separation in a feeder device or in handling; this does not occur in co-spray processes.
- the disadvantage of co-spraying is that polymers and/or solid lubricants have low density, they are hard to feed and tend to melt or decompose in plasma flame. This results in manufacturing down time and material loss. In some cases nozzle build-up and/or nozzle loading may also occur resulting in excessive production down time.
- the benefit of a blend is a simpler overall process for manufacturing abradable coatings and abradable seals.
- agglomeration by mechanical cladding of the solid lubricant increases density so that it approaches density of metal or ceramic matrix phase; allowing for more 1) blend uniformity; 2) higher entrapment of the solid lubricant phase when applied by via thermal spray process and 3) better flowability when co-sprayed due to increase particle weight.
- mechanical agglomeration using a cladding process uses solid lubricant, such as HBN, and cladding with a fine metal powder, for example nickel alloy and organic binder.
- the metal powder is generally less than 44 microns in size, and is typically less than 20 microns, and the solid lubricant is generally greater than 54 microns, and is typically 120 microns on average.
- the metal powder can be iron, nickel or cobalt based or combinations of the three.
- Metal powders may also contain chromium between about 0-40 wt%, aluminum between about 0-15 wt%, and additional additives of key elements such as, but not limited to, yttrium, hafnium, silicon, rhenium, tungsten, tantalum and tungsten.
- MCrAIY's and intermetallics such as FeaAI, iron aluminide, nickel aluminide, may also be used.
- Final agglomeration can then be screened to less than about 60 mesh, which is about 250 microns. In a preferred embodiment the final agglomeration can then be screened between less than about 60 mesh, which is about 250 microns and at greater than about 230 mesh, which is about 63 microns.
- the 63-250 micron size powder is clad with fine particles of metal attached to the wall of the solid lubricant with an organic binder.
- Solid lubricants can be, for example, HBN, agglomerated boron nitride (ABN), graphites, fluorides, talc. Generally the solid lubricant will be greater than about 45 microns, and preferably greater than about 53 microns.
- the solid lubricant can be substituted with a polymer, whereby the polymer can be polyesters, polyamides, polyimides and/or acrylic based polymers.
- the polymer powder will be greater than about 45 microns, and preferably greater than about 53 microns.
- Cladding increases the density of the powder and protects solid lubricant/polymer from the high temperature plasma or combustion flame thereby reducing decomposition during the coating process. Additionally, the increased density results in greater chemical uniformity of the resultant blends. The increased density will also improve flowability if the powder is co-sprayed with metal or ceramic.
- the polymer or solid lubricant clad material is about 10-20 wt% when with metal or ceramic powder.
- the metal/ceramic powder can be the same or different chemistry and/ or manufacturing process as metal/ceramic used in cladding process. Generally the size of metal/ceramic powder is between about 120 microns and about 45 microns. However, powder range could be -250 microns + 10 microns. When co-sprayed, typical deposition rate of metal to clad composite is about 1 :1 to 3:1 with and entrapment of clad particle in the coating of 20-50 vol%.
- HBN can be replaced by ABN, which can be, e.g., bentonite binder with HBN composite, graphite or a polymer.
- the polymer is, for example, but not limited to, polyester, polyamides, polyimides, and/or acrylic based polymers.
- metal alloy can be replaced by metal oxide ceramics such as, for example, yttria stabilized zirconia.
- the binder can be organic or inorganic.
- Fig. 1 shows the component A 10 NiCrAI clad agglomerated hexagonal boron nitride (ABN) and the component B 12 Ni clad Polyester forming the
- component A 10 has, for example d50 particle size: 68 pm and component B 12 has, for example d50: 72pm.
- component A 10 is an agglomeration by spray drying of NiCrAI clad ABN with NiCrAI.
- component A 10 is atomised and has a d50 of approximately 20um.
- the use of even finer HBN is a substitute for ABN, together with NiCrAI cladding.
- the powder should be agglomerated.
- Cladding fine for example 10 micron HBN is also feasible.
- agglomeration introduces binders which introduce another variant to coating properties.
- Another example is to agglomerate NiCrAI clad HBN with d50 about 10 microns, and then blend this agglomerated material with Ni clad polyethylene.
- the thermal spray powder is such that
- Constituent A is composite of: Metal / alloy + solid lubricant ( HBN ) + ceramic composite and
- Constituent B is composite of: Metal / alloy + plastic
- the ceramic composite in constituent A is what is added to the HBN to make it ABN.
- Another example is cladding, using a binder, of a metal alloy onto ABN and polymer.
- Ni5Cr5AI can be used as a cladding alloy for polymer with a fine enough grade. In this manner there is less residual nickel after spraying and the result is better oxidation resistance.
- component A 10 is agglomerated with a binder to form component A agglomerated 16.
- a blend of component A agglomerated 16 with component B 12 results in the blend 18.
- cladding with a protective (metal) coating is needed for product spray and manufacture robustness.
- Minimum and maximum particle size ranges for components A and B are predefined.
- a "mismatch" in particle size and apparent density (AD) between components A and B should not fall outside a predetermined window.
- One preferred embodiment is when AD and particle size of component A is approximately or equal to component B, or when the apparent density and particle size of component A approaches the apparent density and particle size of component B.
- the AD for component A is 2.2 or greater.
- the increase of the AD of the clad ABN from about 1.7 to 2.2 or higher may be accomplished by introducing some very fine, but high density material in the boron nitride (ABN) agglomerate, for example zirconia, ytterbia, dysprosia, or metal. This will result in a more robust product for spraying.
- the AD can also be similarly increased by increasing thickness of the clad. Caution must be used not to add too much metal matrix as this could overprotect the boron nitride.
- Binders are often referred to as 'temporary binding agents' when talking about making granulates.
- Known organic binder materials include poly vinyl alcohols which include polyvinyl acetate (PVA), polyvinyl pyrrolidinone (PVP) and any others similar binders. Binders also include various synthetic and natural polymers, for example, acrylic latex compositions and carboxymethylcellulose (CMC), and other similar compounds.
- the thermal spray powder has a first component A mechanically blended with a second component B, wherein the first component A is at least one of Ni -Cr- Al clad ABN, Ni-Cr-AI clad HBN, Ni-Cr-AI clad agglomerated boron nitride powder, Ni-Cr-A!
- component B is a polymer clad with at least one of nickel, nickel alloys, nickel chrome alloys, nickel chrome aluminum alloys, nickel aluminum alloys, cobalt and cobalt alloys.
- the clad polymer is a fugitive phase. In another embodiment, the clad polymer is a porosity former. In another
- the particle size is about 40 to about 120 microns.
- the average particle size ratio of component A to component B is approximately 0.5 to approximately 1.5, preferably approximately 0.7 to
- the apparent density for component A is a minimum of 1.5. In another embodiment, the apparent density of component B is a minimum of 2.5.
- the Ni-Cr-AI clad ABN is approximately 5 wt.% to approximately 15wt.% Cr and approximately 5wt.% to approximately 5 wt.% Al.
- the thermal spray powder further comprises component A', wherein A' is Ni 5+x wt.% - Cr 5+y wt.% - Al clad ABN, and wherein x is greater than 5 wt.% and y is 0-10 wt.%.
- Fig. 4 shows another example of a blend of the invention.
- Component A 10 is agglomerated with component C 20 with either an organic or inorganic binder (not shown), to form component A+C agglomerate 22.
- Component C 20 is nickel or cobalt alloy.
- Blend 24 is an example of five distinctly different phases making this a five phase blend.
- Fig. 5 shows another example of a blend of the invention.
- Component B 12 continues to be nickel clad polyester, and component C 20 continues to be nickel or cobalt alloy.
- Component D 26 is ABN or HBN.
- Component C 20 and Component D 26 are agglomerated with an organic or inorganic binder (not shown) to form component C+D agglomerate 28.
- component B 12 is blended with component C+D 28, the result is new blend 30.
- Fig. 6 is an example of a variation of component B 12 that can be used in any of the inventive blends.
- the clad polyester core 40 for component B 12 is replaced by an agglomerate of polyester/polymer 34 plus metal alloy 32 and/or HBN or very fine high density ceramic phase. This increases the density of the polyester phase even more.
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- Coating By Spraying Or Casting (AREA)
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Abstract
Description
Claims
Priority Applications (7)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
SG2012026696A SG182251A1 (en) | 2010-01-26 | 2011-01-25 | Abradable composition and method of manufacture |
JP2012550210A JP5788906B2 (en) | 2010-01-26 | 2011-01-25 | Abrasive composition and method for producing the same |
CN201180007056.4A CN102822256B (en) | 2010-01-26 | 2011-01-25 | Abradable compositions and manufacture method thereof |
BR112012018243A BR112012018243B8 (en) | 2010-01-26 | 2011-01-25 | SPRAYING POWDER AND METHOD TO MANUFACTURE THIS POWDER |
EP11737523.8A EP2528966B1 (en) | 2010-01-26 | 2011-01-25 | Abradable composition and method of manufacture |
US13/575,237 US9103013B2 (en) | 2010-01-26 | 2011-01-25 | Abradable composition and method of manufacture |
CA2784665A CA2784665C (en) | 2010-01-26 | 2011-01-25 | Abradable composition and method of manufacture |
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
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US29839110P | 2010-01-26 | 2010-01-26 | |
US61/298,391 | 2010-01-26 | ||
US38272910P | 2010-09-14 | 2010-09-14 | |
US61/382,729 | 2010-09-14 |
Publications (1)
Publication Number | Publication Date |
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WO2011094222A1 true WO2011094222A1 (en) | 2011-08-04 |
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ID=44319722
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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PCT/US2011/022445 WO2011094222A1 (en) | 2010-01-26 | 2011-01-25 | Abradable composition and method of manufacture |
Country Status (9)
Country | Link |
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US (1) | US9103013B2 (en) |
EP (1) | EP2528966B1 (en) |
JP (1) | JP5788906B2 (en) |
CN (1) | CN102822256B (en) |
BR (1) | BR112012018243B8 (en) |
CA (1) | CA2784665C (en) |
SG (2) | SG182251A1 (en) |
TW (1) | TWI519388B (en) |
WO (1) | WO2011094222A1 (en) |
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WO2022155134A1 (en) * | 2021-01-12 | 2022-07-21 | Oerlikon Metco (Us) Inc. | Composite thermal spray powder of oxides and non-oxides |
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- 2011-01-25 JP JP2012550210A patent/JP5788906B2/en active Active
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Also Published As
Publication number | Publication date |
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BR112012018243A2 (en) | 2021-01-12 |
EP2528966A1 (en) | 2012-12-05 |
SG182251A1 (en) | 2012-08-30 |
TW201139059A (en) | 2011-11-16 |
US20120295825A1 (en) | 2012-11-22 |
CN102822256A (en) | 2012-12-12 |
BR112012018243B8 (en) | 2022-09-27 |
BR112012018243B1 (en) | 2021-08-31 |
CA2784665A1 (en) | 2011-08-04 |
JP5788906B2 (en) | 2015-10-07 |
US9103013B2 (en) | 2015-08-11 |
TWI519388B (en) | 2016-02-01 |
CN102822256B (en) | 2016-10-05 |
SG10201500165RA (en) | 2015-03-30 |
EP2528966B1 (en) | 2022-06-29 |
EP2528966A4 (en) | 2017-07-05 |
JP2013518182A (en) | 2013-05-20 |
CA2784665C (en) | 2018-05-22 |
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