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Shielded ceramic thermal spray coating

A technology of thermal spraying and coating, which is applied in the direction of ceramic layered products, coatings, molten spraying, etc., and can solve the problems of inability to obtain deposition parameters and low surface speed

Inactive Publication Date: 2006-09-13
PRAXAIR ST TECH INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Problems solved by technology

This often means that for machine applied coatings, surface speeds are necessarily lower, which may make it difficult or impossible to achieve the desired deposition parameter settings
[0010] In conclusion, the state of the art thermal spray methods are limited by their ability to deposit ceramic coatings, especially oxide coatings, with desired microstructure, residual stress and other properties on some complex parts, partly due to the required standoff distance and a limited range of surface velocities

Method used

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Examples

Experimental program
Comparison scheme
Effect test

Embodiment 1

[0017]A series of experiments were performed using a Model 1108 Praxair plasma torch with a gas shield. The shielding device consisted of a flat perforated metal disk surrounding and in face of the plasma torch nozzle, the disk having an inner diameter of about 1.0 inches and an outer diameter of 1.4 inches. The shield has a 0.75 inch long hollow barrel or wall projecting perpendicular to the porous metal disk to further direct the gas flowing through the disk coaxially with the torch effluent. Thermocouples are used to map the downstream temperature of the hot gas effluent. Metal ring fixtures were fabricated capable of holding 12 K-type thermocouples at different radial distances from the center of the ring. The rings were aligned so that their centers were on the centerline of the torch effluent and moved to various distances downstream of the torch during data acquisition. Plot the temperature profile as a function of radial and downstream distance relative to the torch ...

Embodiment 2

[0030] Zirconia coatings were produced with and without ambient temperature argon shading similar to the shading in Example 1, except with a 0.56 inch long extension. Both have a standoff of 0.75 inches. It was found that those coatings produced with a gas masking of 500 cfh argon flow had a higher density than those without masking, 92.3% vs. 91.8%. Deposition efficiency increased from 35% to 38%, and deposition rate increased from 220 to 240 mil square inches per minute. This results in a higher segmental crack density, an effect that is required for resistance to thermal shock and thermal fatigue. The use of masking also produced coatings with a more uniform microstructure than those produced without gas masking at the same standoff distance. Alternatively, this effect also allows the generation of the same microstructure and density with a gas shield at longer standoff distances as without the gas shield. It was also found that a blanket flow of 500 cfh argon produced b...

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Abstract

This invention provides a unique method of thermally spraying high melting point material, such as ceramic materials, at an extended standoff using a gas shield and producing microstructure properties having the same properties using a short standoff without a gas shield. It is particularly useful for controlling the microstructure of a ceramic coating at an extended standoff to facilitate the coating of components with a complex shape.

Description

field of invention [0001] The present invention relates generally to the field of thermal spraying of ceramic materials, and more particularly to spraying ceramic materials at extended standoffs. Background of the invention [0002] In thermal spray deposition, a material in powder, wire, or rod form is heated to near or just above its melting point, and the molten or nearly molten particles are accelerated in a gas stream to high velocity before impinging on the surface to be coated, the substrate . On impact, the particles flow onto a thin layered splat where they solidify and cool rapidly. Coatings consist of many plies. Materials such as metals, ceramics, cermets, and some polymers can be deposited by thermal spray methods. A variety of thermal spray equipment can be used, including plasma, detonation guns, high velocity oxy-fuel, filament arc, and flame spray. Among them, plasma spraying is one of the best for ceramic deposition because of the very high temperatures...

Claims

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Application Information

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Patent Type & Authority Applications(China)
IPC IPC(8): C23C4/10C23C4/12B32B9/00B32B15/04B32B18/00H05H1/34
CPCC23C4/105C23C4/10H05H1/341C23C4/12C23C4/11
Inventor T·A·泰勒
Owner PRAXAIR ST TECH INC
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