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Cold gas spray coating methods and compositions

a technology of gas spray coating and composition, applied in the direction of pressure inorganic powder coating, metal-working apparatus, transportation and packaging, etc., can solve the problems of large and expensive articles, corrosion and wear of metal alloys, and high cost and significant problems, and achieve low porosity and low oxide content

Inactive Publication Date: 2018-09-13
SULZER METCO (US) INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent describes new devices and methods for accessing and using them. These devices have certain technical effects that improve their performance and reliability. These effects can benefit a wide range of industries and applications.

Problems solved by technology

For example, there have been problems associated with corrosion and wear of metal alloys that are used to fabricate many different types of components.
This can represent a costly and significant problem associated with large and expensive articles, such as transmission and gearbox housings for rotary aircraft, for example.

Method used

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  • Cold gas spray coating methods and compositions
  • Cold gas spray coating methods and compositions
  • Cold gas spray coating methods and compositions

Examples

Experimental program
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Effect test

example 1

[0044]The following blends were sprayed as described below: Sample 1: a blend of INCONEL 718 with 5 wt. % Metco 480NS (Ni-5Al); Sample 2: a blend of INCONEL 718 with 5 wt % pure Nickel; Sample 3: a blend of HASTELLOY C276 with 5 wt % pure Nickel. The above powders were sprayed using cold gas spray parameters using a conventional Kinetiks 8000 gun typically under the following conditions: Temperatures (process flow gas): 900° C.-950° C.; Process flow gas (m3 / h) : 92-94; Gas pressure: 40 bar; Spray distances: 40-60 mm; Coating thickness: approx. 1 mm; Powder feed rate: 30-34 g / min. For the selected the parameters, deposition efficiencies of over 80% were obtained, and at least 88% deposition efficiencies were obtained for each powder blend using an optimised parameter.

[0045]Micrographs of the coatings are shown in FIGS. 5 to 10 and 14. All coatings had measured porosities below 1.6% Hardness (Vickers HV03 (ASTM E384)) of each coating was measured and are as shown in the figures. Typic...

example 2

[0046]Some examples of material combinations which can be used are shown in the following tables, Tables 2 to 4.

TABLE 2Second PhaseBase AlloyAdditionApproximateSecondApproximateSize RangePhaseSize RangeBase AlloyμmAdditionWeight %μmINCONEL−30 to +5Nickel3 to 10−30 to +5 / 718−45 to +11INCONEL−30 to +5Ni—5Al3 to 10−30 to +5 / 718−45 to +11INCONEL−30 to +5Ni—20Al3 to 10−125 to +45718INCONEL−30 to +5Ni—Al—Mo3 to 10−125 to +45718INCONEL−30 to +5Ni 5Mo 5.5Al3 to 10 −90 to +45718INCONEL−30 to +5NiCrAlMo3 to 10 −90 to +45718INCONEL−30 to +5NiCrAl3 to 10−125 to +45718INCONEL−30 to +5Al—12Si3 to 10−125 to +45718INCONEL−30 to +5Alumina3 to 10−30 to +5718INCONEL−30 to +58YSZ3 to 10−30 to +5718

TABLE 3Base AlloySecond PhaseApproximateSecondApproximateSize RangePhaseSize RangeBase AlloyμmAdditionWeight %μmNiCrWMo−30 to +5Nickel3 to 10−30 to +5 / (e.g., HASTELLOY C276)−45 to +11NiCrWMo−30 to +5Ni—5Al3 to 10−30 to +5 / −45 to +11NiCrWMo−30 to +5Ni—20Al3 to 10−125 to +45NiCrWMo−30 to +5Ni—Al—Mo3 to 10−125 t...

example 3

[0047]Some examples of material combinations which can be used and representative properties are shown in the following table.

TABLE 5CoatingAttribute / Average / MaterialstatePropertyUnitstypicalMinimumMaximumInconel 718 +as-sprayedCoatingg / cm37.357.107.605% wt. %densityNi-5 wt % AlInconel 718 +as-sprayedporosity%0.60.002.005% wt. %Ni-5 wt % AlInconel 718 +as-sprayedDeposition%7260.689.05% wt. %efficiencyNi-5 wt % AlInconel 718 +as-sprayedTensileMPaGreater than34 is5% wt. %strength36 MPaspecifiedNi-5 wt % Alaccording tolower limitASTM C 633Inconel 718 +as-sprayedHardnessHV300gf460.304204995% wt. %(Vickers(kg · mm−2)Ni-5 wt % Aldiamond)Inconel 718 +AnnealedHardnessHV300gf251.62292765% wt. %(1060° C. / 2 h(Vickers(kg · mm−2)Ni-5 wt % Alin vacuum)diamond)Inconel 718 +as-sprayedCoatingmm100155% wt. %and annealedthicknessNi-5 wt % Al

[0048]Representative steel and stainless steel alloys useful with the processes described herein can comprise: Fe balance (bal.) +qCr+rAl+sMo+tCo+xMn+xNi+zC+uN+wV ...

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Abstract

Cold gas spray coating methods, compositions and articles. A cold gas spray method is described including spraying a composition containing at least one nickel or iron based material blended with a softer, shear-deformable, secondary phase metal and / or metal alloy, onto a surface to deposit a dense, porous coating. The compositions used in and articles produced by such methods are also described.

Description

TECHNICAL FIELD[0001]The field of art to which this invention generally pertains is cold gas spray coating.BACKGROUND[0002]Cold gas spray coating is a coating deposition method which uses powder material accelerated at high speeds through gas jets which adheres to a surface during impact. Metals, polymers and ceramics are some representative materials which can be deposited using cold gas spray techniques. Unlike thermal spraying methods, such as plasma spraying, arc spraying, and flame spraying, for example, the powders are not externally melted during spraying. The technology has particular utility in the area of parts repair. For example, there have been problems associated with corrosion and wear of metal alloys that are used to fabricate many different types of components. This can represent a costly and significant problem associated with large and expensive articles, such as transmission and gearbox housings for rotary aircraft, for example. Cold gas spray coating provides on...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): C23C24/04B22F1/148
CPCC23C24/04B22F2998/10B22F2009/041B22F9/026B22F1/0096C22C1/0433C22C19/055C22C19/056C22C19/07C22C33/02C22C38/00B22F1/148
Inventor WILSON, SCOTTBARTH, ALEXANDERNESTLER, MONTIAKUDAPA, SATYA N.
Owner SULZER METCO (US) INC
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