Amorphous Mixed Metal Oxide Feedstocks for Thermal Spray Coatings
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Solution Overview
Problem
The thermal spray process for depositing nanostructured coatings faces challenges with crystalline nanopowders, which clog equipment and require high-temperature preparation, increasing costs, and result in chemically heterogeneous coatings.
Innovation Solution
Using amorphous mixed metal oxide feedstocks, which can be prepared at lower temperatures and are chemically homogeneous, allowing for energy savings and improved coating homogeneity through the formation of nanostructured alumina-zirconia coatings with specific grain sizes and chemical distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If crystalline nanopowders are used as feedstock, then nanostructured coatings can be deposited, but the equipment clogs due to particle size and high-temperature preparation is required
Solution Approach 1:
The invention changes the crystalline state parameter of the feedstock from crystalline to amorphous. Amorphous mixed metal oxide powders can be prepared at lower temperatures (avoiding the high-temperature preparation required for crystalline powders) and do not clog equipment. The amorphous feedstock is transformed into a crystalline coating during the thermal spray process, achieving the desired nanostructured coating while avoiding feedstock preparation issues.
2Manufacturing precision
If crystalline nanopowders are used, then coatings can be formed, but chemical heterogeneity occurs in the coating
Solution Approach 1:
The invention changes the crystalline state parameter of the feedstock from crystalline to amorphous. Amorphous mixed metal oxide powders provide chemical homogeneity at the molecular level because the atoms are randomly distributed throughout the amorphous structure. When this amorphous feedstock is melted and rapidly cooled during thermal spray deposition, it forms a homogeneous crystalline coating with uniform chemical composition, eliminating the chemical heterogeneity that occurs when mixing separate crystalline powders.
3Manufacturing precision
If high-temperature preparation is used for crystalline powders, then nanocrystalline feedstock is obtained, but energy consumption increases
Solution Approach 1:
The invention changes the crystalline state parameter of the feedstock from crystalline to amorphous. Amorphous mixed metal oxide powders can be prepared at significantly lower temperatures compared to nanocrystalline powders. The amorphous structure is formed by controlling the cooling rate or using sol-gel methods, avoiding the high-temperature sintering required for crystallization. This reduces the preparation energy while still providing a feedstock that transforms into the desired crystalline coating structure during thermal spray processing.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables energy-efficient production of chemically homogeneous nanostructured coatings with improved mechanical properties, such as high density and hardness, by utilizing amorphous alumina-zirconia powders prepared at reduced temperatures and deposited via suspension plasma spray.
Implementation Method 1
The thermal spray process has been widely used to deposit nanostructured coatings
Implementation Method 2
deposited via suspension plasma spray
Data Source
AI summary
Amorphous mixed metal oxides are used as a feedstock for thermal spray coating. Compared to thermal spray coating methods utilizing crystalline metal oxide feedstocks, the present method reduces energy consumption and expands the range of feedstock chemical compositions. The present method also produces coatings with improved chemical homogeneity. Methods of preparing the amorphous mixed metal oxides are also described.