Multi-Oxide Thermal Spraying Powder for Smoother Homogeneous Films
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing thermal spraying powders containing multiple oxides face challenges in achieving high fineness and low surface roughness while minimizing the proportion of separated phases in the resulting film.
Innovation Solution
The thermal spraying powder is composed of a multiple oxide with specific particle size distribution, including a particle diameter D10 of 10 µm or more and D50 of 40 µm or less, and contains metal oxides with a boiling point difference of 500°C or higher, formed from secondary particles like granulated-sintered or melted-pulverized oxides, to reduce phase separation and surface roughness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional thermal spraying powder with smaller particle sizes is used, then fineness of the thermal spraying film is improved, but surface roughness increases and separated phases form more readily
Solution Approach 1:
The patent changes the particle size distribution parameters by specifying D10 ≥ 10 μm and D50 ≤ 40 μm, which optimizes the balance between fineness and surface quality. This parameter optimization prevents excessive fineness that would cause roughness and phase separation while maintaining adequate film fineness
Solution Approach 2:
The patent uses composite metal oxide materials (such as YAlO3, YAG, YAM) that combine multiple oxides with different boiling points. This composite approach ensures uniform melting and spraying behavior, reducing phase separation while maintaining film fineness and surface quality
2Ease of manufacture
If metal oxides with small boiling point difference are used, then ease of manufacture is improved, but phase separation in the thermal spraying film increases
Solution Approach 1:
The patent changes the boiling point difference parameter to ≥500°C between component metal oxides. This parameter change ensures that during thermal spraying, components melt and deposit uniformly without excessive vaporization differences, preventing phase separation while maintaining compositional stability in the film
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
This composition results in a thermal spraying film with improved fineness, reduced surface roughness, and decreased proportion of separated phases, enhancing the film's structural integrity and quality.
Implementation Method 1
particle size distribution measuring method by laser diffractive scattering
Implementation Method 2
thermal spraying powder containing a multiple oxide including a plurality of metal oxides... Under a condition at 1 atmosphere, there is a difference of 500°C or higher between the maximum value and the minimum value of boiling points
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Provided is a technology that improves fineness and reduces surface roughness as well as reduces the proportion of a separated phase in a thermal spraying film. The thermal spraying powder disclosed herein is a thermal spraying powder containing a multiple oxide including a plurality of metal oxides. In the thermal spraying powder, the particle diameter D10, which is a particle diameter at a point where a cumulative particle volume accumulated from the side of small particle diameters, is 10% of the total particle volume in a cumulative particle diameter distribution on volume basis based on a particle size distribution measuring method by laser diffractive scattering is 10 µm or more, and the particle diameter D50, which is a particle diameter at a point where a cumulative particle volume accumulated from the side of small particle diameters is 50% of the total particle volume in a cumulative particle diameter distribution on volume basis based on a particle size distribution measuring method by laser diffractive scattering is 40 µm or less. Under a condition at 1 atmosphere, there is a difference of 500°C or higher between the maximum value and the minimum value of boiling points among a plurality of metal oxides. Use of a thermal spraying powder with such a composition allows a thermal spraying film to have improved fineness and reduced surface roughness, as well as less proportion of a separated phase.