Rare Earth Oxide Thermal Spray Material for Dense Film Formation
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Solution Overview
Problem
Yttrium oxyfluoride is prone to decomposition during thermal spraying, and suspension thermal spraying faces challenges in forming dense films on curved surfaces and achieving thick films, while conventional thermal spraying materials with larger particle sizes have poor fluidity and are difficult to process.
Innovation Solution
A rare earth oxide thermal spraying material with a volume-based average particle size of 10-18 μm, a compression degree of ≤13, and a BET specific surface area of 0.1-2 m²/g, which allows for the formation of dense and low-porosity films through atmospheric plasma spraying, even on curved surfaces, by optimizing particle size distribution and surface treatment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If smaller particle size thermal spraying material is used to form dense films with low porosity, then corrosion resistance is improved, but fluidity deteriorates making it difficult to process
Solution Approach 1:
The patent applies parameter changes by precisely controlling the particle size distribution parameters (D10=5-15 μm, D50=10-18 μm, D90=15-25 μm) and surface characteristics (BET specific surface area, compression degree) to achieve optimal balance between fluidity and film density. This parameter optimization allows smaller particles to maintain good flowability while forming dense coatings.
2Manufacturing precision
If suspension thermal spraying is used to form dense films on curved surfaces, then film density is improved, but ease of forming on curved surfaces and achieving thick films deteriorates
Solution Approach 1:
The patent replaces the suspension delivery system with a dry powder atmospheric plasma spraying system. By using particles with optimized size distribution and surface characteristics, the system achieves suspension-like film density without the complexity of slurry preparation and delivery, enabling effective coating of curved surfaces and thick film formation.
3Ease of operation
If conventional thermal spraying material with larger particle size is used, then fluidity is improved, but film density and corrosion resistance deteriorate
Solution Approach 1:
The patent changes the particle size parameters from conventional larger sizes to an optimized distribution (D10=5-15 μm, D50=10-18 μm, D90=15-25 μm) with controlled surface properties (BET specific surface area 0.1-2.0 m²/g, compression degree 10-15). This parameter optimization enables particles to maintain good fluidity while forming dense, low-porosity films with enhanced corrosion resistance.
4Reliability
If yttrium fluoride is used for thermal spraying, then corrosion resistance is improved, but decomposition during spraying occurs leading to mixture of fluoride and oxide
Solution Approach 1:
The patent uses rare earth oxide (such as yttrium oxide) as a thermally stable alternative to yttrium fluoride. While oxide has slightly different properties, it maintains excellent corrosion resistance and, crucially, does not decompose during thermal spraying, ensuring compositional stability and eliminating the need for post-spraying remediation.
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 material achieves high fluidity and forms dense, low-porosity thermal sprayed films with improved corrosion resistance, enabling efficient deposition on complex geometries and achieving thick film thicknesses.
Implementation Method 1
atmospheric plasma spraying
Implementation Method 2
when the yttrium fluoride passes through a flame at not less than 3,000° C. and melts
Implementation Method 3
thermal sprayed film having excellent corrosion resistance is formed on the surface of metal aluminum or aluminum oxide ceramics
Data Source
AI summary
Provided is a rare earth oxide thermal spraying material which has a granular form having a volume-based average particle diameter D50 of 10 μm to 18 μm inclusive as measured by a laser diffraction scattering method, a compression degree of 13 or less and a BET specific surface area of 0.1 m2/g to 2 m2/g inclusive. The rare earth oxide thermal spraying material according to the present invention can form a dense thermally sprayed film having a small porosity even by atmospheric plasma spraying in which a thermal spraying material is supplied in a solid (particle) form. When a thermally sprayed film is formed by atmospheric plasma spraying using the rare earth oxide thermal spraying material according to the present invention, it becomes possible to form the thermally sprayed film in a curved shape easily and to form the thermally sprayed film in a large thickness.