Nickel-based thermal spray powder and coating and preparation method thereof
[Patent Description] Zhenji thermal spray powder and coating and its preparation method
The application is the divisional application of the Chinese patent application 201180013534.2 of the application date on February 1st, 2011, titled " base thermal spraying powder and coating and preparation method thereof ".
[000 citing related applications
This application claims priority to U.S. Provisional Application Serial No. 61/300,381 filed on February 1, 2010, which is incorporated herein by reference in its entirety.
All publications, patents and patent applications cited in this specification are incorporated herein by reference in their entirety.
【Background technique】
[0005] The thermal spray process is generally referred to as a process that uses heat to deposit melted or semi-melted material onto a substrate to protect the substrate from abrasion and corrosion. The material to be deposited is supplied, for example, in powder form in a thermal spray process. Such powders include small particles such as between a 100 mesh U.S. Standard sieve size (149 microns) and about 2 microns.
[0006] The thermal spray process generally includes three distinct steps; the first step is to melt the material, the second step is to atomize the material, and the third step is to deposit the material onto the substrate. For example, the arc spray process uses an electric arc to melt the material and a compressed gas to atomize and deposit the material onto a substrate.
[0007] Materials known as hardfacing alloys can be used for coatings prepared, for example, by thermal spraying. Typically, alloy coatings are used for case hardening to provide wear resistance, especially where the desired surface finish is required. However, many coatings designed to operate at elevated temperatures and provide corrosion and wear properties often fail due to poor coating density, which results in corrosive products reaching the substrate and causing spalling. For example, composite coatings designed for wear protection often fail due to matrix erosion, resulting in loss of the composite hard phase. Accordingly, there is a need for improved materials for use in thermal spray coatings.
[0008] Overview
Some embodiments provide methods comprising the use of fully alloyed powders to form a wear and corrosion resistant coating on the substrate by a thermal spray process to coat substrates and coatings resulting from the presently described methods. Floor.
One embodiment provides a coating comprising: a powder-containing composition comprising an alloy comprising a solid solution phase comprising inert and a first transition metal element comprising at least one transition metal element and at least one non-metallic element component phase.
[0011] An alternative embodiment provides a powder-containing composition comprising an alloy represented by the formula: (Ni total ry)g(MbN), wherein: M represents a transition metal element in the first component phase; N represents a non-metallic element in the first component phase; a, b, and C are each greater than 0 and independently represent weight percent; and X and y are each greater than 0 and independently represent weight percent of the Ni-containing solid solution phase. In some embodiments, a is about 85-95, b is about 0.1-10, c is about 5-10, and the ratio of x to y is 0.5-1.9.
One embodiment provides a method of forming a coating, the method comprising: providing a substrate; and disposing a coating on the substrate, the coating comprising; a powder-containing composition comprising an alloy, the alloy comprising an ingot-containing composition A solid solution phase and a first component phase containing at least one transition metal element and at least one non-metal element.
Another embodiment provides a method of forming a coating, comprising: providing a mixture comprising tin, at least one transition metal element other than tin, and at least one non-metal element; forming the mixture into a powder-containing composition, wherein The composition comprises an alloy comprising a solid solution phase containing the ingot and a first component phase containing a transition metal element and a non-metallic element; and disposing the powder-containing composition on a substrate to form a coating.
[0014] An alternative embodiment provides a method of forming a coating, the method comprising: depositing a coating on a substrate, the coating comprising: a powder-containing composition comprising an alloy of the formula: (Ni, Zn) y), (MbN.) represents, wherein; M represents the transition metal element in the first component phase; N represents the non-metallic element in the first component phase; a, b, and C independently represent weight percentages; and X and y each independently represent the weight percent of the solid solution phase containing the zirconium; and (i) a is about 85 to about 95, (ii) b is about 0.1 to about 10, (iii) c is about 5 to about 10 10, and (iv) the ratio of x to y is from about 0.5 to about 1.9.
【Description of drawings】
1 shows a schematic diagram of a high-speed oxy-fuel (VOF) process.
Fig. 2 shows the schematic diagram of arc wire thermal spraying process.
[0017] FIG. 3 shows a schematic diagram of a plasma thermal spray process.
[0018] FIG. 4 shows a SEM micrograph of a cross-section of a coating according to one embodiment.
【detailed description】
One embodiment provides a coating comprising a powder-containing composition having an alloy having a solid solution phase comprising inert and a first component comprising at least one transition metal and at least one non-metal . The composition can be applied to a substrate to form a coating. In one embodiment, the alloy can be represented by the formula; (Ni cory), (MbN.), wherein; M represents a transition metal element in the first component phase; N represents a non-metallic element in the first component phase ; a, b, and C are each greater than 0 and independently represent weight percent; and X and y are each greater than 0 and independently represent weight percent of Ni-sol solid solution phase. In one embodiment, a may be about 85-95, b may be about 0.1-10, c may be about 5-10, and the ratio of x to y may be 0.5-1.9.
Powder-Containing Compositions
[0021] The term "powder-containing composition" means any composition in which a powder is contained. The term "powder" means a substance comprising ground, pulverized or otherwise finely divided solid particles.
Phase
[0023] The term "phase" herein may mean a phase that can be found in a thermodynamic phase diagram. A phase is a region of space (thermodynamic system) in which all physical properties of a material are substantially uniform. Examples of physical properties include density, refractive index, chemical composition, and lattice periodicity. A brief description is that a phase is a chemically homogeneous, physically distinct and (often) mechanically separable region of material. For example, in a system of ice and water in a glass jar, cubes of ice are one phase, water is the second phase, and moist air above the water is the third phase. Jar glass is another separate phase. Phase can mean a solid solution, which can be a binary, triadic, quaternary, or more elemental solution or compound, such as an intermetallic compound.
[0024] While the alloyed powder-containing compositions described herein may be single phase, it is desirable to make the composition multiphase. For example, the composition can have at least two phases, at least three phases, at least four phases, or more phases. In one embodiment, the alloy composition may comprise a metal solid solution phase and an additional phase, which may be another metal solid solution phase or a phase that is not a metal solid solution. For example, the additional phase can be a compound phase. The metal solid solution phase can be any type of metal solid solution, depending on the chemical composition of the solution. For example, it may be a metal-based solution, the metal being a transition metal, such as bromide. In one embodiment, the metal solution may include an indium-phosphonium (Ni-Cl) metal solution.
[0025] The second phase can be, for example, a compound phase. The compound may be a binary compound, a triadic compound, a quaternary compound, or a compound having more than four elements. Referring to the above formula, the compound can be a metal-nonmetal compound (eg, MN). M may represent a metal, such as a transition metal, and N may represent a non-metal. As also described above, the compound may have multiple M and/or N. In one embodiment, depending on the chemical composition, and in particular on N, the additional phase may be, for example, carbides, hydrates, or both. Thus, the second phase may be a carbide compound, and the third phase, if present, may be a boride, or vice versa. Alternatively, the second and third phases can be carbides or borides. In one embodiment, the additional phase(s) may comprise a compound; boronite, carbide, boronite, or a combination thereof.
Metals, Transition Metals and Nonmetals
[0027] The term "metal" means an electropositive chemical element. The term "element" in this specification generally means an element found in the Periodic Table of the Elements. Physically, a metal atom in the ground state contains a partially filled band with an empty state close to the occupied state. Chemically, upon entering a solution, metal atoms release electrons to become positive ions. The term "transition metal" is any metal element in Groups 3-12 of the Periodic Table of the Elements that has an incomplete inner electron shell and acts as the most and least electropositive transition link in a series of elements. Transition metals are characterized by a variety of valences, colored compounds, and the ability to form stable complex ions. The term "nonmetal" means a chemical element that does not have the ability to lose electrons and form positive ions.
[0028] The symbol N represents one or more non-metallic elements. Depending on the application, any suitable non-metallic element or combination thereof may be used. The alloy composition may also include multiple non-metallic elements, such as at least two, at least three, at least four or more non-metallic elements. In this case, the symbol "N" represents and includes various non-metal elements, and the chemical formula may have Ni, N2, Ns, or the like. The non-metallic element can be any element found in Groups 13-17 of the Periodic Table of the Elements. For example, the non-metal element can be any of F, Cl, Br, I, At, O, S, Se, Te, Po, N, P, As, Sb, Bi, C, Si, Ge, Sn, Fe, and B either. Occasionally, a non-metal element may also mean some of the metalloids of Groups 13-17 (eg, B, Si, Ge, As, Sb, Te, and Fe). In one embodiment, the non-metal element may include B, Si, C, P, or a combination thereof. Thus, the alloy composition comprises borides, carbides, or both.
[0029] The symbol M represents one or more transition metal elements. For example, M can be rail, iron, hunger, inscription, paving, iron, diamond, inlay, copper, front, ingot, wrong, soul, steel, get, nail, ingot, button, silver, simple, give, thick, crane , chain, hungry, silver, pin, gold, clerical, element 104, element 105, element 106, element 107, element 108, element 109, element 110, element 111, element 112 any. In one embodiment, M may represent Sc, Y, La, Ac, Ti, Zr, Hg, V, Pe, Ta, Cr, Mo, W, Mn, Tc, Re, Fe, Ru, Os, Co, Fe , at least one of Ir, Ni, Pd, Pt, Qi, Ag, Au, Zn, Cd and Hg. Depending on the application, any suitable transition metal element or combination thereof may be used. The alloy composition may contain multiple transition metal elements, such as at least two, at least three, at least four, or more transition metal elements. In this case, the symbol "M" represents and includes various transition metal elements, and the chemical formula may have Mi, M2, Ms, and the like. In one embodiment, the transition metal element includes Fe, Ti, Zr, or a combination thereof.
The alloy in the powder-containing composition can be of any shape or size, for example, the alloy can have the shape of a pellet, it can have a shape such as a sphere, a ball, a wire, a rod, a flake, a flake, or irregular shape. The pellets can be of any suitable size. For example, it may have a range of about 1 micrometer to about 100 micrometers, such as about 5 micrometers to about 80 micrometers, such as about 10 micrometers to about 60 micrometers, such as about 15 micrometers to about 50 micrometers, such as about 15 micrometers to about 45 micrometers, such as about 20 micrometers to about Average diameter of 40 microns, such as about 25 microns to about 35 microns. In some embodiments, smaller particles such as those in the nanometer range or larger particles such as those greater than 100 microns may be used.
