U.S. patent application number 15/568703 was filed with the patent office on 2018-09-13 for cold gas spray coating methods and compositions.
This patent application is currently assigned to OERLIKON METCO (US) INC.. The applicant listed for this patent is OERLIKON METCO (US) INC.. Invention is credited to Alexander BARTH, Satya N. KUDAPA, Montia NESTLER, Scott WILSON.
Application Number | 20180258539 15/568703 |
Document ID | / |
Family ID | 57608602 |
Filed Date | 2018-09-13 |
United States Patent
Application |
20180258539 |
Kind Code |
A1 |
WILSON; Scott ; et
al. |
September 13, 2018 |
COLD GAS SPRAY COATING METHODS AND COMPOSITIONS
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.
Inventors: |
WILSON; Scott; (Zurich,
CH) ; BARTH; Alexander; (Wohlen, CH) ;
NESTLER; Montia; (Ridgefield, NJ) ; KUDAPA; Satya
N.; (Sterling Heights, MI) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
OERLIKON METCO (US) INC. |
Westbury |
NY |
US |
|
|
Assignee: |
OERLIKON METCO (US) INC.
Westbury
NY
|
Family ID: |
57608602 |
Appl. No.: |
15/568703 |
Filed: |
June 29, 2015 |
PCT Filed: |
June 29, 2015 |
PCT NO: |
PCT/US2015/038320 |
371 Date: |
October 23, 2017 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C23C 24/04 20130101;
C22C 19/07 20130101; C22C 19/055 20130101; C22C 33/02 20130101;
B22F 2998/10 20130101; B22F 9/026 20130101; C22C 19/056 20130101;
B22F 1/0096 20130101; C22C 1/0433 20130101; B22F 2009/041 20130101;
C22C 38/00 20130101; B22F 2998/10 20130101; B22F 2009/041 20130101;
B22F 9/026 20130101; B22F 1/0096 20130101 |
International
Class: |
C23C 24/04 20060101
C23C024/04 |
Claims
1. A cold gas spray method comprising spraying a composition
containing a primary phase of at least one nickel or iron based
material blended with a softer, shear-deformable, secondary phase
metal and/or metal alloy, to deposit a dense, or porous coating on
a substrate.
2. The method of claim 1, wherein the primary phase of nickel or
iron based material contains one or more of steel, stainless steel,
nickel alloy, nickel superalloy, cobalt alloy, titanium alloy, and
intermetallics.
3. The method of claim 1, wherein the primary phase of nickel or
iron based material contains one or more of nickel cladding, nickel
powder, blended nickel-aluminum powder, and ceramic.
4. The method of claim 1, wherein the secondary phase contains one
or more of copper, aluminum, silver, zinc, platinum, palladium, and
alloys thereof.
5. The method of claim 1, wherein the secondary phase contains
nickel particles at least partially clad with aluminum flakes.
6. The method of claim 3, wherein the ceramic contains one or more
of YSZ, alumina, tungsten carbides, CrC, TiO.sub.2, TiO.sub.x=1.7
to 1.9, and SiC.
7. The method of claim 3, wherein the ceramic is clad with a soft
ductile alloy.
8. The method of claim 1, wherein the coating is at least 1
millimeter thick.
9. The method of claim 1, wherein the coating has substantially no
residual stress, low porosity, low oxide content, and substantially
no internal cracking.
10. The method of claim 1, wherein the composition is sprayed at an
average velocity of at least about 600 meters per second, at spray
plume temperatures less than about 1000.degree. C., at a feed rate
greater than about 20 grams per minute.
11. The method of claim 1, wherein the primary and secondary phase
metals are combined by one or more of mechanical blending,
mechanical alloying, mechanical cladding, agglomeration by spray
drying, pelletizing, chemical vapor deposition, physical vapor
deposition, electrochemical deposition and/or plasma
densification.
12. The method of claim 11, wherein the agglomeration comprises
agglomeration of nano-scale powders.
13. The method of claim 11, wherein the physical vapor deposition
comprises fluidized bed physical vapor deposition.
14. The method of claim 11, wherein the chemical vapor deposition,
physical vapor deposition, and/or electrochemical deposition
comprises deposition of at least one secondary phase metal on the
outer surface of at least one primary phase metal.
15. A composition particularly adapted for use in cold spray
coating, comprising at least one primary phase of nickel or iron
based material blended with a softer, shear-deformable, secondary
phase metal and/or metal alloy.
16. The composition of claim 15, wherein the primary phase of
nickel or iron based material contains one or more of steel,
stainless steel, nickel alloy, nickel superalloy, cobalt alloy,
titanium alloy, and intermetallics.
17. The composition of claim 15, wherein the primary phase of
nickel or iron based material contains one or more of nickel
cladding, nickel powder, blended nickel-aluminum powder, and
ceramic.
18. The composition of claim 15, wherein the secondary phase
contains one or more of copper, aluminum, silver, zinc, platinum,
palladium, and alloys thereof.
19. The composition of claim 15, wherein the secondary phase
contains nickel particles at least partially clad with aluminum
flakes
20. The composition of claim 17, wherein the ceramic contains one
or more of YSZ, alumina, tungsten carbides, CrC, TiO x=1.7 to 1.9,
and SiC.
21. The composition of claim 17, wherein the ceramic is clad with a
soft ductile alloy.
22. The coated article produced by the method of claim 1.
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 one method of repairing such parts.
The process has also been used to repair aircraft engines, gas
turbines, and parts used in the oil and gas industry, etc. While
the basic technology has been found to be a cost effective and
environmentally acceptable technology for providing such repair and
other surface protection purposes, there is a constant search in
this area for ways to make, use and improve this process in more
efficient and effective ways, which can also potentially increase
its usefulness and applicability.
[0003] The compositions and methods described herein meet the
challenges described above, including, among other things,
achieving more efficient and effective processing.
BRIEF SUMMARY
[0004] A cold gas spray method is described including spraying a
composition containing a primary phase of at least one nickel or
iron based material blended with a softer, shear-deformable,
secondary phase metal and/or metal alloy, to deposit a dense, or
porous coating on a substrate.
[0005] Additional embodiments include: the method described above
where the primary phase of nickel or iron based material contains
one or more of steel, stainless steel, nickel alloy, nickel
superalloy, cobalt alloy, titanium alloy, and intermetallics: the
method described above where the primary phase of nickel or iron
based material contains one or more of nickel cladding, nickel
powder, blended nickel-aluminum powder, and ceramic; the method
described above where the secondary phase contains one or more of
copper, aluminum, silver, zinc, platinum, palladium, and alloys
thereof; the method described above where the secondary phase
contains nickel particles at least partially clad with aluminum
flakes; the method described above where the ceramic contains one
or more of YSZ, alumina, tungsten carbides, CrC, TiO.sub.2,
TiO.sub.x=1.7 to 1.9, and SiC; the method described above where the
ceramic is clad with a soft ductile alloy; the method described
above where the coating is at least 1 millimeter thick; the method
described above where the coating has substantially no residual
stress, low porosity, low oxide content, and substantially no
internal cracking; the method described above where the composition
is sprayed at an average velocity of at least about 600 meters per
second, at spray plume temperatures less than about 1000.degree.
C., at a feed rate greater than about 20 grams per minute; the
method described above where the primary and secondary phase metals
are combined by one or more of mechanical blending, mechanical
alloying, mechanical cladding, agglomeration by spray drying,
pelletizing, chemical vapor deposition, physical vapor deposition,
electrochemical deposition and/or plasma densification; the method
described above where the agglomeration comprises agglomeration of
nano-scale powders; the method described above where the physical
vapor deposition comprises fluidized bed physical vapor deposition;
the method described above where the chemical vapor deposition,
physical vapor deposition, and/or electrochemical deposition
comprises deposition of at least one secondary phase metal on the
outer surface of at least one primary phase metal.
[0006] Additional embodiments also include: a composition
particularly adapted for use in cold spray coating, comprising at
least one primary phase of nickel or iron based material blended
with a softer, shear-deformable, secondary phase metal and/or metal
alloy; the composition described above where the primary phase of
nickel or iron based material contains one or more of steel,
stainless steel, nickel alloy, nickel superalloy, cobalt alloy,
titanium alloy, and intermetallics; the composition described above
where the primary phase of nickel or iron based material contains
one or more of nickel cladding, nickel powder, blended
nickel-aluminum powder, and ceramic; the composition described
above where the secondary phase contains one or more of copper,
aluminum, silver, zinc, platinum, palladium, and alloys thereof;
the composition described above where the secondary phase contains
nickel particles at least partially clad with aluminum flakes the
composition described above where the ceramic contains one or more
of YSZ, alumina, tungsten carbides, CrC, TiO.sub.2, TiO.sub.x=1.7
to 1.9, and SiC; the composition described above where the ceramic
is clad with a soft ductile alloy; and the coated articles produced
with the compositions and by the methods described above.
[0007] These, and additional embodiments, will be apparent from the
following descriptions.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 shows representative pressures vs. velocities for
particles described herein.
[0009] FIGS. 2, 3, 4 and 5 show schematic representations of some
embodiments of the processes described herein.
[0010] FIGS. 6, 7, 8, 9, 10 and 11 show micrographs of some of the
embodiments of the processes described herein.
[0011] FIG. 12 shows some processing parameter embodiments of the
processes described herein.
[0012] FIGS. 13 and 14 show micrographs of some of the embodiments
of the processes described herein.
DETAILED DESCRIPTION
[0013] The particulars shown herein are by way of example and for
purposes of illustrative discussion of the various embodiments of
the present invention only and are presented in the cause of
providing what is believed to be the most useful and readily
understood description of the principles and conceptual aspects of
the invention. In this regard, no attempt is made to show details
of the invention in more detail than is necessary for a fundamental
understanding of the invention, the description making apparent to
those skilled in the art how the several forms of the invention may
be embodied in practice.
[0014] The present invention will now be described by reference to
more detailed embodiments. This invention may, however, be embodied
in different forms and should not be construed as limited to the
embodiments set forth herein. Rather, these embodiments are
provided so that this disclosure will be thorough and complete, and
will fully convey the scope of the invention to those skilled in
the art.
[0015] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
terminology used in the description of the invention herein is for
describing particular embodiments only and is not intended to be
limiting of the invention. As used in the description of the
invention and the appended claims, the singular forms "a," "an,"
and "the" are intended to include the plural forms as well, unless
the context clearly indicates otherwise. All publications, patent
applications, patents, and other references mentioned herein are
expressly incorporated by reference in their entirety.
[0016] Unless otherwise indicated, all numbers expressing
quantities of ingredients, reaction conditions, and so forth used
in the specification and claims are to be understood as being
modified in all instances by the term "about." Accordingly, unless
indicated to the contrary, the numerical parameters set forth in
the following specification and attached claims are approximations
that may vary depending upon the desired properties sought to be
obtained by the present invention. At the very least, and not as an
attempt to limit the application of the doctrine of equivalents to
the scope of the claims, each numerical parameter should be
construed in light of the number of significant digits and ordinary
rounding approaches.
[0017] Notwithstanding that the numerical ranges and parameters
setting forth the broad scope of the invention are approximations,
the numerical values set forth in the specific examples are
reported as precisely as possible. Any numerical value, however,
inherently contains certain errors necessarily resulting from the
standard deviation found in their respective testing measurements.
Every numerical range given throughout this specification will
include every narrower numerical range that falls within such
broader numerical range, as if such narrower numerical ranges were
all expressly written herein.
[0018] Additional advantages of the invention will be set forth in
part in the description which follows, and in part will be obvious
from the description, or may be learned by practice of the
invention. It is to be understood that both the foregoing general
description and the following detailed description are exemplary
and explanatory only and are not restrictive of the invention, as
claimed.
[0019] Powder material mixtures when subjected to impact induced
high shock stresses exhibit a variety of dominant and in some cases
complimentary effects (see, for example, Eakins D E, Thadhani N N,
"Shock Compression of Reactive Powder Mixtures", International
Materials Reviews, 2009,Vol:54, ISSN:0950-6608, Pages:181-213,
hereinafter referred to as the Eakins article; also Boslough M. B.,
"Shock-induced Chemical Reactions in Ni--Al Powder Mixtures:
Radiation Pyrometer Measurements", Chemical Physical Letters, Vol.
150, 5/6, August 1989, p618-622, hereinafter referred to as the
Boslough article; and Do, I .P. H., Benson D. J. "Micromechanical
Modeling of Shock-Induced Chemical Reactions in Heterogeneous
Multi-Material Powder Mixtures." Int. Journal of Plasticity, Vol
17, 4, 2001, p.641-668) hereinafter referred to as the Do article;
all of which are herein incorporated by reference): [0020] 1) Shear
deformation to large strains with modified microstructures and high
defect concentrations. [0021] 2) Physical changes such as phase
changes e.g. phase transformations in iron and metastable steels
and metal alloys (see, for example, E. Moin, L. E. Murr, Mater.
Sci. Eng., 37 (3) (1979) 249 and C. J. Heathcock, B. E. Protheroe,
A. Ball, Wear, 81 (1982) 311-327), or melting. [0022] 3) Chemical
changes where reaction kinetics are accelerated by the shock energy
to produce reactions such as degradation, oxidation or exothermic
reactions.
[0023] These effects have recently been well documented in the
literature (e.g. see the Eakins article noted above) with
informative models developed to predict propensity for material
combinations to chemically react or physically combine with one
another to produce new stable, or metastable, materials with
commercial potential, purely through the introduction of impact or
shock energy.
[0024] Key parameters useful for attempting to predict the
propensity of powder material combinations to chemically react with
each other or, alternatively, physically combine with one another
by mechanical deformation and mixing without chemical reaction,
have been observed to be the following (e.g. see the Eakins article
noted above):
1 ) Impedance Difference = .rho. A C A - .rho. B C B .rho. B C B
.times. 100 2 ) Yield strength difference = .sigma. A - .sigma. B
.sigma. B .times. 100 ##EQU00001## [0025] Where: [0026]
.rho..sub.A=density of powder material A, .rho..sub.B=density of
powder material B [0027] C.sub.A=speed of sound in material A,
C.sub.B=speed of sound in material B [0028] .sigma..sub.A=yield
strength material A, .sigma..sub.B=yield strength material B
[0029] Based on these equations, the following "Impedance
difference" and "yield strength difference" calculations can be
made using typically available data for three common materials
namely Nickel, INCONEL 718 superalloy and pure Aluminum (room
temperature) (see Table 1 below). Combinations of Nickel and
INCONEL 718 result in a very large yield strength difference of
884% and small impedance difference of 4.9%. Combinations of Nickel
and Aluminum have a much higher impedance difference of 150% with a
lower yield strength difference of 320%.
[0030] Large differences in yield and impedance difference can
result in large degrees of deformation inhomogeneity and
inter-material mixing when they are subjected to sufficiently high
impact shocks, yet the high values have been found by experimental
shock testing of powder compacts (e.g. see the Eakins article noted
above) (approx. 3.5 GPa) to be ineffective in terms of promoting
chemical reactions between powder materials that have exothermic
reaction potential e.g. between Ni and Al. Chemical reactions e.g.
exothermic reactions, have been shown to be promoted for material
combinations subjected to high shock stresses where impedance and
yield strength differences are both low e.g. between Nickel and
Silicon (e.g. see the Eakins article noted above), or Niobium and
Silicon (e.g. see the Do article noted above).
TABLE-US-00001 TABLE 1 Yield Density: Speed of Yield Impedance
strength Material .rho. sound: C Strength: .sigma. difference
difference Units kg/m.sup.3 m/s Mpa % % (room temp.) (room temp.)
typical value typical value Nickel 8912 4796 105 Ni vs. Ni vs.
INCONEL INCONEL 718: 4.9 718: 884 INCONEL 8190 4974 1034 718
Aluminum 2700 6320 25 Al vs. Ni: Al vs. Ni: 150 320
[0031] In relating the abovementioned observations on shock
deformation of compacted particles to cold gas spraying, metallic
alloy powder particles are accelerated to velocities of at least
500 m/s (meters/second) and higher. Particle impact stresses
produced on a rigid surface can be estimated using peak pressure
calculations where the impedance is multiplied by
0.5.times.particle velocity (see, for example, R. C. Dykhuizen, M.
F. Smith, D. L. Gilmore, R. A. Neiser, X. Jiang, S. Sampath,
"Impact of High Velocity Cold Spray Particles", Journal of Thermal
Spray Technology, December 1999, Volume 8, Issue 4, pp
559-564).
[0032] For particle velocities above 500 m/s, peak contact
pressures easily reach above 4 GPa for Aluminum and are some three
times higher for harder INCONEL 718 and Nickel powders (FIG. 1).
The range of impact stresses are similar if not higher than those
observed in impact shock experiments (e.g. see the Eakins article
noted above). These conditions are conducive for compaction and
mechanical mixing phenomena to compacted Hugoniot dense solid. Cold
gas spraying combination of alloys such as Nickel and INCONEL 718
have high mechanical mixing potential given the large yield
strength difference between them and this is borne out by the high
deposition efficiencies observed on cold gas spraying for example
INCONEL718 powder with up to 10 wt. % pure nickel powder at the
conditions shown in FIG. 12 herein, for example.
[0033] Distributing the softer nickel powder onto the entire
exposed surface areas of the functional matrix alloy powder
particles (e.g. INCONEL 718 powder particles of typical average
diameter of 25 micron) is ideal but thoroughly impractical given
the need for a higher weight percentage of nickel powder in the
blend, which will inevitably negatively impact the desired
mechanical, physical and chemical properties needed for engineering
and commercial usage. A way to overcome this is by cladding
individual INCONEL 718 particles with a thin layer of nickel e.g.
2-3 micron that can be applied using electrochemical (autoclave
cladding) or chemical vapor deposition techniques as described
herein. Here the amount of extra nickel added to the INCONEL 718 is
of the order of 5-15wt. % and is able to function to maximum
benefit by covering 100% of all INCONEL 718 particle surfaces. A
typical micrograph showing such a cold gas sprayed microstructure
is shown in FIG. 13 herein.
[0034] While shock compression models show that the promotion of
coating densification by exothermic reactions between reactive
species such as Ni and Al powders are generally not possible due to
the very high yield stress difference and impedance difference
measurements seen (Table 1) for these two materials, chemical
reaction (exothermic) processes can be initiated if there is a
large differential in particle morphology and particle size under
sufficiently high impact shock stress conditions (e.g. see the
Eakins article noted above) or very high impact shock stresses e.g.
14 GPa (e.g. see the Boslough article noted above). In this regard,
if the particle morphologies are significantly different e.g. round
particle Ni vs. smaller and flake-like Al, then chemical reactivity
is observed to increase and promote exothermic reactions between Ni
and Al. A part of this invention was to utilize this concept and
make use of the addition of nickel particles that are clad or
partially clad with aluminum flakes as a secondary "exothermic and
reactive" phase that was then blended together with INCONEL 718
powder. The resultant high density microstructures and high
deposition efficiencies produced through the use of such a blend
are shown, for example, in FIGS. 6 to 11, 13 and 14 herein, further
demonstrating the efficacy.
[0035] As stated above, cold gas deposition processes are described
herein to produce dense and porous coatings. These coatings have
particular applicability for aero component repair, for producing
bondcoats, porous and dense metallic coatings, porous and dense
metal matrix (ceramic filler) composites, and abradable coatings,
among others.
[0036] The cold gas spray method described herein describes the use
of binary or ternary blends of alloy combinations to deposit,
primarily, thick (e.g. 1 mm with typical coating thickness ranges
of above 0.2 millimeter up to 1.5 mm or more, e.g., up to 10 mm)
nickel based superalloy type coatings by cold gas spray, but can be
extended to other similar coating systems. Use of a harder
superalloy powder e.g. INCONEL 718 together with a smaller amount
(typical compositions being e.g. 5, 10, 15 or 20 wt. % with the
possibility of compositions having up to 45wt %) of a soft,
shear-deformable, secondary phase powder or cladding such as pure
nickel or Ni--Al composite powders (or variants of Ni--Al composite
powders with Al contents of typically 20 wt. % to a maximum of
approximately 30 wt. %) which softens and generate heat energy
during the massive shear deformation processes arising during cold
spray. The heat energy is generated by plastic deformation
processes or a combination of plastic deformation and exothermic
reactions e.g. between unreacted Ni and Al. In addition, the
concept can be altered by using fine, hard ceramic powder particles
instead of/or together with the softer metal phase with the theory
that the ceramic phases also generate shear mismatch and heat when
deposited with a superalloy phase. The use of such unique alloy
blends reduces the need for development of higher
temperature/higher velocity cold gas spray parameters and
equipment.
[0037] The process described herein has particular utility for
repair coatings for nickel superalloy components, and especially
those with high deposition efficiencies (>80% deposition
efficiency), to at least 1 mm thick, with little or no residual
stress (coating does not spall off or bend), low porosity i.e.
<2%, low oxidation/oxide content arising from deposition
process, and minimal internal cracking of coating i.e. cracks
between splats; will supersede current high velocity oxy-fuel
(HVOF) or Air Plasma Spray repair solutions which tend to have
higher residual stress, higher porosity, higher oxidation; will
reduce the need for development of "higher temperature/higher
velocity" cold gas spray parameters and equipment through the use
of these unique material combinations.
[0038] The process described herein, utilizes the mismatch in
physical, mechanical and chemical properties between two (or more)
components of a blend of alloy components where: Component 1 is a
nickel superalloy such as INCONEL 718 or other superalloy such as
HASTELLOY (registered trademark of Haynes International, Inc.)
C276, INCONEL 625; or Component 1 is a nickel alloy such as NiCrAl,
NiCrAlMo. or NiAlMo; or Component 1 is an Iron based alloy such as
FeNiAlMo and Component 2 is: A softer, more ductile alloy such as
Nickel, Ni-5wt %Al, Ni-20wt %Al or Al-12Si alloy, with a total
weight percent less than that of Component 1, with typical ranges
of 3, 4, 5, 6, 7, 8, 9 and 10 wt. % of total blend content.
[0039] The uniqueness of this approach includes the following. The
blend of component 1 and 2 is sprayed using conventional cold gas
spray (kinetic spray) using the following minimum basic parameters:
powder particle feed spray velocities that exceed at least 600
meters/second on average, spray plume temperatures that are less
than approximately 1000.degree. C., powder feed rates that are
greater than 20 gram/minute. During the spray deposition process
the softer, more ductile Component 2: is deformed in preference to
the harder and stiffer Component 1, deforms to very high plastic
strains by compressive shear between the harder surfaces of
Component 1 particles and is extruded into the voids and gaps
between splats (particles of material that deform on impact) of
Component 1, generates heat (friction heat and deformation energy)
during the high plastic strain deformation process that assists
with softening of both Components 1 & 2, generates heat during
the high plastic strain deformation process via exothermic reaction
between two or more components in Component 2, e.g. exothermic
reaction between Nickel and Aluminum, or by an exothermic reaction
between Component 2 and Component 1, is prone to adiabatic shear
plastic deformation processes that encourage rapid shear
localization and heat generation, with resultant high strain
deformation and extrusion/melting processes.
[0040] The result of the aforementioned is deposition of nickel
superalloys, (traditionally very difficult to deposit using cold
gas spray with typical "best case" deposition efficiencies of
around 70%, i.e., 30% of the material sprayed bouncing or failing
off) with a minimum of defects and sufficient strength (similar to
that attained with air plasma spray coatings, e.g., about 34 MPa or
about 5000 psi) using the assistance of a small amount of a ductile
or ductile/exothermic second phase that assist with welding of
nickel superalloy particles together by hot-deformation (or
exothermic) reactions and minimal influence on overall chemistry of
the superalloy coating.
[0041] Exemplary variations of the above can include the following:
where Component 2 is changed to: a fine powder material that is
much harder than Component 1 such as a ceramic e.g. alumina or
yttria stabilized zirconia (YSZ); a fine powder material that is
much harder than Component 1 such as a ceramic e.g. alumina or YSZ
that is clad with a soft ductile alloy such as nickel or composite
Ni-Al powder. The outcome of using such a variation is to utilize
the high hardness and elastic modulus mismatch of the ceramic to
initiate high plastic shear strains onto the surfaces, with
eventual penetration into the surfaces of the Component 1 particle
surfaces during the deformation/impact process. In addition, since
ceramics tend to have low thermal diffusivity/conductivity, the
generation of high friction heating effects at the contact
interfaces between ceramic and metal alloy surfaces is likely to be
greatly enhanced and assist with welding and diffusion
processes.
[0042] Further exemplary variations of the above can include: where
Component 2 is changed to: Aluminum bronze alloy e.g. Cu 9.5Al 1 Fe
or Cu 10Al or bronze alloy of similar composition. In addition,
Component 1 further alloy variations can include: NIMONIC 80A and
variants. e.g. Ni (bal.) 18Cr 2Ti 1.5Al11Si 0.2Cu 3Fe 1 Mn 2Co 0.1
C 0.15Zr; NIMONIC 75 and variants; INCONEL 600, INCONEL 617,
INCONEL 625 and variants; HASTELLOY W, HASTELLOY N, HASTELLOY X,
HASTELLOY C, HASTELLOY B and variants; Haynes 214, Haynes 230 and
variants; CMSX-4 alloy and variants; Cobalt based alloys such as
commonly known STELLITE.TM. (Kennametal Stellite Company) or
STELLITE-like alloys; CoNiCrAlY and NiCrAlY alloys typically used
as bondcoats for thermal barrier coatings.
[0043] Further exemplary variations of the above can include
Component 1 using one (or more) of the alloys above (powder
morphology): Component 1 powder is clad with a thin layer of nickel
metal e.g. about 0.5 to about 5 microns thick (or close to this
range) using electroless chemical cladding techniques, or chemical
autoclave cladding or chemical vapor deposition techniques;
Alternatives to using nickel cladding include metal variants such
as copper, zinc, aluminum, iron and alloys of these with
nickel.
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.degree. C.-950.degree. C.;
Process flow gas (m.sup.3/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. Typically 450-460 HV03 was the range obtained
for all as-sprayed coatings.
EXAMPLE 2
[0046] Some examples of material combinations which can be used are
shown in the following tables, Tables 2 to 4.
TABLE-US-00002 TABLE 2 Second Phase Base Alloy Addition Approximate
Second Approximate Size Range Phase Size Range Base Alloy .mu.m
Addition Weight % .mu.m INCONEL -30 to +5 Nickel 3 to 10 -30 to +5/
718 -45 to +11 INCONEL -30 to +5 Ni--5Al 3 to 10 -30 to +5/ 718 -45
to +11 INCONEL -30 to +5 Ni--20Al 3 to 10 -125 to +45 718 INCONEL
-30 to +5 Ni--Al--Mo 3 to 10 -125 to +45 718 INCONEL -30 to +5 Ni
5Mo 5.5Al 3 to 10 -90 to +45 718 INCONEL -30 to +5 NiCrAlMo 3 to 10
-90 to +45 718 INCONEL -30 to +5 NiCrAl 3 to 10 -125 to +45 718
INCONEL -30 to +5 Al--12Si 3 to 10 -125 to +45 718 INCONEL -30 to
+5 Alumina 3 to 10 -30 to +5 718 INCONEL -30 to +5 8YSZ 3 to 10 -30
to +5 718
TABLE-US-00003 TABLE 3 Base Alloy Second Phase Approximate Second
Approximate Size Range Phase Size Range Base Alloy .mu.m Addition
Weight % .mu.m NiCrWMo -30 to +5 Nickel 3 to 10 -30 to +5/ (e.g.,
HASTELLOY C276) -45 to +11 NiCrWMo -30 to +5 Ni--5Al 3 to 10 -30 to
+5/ -45 to +11 NiCrWMo -30 to +5 Ni--20Al 3 to 10 -125 to +45
NiCrWMo -30 to +5 Ni--Al--Mo 3 to 10 -125 to +45 NiCrWMo -30 to +5
Ni 5Mo 5.5Al 3 to 10 -90 to +45 NiCrWMo -30 to +5 NiCrAlMo 3 to 10
-90 to +45 NiCrWMo -30 to +5 NiCrAl 3 to 10 -125 to +45 NiCrWMo -30
to +5 Al--12Si 3 to 10 -125 to +45 RENE .RTM. 80 (READE) -30 to +5
Nickel 3 to 10 -30 to +5/ Ni14Cr4Mo3Al5Ti9.5Co4W -45 to +11 RENE 80
-30 to +5 Ni--5Al 3 to 10 -30 to +5/ -45 to +11 RENE 80 -30 to +5
Ni--20Al 3 to 10 -125 to +45 RENE 80 -30 to +5 Ni--Al--Mo 3 to 10
-125 to +45 RENE 80 -30 to +5 Ni 5Mo 5.5Al 3 to 10 -90 to +45 RENE
80 -30 to +5 NiCrAlMo 3 to 10 -90 to +45 RENE 80 -30 to +5 NiCrAl 3
to 10 -125 to +45 RENE 80 -30 to +5 Al--12Si 3 to 10 -125 to +45
FeNiAlMo -30 to +5 Nickel 3 to 10 -30+5/ -45 to +11 FeNiAlMo -30 to
+5 Ni--5Al 3 to 10 -30+5/ -45 to +11 FeNiAlMo -30 to +5 Ni--20Al 3
to 10 -125 to +45 FeNiAlMo -30 to +5 NiCrAl 3 to 10 -125 to +45
TABLE-US-00004 TABLE 4 Nickel Nickel Ni--Al Softer Main Cladding*
Powder** Powder** Alloy** Ceramics Component (NC) (NB) (NiAl) (SA)
(CER) Steels (St) (St) + .gtoreq.5- (St) + .gtoreq.5- (St) +
.gtoreq.5- (St) + .gtoreq.5- (St) + .gtoreq.5- 20 wt % (NC) 40 wt %
(NB) 40 wt % (NiAl) 40 wt % (SA) 40 wt % (CER) Stainless (SS) +
.gtoreq.5- (SS) + .gtoreq.5- (SS) + .gtoreq.5- (SS) + .gtoreq.5-
(SS) + .gtoreq.5- Steels (SS) 20 wt % (NC) 40 wt % (NB) 40 wt %
(NiAl) 40 wt % (SA) 40 wt % (CER) Nickel (NA) + .gtoreq.5- (NA) +
.gtoreq.5- (NA) + .gtoreq.5- (NA) + .gtoreq.5- (NA) + .gtoreq.5-
Alloys (NA) 20 wt % (NC) 40 wt % (NB) 40 wt % (NiAl) 40 wt % (SA)
40 wt % (CER) Nickel (NSA) + .gtoreq.5- (NSA) + .gtoreq.5- (NSA) +
.gtoreq.5- (NSA) + .gtoreq.5- (NSA) + .gtoreq.5- Superalloys 20 wt
% (NC) 40 wt % (NB) 40 wt % (NiAl) 40 wt % (SA) 40 wt % (CER) (NSA)
Cobalt (CA) + .gtoreq.5- (CA) + .gtoreq.5- (CA) + .gtoreq.5- (CA) +
.gtoreq.5- (CA) + .gtoreq.5- Alloys (CA) 20 wt % (NC) 40 wt % (NB)
40 wt % (NiAl) 40 wt % (SA) 40 wt % (CER) Titanium (TA) +
.gtoreq.5- (TA) + .gtoreq.5- (TA) + .gtoreq.5- (TA) + .gtoreq.5-
Alloys (TA) 20 wt % (NC) 40 wt % (NB) 40 wt % (NiAl) 40 wt % (SA)
Intermetallics (INT) + .gtoreq.5- (INT) + .gtoreq.5- (INT) +
.gtoreq.5- (INT) + .gtoreq.5- (INT) 20 wt % (NC) 40 wt % (NB) 40 wt
% (NiAl) 40 wt % (SA) Ceramics (CER) (CER) + .gtoreq.5- (CER) +
.gtoreq.5- (CER) + .gtoreq.5- (CER) + .gtoreq.5- 20 wt % (NC) 40 wt
% (NB) 40 wt % (NiAl) 40 wt % (SA) *Clad layer over surface of
powder core **Blended
EXAMPLE 3
[0047] Some examples of material combinations which can be used and
representative properties are shown in the following table.
TABLE-US-00005 TABLE 5 Coating Attribute/ Average/ Material state
Property Units typical Minimum Maximum Inconel 718 + as-sprayed
Coating g/cm.sup.3 7.35 7.10 7.60 5% wt. % density Ni-5 wt % Al
Inconel 718 + as-sprayed porosity % 0.6 0.00 2.00 5% wt. % Ni-5 wt
% Al Inconel 718 + as-sprayed Deposition % 72 60.6 89.0 5% wt. %
efficiency Ni-5 wt % Al Inconel 718 + as-sprayed Tensile MPa
Greater than 34 is 5% wt. % strength 36 MPa specified Ni-5 wt % Al
according to lower limit ASTM C 633 Inconel 718 + as-sprayed
Hardness HV300gf 460.30 420 499 5% wt. % (Vickers (kg mm.sup.-2)
Ni-5 wt % Al diamond) Inconel 718 + Annealed Hardness HV300gf 251.6
229 276 5% wt. % (1060.degree. C./2 h (Vickers (kg mm.sup.-2) Ni-5
wt % Al in vacuum) diamond) Inconel 718 + as-sprayed Coating mm 10
0 15 5% wt. % and annealed thickness Ni-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 in any combination, where: q, r,
s, t, x, y, z, u, w=any value between 0 to 50 wt (weight) %
provided that the sum thereof is no greater than 70%.
[0049] Representative nickel alloys useful with the processes
described herein can comprise: Ni (bal.)
+qCr+rAl+sMo+tCo+xMn+xFe+zC+uY+vCu+wSi in any combination, where:
q, r, s, t, x, y, z, u, v =any value between 0 to 50 wt % provided
that the sum thereof is no greater than 70% wt %.
[0050] Representative cobalt alloys useful with the processes
described herein can comprise: Co (bal.) +qCr +rAl +sMo +tNi +xY
+xFe +zC +uCu +wSi in any combination, where: q, r, s, t, x, y, z,
u, wSi =any value between 0 to 50 wt % provided that the sum
thereof is no greater than 70% wt %.
[0051] Representative nickel super alloys useful with the processes
described herein can comprise: INCONEL 718, HASTELLOY (Haynes
International) C276, INCONEL (Special Metals Corporation) 625,
NiCrAl, NiCrAiMo, NiAlMo, NIMONIC.TM.(Special Metals Corporation)
80A, Ni 18Cr 2Ti 1.5A11Si 0.2Cu 3Fe 1 Mn 2Co 0.1 C 0.15Zr, NIMONIC
75, INCONEL 600, INCONEL 617, INCONEL 625, HASTELLOY W, HASTELLOY
N, HASTELLOY X, HASTELLOY C, HASTELLOY B, Haynes 214, Haynes 230,
CMSX-4 alloy, Cobalt based alloys, STELLITE, CoNiCrAlY and/or
NiCrAlY alloys.
[0052] Representative titanium alloys useful with the processes
described herein can comprise: Ti-6Al-4V and all titanium alloy
grades 6 to 38.
[0053] Representative intermetallics useful with the processes
described herein can comprise: NiAl, NiAl.sub.3, Ni.sub.3Al, TiAl,
Ti.sub.3Al, Fe.sub.3Al, Ni.sub.3Si, CrSi.sub.2, MoSi2, NbSi.sub.2,
TaSi.sub.2, VSi.sub.2, and TiSi.sub.2.
[0054] Representative ceramics useful with the processes described
herein can comprise: YSZ, Alumina, tungsten carbides, CrC,
TiO.sub.2, TiO.sub.x=1.7 to 1.9, SiC and powders with a size range
of about 3 to about 120 micrometers mean diameter.
[0055] Representative nickel cladding useful with the processes
described herein can comprise: electroless deposited nickel,
chemically vapor deposited nickel (CVD) or chemically autoclave
clad nickel, nickel metal .gtoreq.97wt. %, cladding thickness
ranges of about 0.2 to about 15 micrometers thick, cladding surface
coverage of a minimum of about 10% of surface area to about 100% of
surface area of powder particle (core).
[0056] Representative nickel powder useful with the processes
described herein can comprise: nickel powder, nickel metal
.gtoreq.97wt. % Ni, and size ranges of about 3 to about 50
micrometers mean diameter.
[0057] Representative nickel-aluminum powders useful with the
processes described herein can comprise: nickel clad aluminum,
typically Ni+xAl where x=about 5 to about 30 wt %, Ni5Al type such
as Diamalloy 4008NS, Metco 450NS, Metco 450P, and Metco 480NS, Ni
20Al type such as Metco 404NS, Metco 1101, and Metco 2101ZB. Also,
NiAlMo such as Ni 5Mo 5.5Al agglomerated (mechanically clad)
powders, e.g. Metco 447NS.
[0058] Representative softer alloys useful with the processes
described herein can comprise: copper and typical alloys of copper:
including: Cu (bal.) +xNi+yAl+zZn+uSn in any combination, where: x,
y, z, u=any value between 0 to about 50 wt % provided that the sum
thereof is no greater than 70 wt %; aluminum and typical alloys of
Al: including: Al(bal.) +xCu+xMg+yMn+zZn+uSi in any combination,
where: x, y, z, u=any value between 0 to about 50 wt % provided
that the sum thereof is no greater than 70 wt %; silver metal
.gtoreq.97wt. % Ag, and silver alloys; zinc metal .gtoreq.97wt. %
Zn and zinc alloys; platinum and palladium metal .gtoreq.97wt. % Pt
or Pd, and Pt and Pd alloys.
[0059] FIG. 2 demonstrates the dynamic impact/contact between the
particles where particle velocity is generally >500 m/s. The
particle size ranges A & B generally are <50 microns. There
will be one or more of a flow (yield) strength mismatch between
materials A and B where: A >B; hardness mismatch between
materials A and B where: A>B; elastic (Young's) modulus mismatch
between materials A and B where: A>B. Generation of friction
heat at interfaces between A & B due to deformation (forging)
processes will be localized mostly in material B.
[0060] In FIG. 3, shows resultant forging and friction welding
where, e.g., Component 1 (A) can be e.g. INCONEL 718, and Component
2 (B), e.g. Nickel or Ni-5Al. Softer shearable second phase
material such e.g. Nickel or Ni-5Al or other soft alloy is
introduced, which deforms/shears easily, generates heat by friction
contact /shear between harder INCONEL 718 particles, for example;
generates heat by friction/exothermic reaction e.g. NiAl. Other
approaches which can also be used are combinations of powders that
either react during spraying or can be diffusion treated post
deposition.
[0061] In FIG. 4, Component 41 can be e.g. INCONEL 718, and
Component 42 can be nickel or nickel-5 Al or other soft alloy. The
softer shearable second phase material such e.g. Nickel or Ni-5Al
or other soft alloy is introduced and: deforms/shears easily
generating heat by friction contact /shear between harder INCONEL
718 particles, and/or generates heat by friction/exothermic
reaction, e.g. NiAl. High shear zone 43 indicates friction heating.
Other approaches which can be used are a combination of powders
that either react during spraying or can be diffusion treated post
deposition.
[0062] In FIG. 5, Component 1 (51) can be, e.g. INCONEL 718 and
Component 2 (52) can be e.g. alumina or YSZ. High shear zone 53
indicates friction heating. This zone can also be generated, e.g.,
by introducing a harder, ceramic, non-shearable second phase
material such e.g. alumina or YSZ, which generates heat by friction
contact /shear between softer INCONEL 718 particles.
[0063] FIGS. 6 and 7 show micrographs of an embodiment of a process
described herein where a INCONEL 718 plus 5% NiAl alloy is applied
by conventional cold gas processing to a substrate (61, not shown
in FIG. 7) utilizing a KINETICS.RTM. 8000 gun (Sulzer Metco), the
coating material (62 and 71) is Sample 1, the porosity is 1.6%, and
the micro hardness is 453 HVO.3 s=32 (ASTM E384).
[0064] FIGS. 8 and 9 show micrographs of an embodiment of a process
described herein where a INCONEL 718 plus 5% NiAl alloy is applied
by conventional cold gas processing to a substrate (81, not shown
in FIG. 9) utilizing a Kinetic 8000 gun, the coating material (82
and 91) is Sample 2, the porosity is 1.5%, and the micro hardness
is 460 HVO.3 s=26.
[0065] FIGS. 10 and 11 show micrographs of an embodiment of a
process described herein where a HASTELLOY C276 plus 5% NiAl alloy
is applied by conventional cold gas processing to a substrate (101,
not shown in FIG. 11) utilizing a Kinetic 8000 gun, the coating
material (102 and 111) is Sample 3, the porosity is 1.2%, and the
micro hardness is 468 HVO.3 s=28.
[0066] FIG. 12 shows some exemplary cold gas spray parameters and
deposition efficiencies (shown in the circles on the graph). See
also Table 6 below using Sample 2.
[0067] FIG. 13 shows an example of a cold gas sprayed coating
microstructure (conventionally etched after coating, e.g, with a
dilute solution of copper sulfate) comprised of INCONEL 718 (131)
with softer outer layer of pure nickel (132) which was clad on
INCONEL 718 particles using a conventional electrochemical coating
method prior to cold gas spraying.
[0068] FIG. 14 shows an example of a cold gas sprayed INCONEL 718
coating (142) deposited onto an INCONEL 718 substrate (141). The
typical composition of the powder used was INCONEL 718 5 wt % Ni5Al
which was cold gas sprayed to a thickness of over 10 mm.
TABLE-US-00006 TABLE 6 Carrier Process Process Deposition Gas Gas
Spray Run Gas Temp. Gas Efficiency Pressure Pressure Distance No.
.degree. C. m.sup.3/hour % (bar) (bar) mm 1 900 94 60 6 40 60 2 900
92 79 10 40 60 3 900 94 65 6 40 40 4 900 92 86 10 40 40 5 950 94 69
6 40 40 6 950 92 90 10 40 40
[0069] Thus, the scope of the invention shall include all
modifications and variations that may fall within the scope of the
attached claims. Other embodiments of the invention will be
apparent to those skilled in the art from consideration of the
specification and practice of the invention disclosed herein. It is
intended that the specification and examples be considered as
exemplary only, with a true scope and spirit of the invention being
indicated by the following claims.
* * * * *