U.S. patent number 3,617,358 [Application Number 04/671,880] was granted by the patent office on 1971-11-02 for flame spray powder and process.
This patent grant is currently assigned to Metco Inc.. Invention is credited to Ferdinand J. Dittrich.
United States Patent |
3,617,358 |
Dittrich |
November 2, 1971 |
FLAME SPRAY POWDER AND PROCESS
Abstract
The flame spraying of the flame spray powder which has been
formed by spray drying of a slip or slurry of fine particles of a
flame spray material. This flame spray powder has individual
particles which are of substantially spheroid shape, of a size
between about 20 mesh and 1 micron, and are formed of multiple
subparticles bound together without fusion by a spray-dried binder
and having a crush resistance of at least 0.7 grams. For the spray
drying, fine particles of any known or conventional flame spray
material or combination thereof, such as metals, ceramics,
carbides, etc., suspended in a slip or slurry of a liquid,
preferably water, with a suitable binder and preferable auxiliary
agents, is atomized into a hot drying gas stream forming the
spheroid larger composite particles.
Inventors: |
Dittrich; Ferdinand J.
(Bellmore, L.I., NY) |
Assignee: |
Metco Inc. (Westbury, L.I.,
NY)
|
Family
ID: |
24696242 |
Appl.
No.: |
04/671,880 |
Filed: |
September 29, 1967 |
Current U.S.
Class: |
427/447; 75/232;
75/240; 75/244; 75/252; 264/12; 264/117; 419/65; 427/450; 427/451;
427/456; 428/328 |
Current CPC
Class: |
C23C
4/04 (20130101); Y10T 428/256 (20150115) |
Current International
Class: |
C23C
4/04 (20060101); B44d 001/097 () |
Field of
Search: |
;117/105.2,93.1,1M,1I,46FS ;264/12,13,117,5,6,7,14
;75/.5,211,.5A,.5AA,.5AB,.5B,.5BA ;29/183.5,192 ;106/1 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Leavitt; Alfred L.
Assistant Examiner: Newsome; John H.
Claims
I claim:
1. A flame spray powder the individual particles of which are of a
substantially spheroid shape having a size between about 1 micron
and minus 20 mesh and formed of multiple subparticles bound
together without fusion by a spray dried binder and having a crush
resistance of at least 0.7 grams, substantially all of said
subparticles having a size of the same order of magnitude below
about 200 mesh.
2. Flame spray powder according to claim 1 having a size between
about 100 mesh and 3 microns.
3. Flame spray powder according to claim 1 in which said binder is
a water-soluble binder.
4. Flame spray powder according to claim 3 in which said binder is
an organic polymer.
5. Flame spray powder according to claim 4 in which said binder is
selected from the group consisting of polyvinyl alcohol, polyvinyl
acetate, gum arabic, carboxy methyl cellulose salts, methyl
cellulose, ethyl cellulose, and polyvinyl butyral dispersions.
6. Flame spray powder according to claim 1 in which said
subparticles are of at least two different flame spray
components.
7. Flame spray powder according to claim 6 having a size of 20 mesh
and 1 micron and in which said subparticles have a size below about
200 mesh.
8. Flame spray powder according to claim 7 in which said binder is
a water-soluble organic binder.
9. Flame spray powder according to claim 8 in which said binder is
selected from the group consisting of polyvinyl alcohol, polyvinyl
acetate, gum arabic, carboxy methyl cellulose salts, methyl
cellulose, ethyl cellulose, and polyvinyl butyral dispersions.
10. Flame spray powder according to claim 1 in which said binder
contains a fluxing material.
11. Flame spray powder according to claim 1 in which said binder
contains a pigment.
12. Flame spray powder according to claim 1 in which said binder is
capable of producing a reducing atmosphere upon thermal
decomposition.
13. Flame spray powder according to claim 1 in which said binder
contains an oxidizing agent.
14. Flame spray powder according to claim 1 in which said binder
contains a material capable of thermally combining with said
subparticles upon flame spraying to form a flame sprayed
coating.
15. Flame spray powder according to claim 1 in which said
subparticles are tungsten carbide subparticles.
16. Flame spray powder according to claim 1 in which said
subparticles are tungsten carbide and cobalt subparticles.
17. Flame spray powder according to claim 1 in which said
subparticles are components of a self-fluxing hard facing
alloy.
18. Flame spray powder according to claim 1 in which said
subparticles are components of mullite.
19. Flame spray powder according to claim 1 in which said
subparticles are of at least two metals capable when melted
together of exothermically reacting to form an intermetallic
compound.
20. Flame spray powder according to claim 19 in which said
subparticles are nickel and aluminum subparticles.
21. Flame spray powder according to claim 1 in which said
subparticles are tungsten carbide and cobalt and said binder is
sodium carboxy methyl cellulose.
22. In the flame spray process in which a flame spray powder is at
least heat-softened in a heating zone and propelled onto a surface
to be coated, the improvement which comprises utilizing a flame
spray powder the individual particles of which are of a
substantially spheroid shape having a size between about 1 micron
and minus 20 mesh, and formed of multiple subparticles bound
together without fusion by a spray-dried binder and having a crush
resistance of at least 0.7 grams.
23. Improvement according to claim 22 in which said binder is an
organic water-soluble binder.
24. Improvement according to claim 22 in which said subparticles
are of at least two different flame spray components.
25. Improvement according to claim 24 in which said components are
metal which exothermically react together at the temperature in the
heating zone forming an intermetallic compound.
26. Improvement according to claim 22 in which said binder contains
material capable of combining with the subparticles at the
temperature in the heating zone to form the flame sprayed
coating.
27. Improvement according to claim 22 in which said subparticles
are selected from the group consisting of tungsten carbide with
cobalt or molybdenum and in which said binder is selected from the
group consisting of carboxy methyl cellulose and polyvinyl
alcohol.
28. A process which comprises spray drying a slip containing fine
particles of a flame spray material and a binder to form
spray-dried aggregate particles having a crush resistance in excess
of about 0.7 gram, passing these spray-dried particles into a
heating zone, heating the particles to at least heat-softened
condition in the zone and propelling the heated particles onto a
surface to form a coating.
29. Process according to claim 28 in which said slip is an aqueous
slip containing an organic water-soluble binder.
30. Process according to claim 29 in which said organic binder is a
member selected from the group consisting of polyvinyl alcohol,
polyvinyl acetate, gum arabic, carboxy methyl cellulose salts,
methyl cellulose, ethyl cellulose, and polyvinyl butyral
dispersions.
31. Process according to claim 28 in which said subparticles have a
particle size below 200 mesh.
32. Process according to claim 28 in which said slip contains fine
particles of at least two different flame spray materials.
33. Process according to claim 32 in which said two different flame
spray materials are materials capable of exothermically reacting
with each other at the temperature in the heating zone to form an
intermetallic compound.
34. Process according to claim 28 in which the slip additionally
contains a material capable of thermally combining with the flame
spray material to form a flame sprayed coating.
35. Process according to claim 28 in which said fine particles of
flame spray material are tungsten carbide and cobalt, and said
binder is sodium carboxy methyl cellulose.
Description
This invention relates to an improved flame spray powder, to a
process for its production, and to a flame spray process utilizing
the same.
Flame spraying involves the feeding of a heat-fusible material into
a heating zone wherein the same is melted or at least heat-softened
and then propelled from the heating zone in a finely divided form,
generally onto a surface to be coated. The spraying is effected
utilizing a device known as a flame spray gun. The material may
initially be in the form of a powder which is designated as a
"flame spray powder," and the guns utilized for spraying the
material initially fed in this powder form are known as
"powder-type flame spray guns." In powder type flame spray guns,
the flame spray powder, usually entrained in a carrier gas, is fed
into the heating zone of the gun which is most commonly formed by a
flame of some type. The powder is either melted or at least the
surface of the grains heat-softened in this zone, and the thus
thermally conditioned particles are propelled onto a surface to
provide the coating. While not required, a blast gas may be
provided in order to aid in accelerating the particles and
propelling them toward the surface to be coated and/or to cool the
workpiece and the coating being formed thereafter. The heat for the
heating zone while most commonly produced from a flame caused by
the combustion of a fuel, such as acetylene, propane, natural gas
or the like, using oxygen or air as the oxidizing agent, may also
be produced by an electric arc flame or plasma flame, or any other
known heating device.
Flame spraying in the initial stages of its commercial development
was mostly used for spraying metals and still is often referred to
as "metallizing," though the same is now used for spraying a much
wider group of materials, including higher melting point or
refractory metals, ceramics, cermets, carbides, and other metal
compounds.
A powdered heat-fusible material in order to be satisfactorily
sprayed and thus considered a "flame spray powder" must have
certain physical characteristics with respect to size, physical
strength, flowability, etc. The powder must be sufficiently
flowable to be passed through the flame spray gun without
difficulty or clogging, and this flowability not only depends on
size, absence of caking materials, such as excess moisture, but on
shape and surface characteristics. In order to produce a
satisfactory coating the powder must have a specific size range, as
for example, between 20 mesh and 1 micron, and preferably between
100 mesh and 3 microns, and the individual particles should not
vary too greatly in their size distribution, i.e., the powder
should be free of excessive fines and larger particles. The
uniformity and quality of the coating formed by flame spraying is
often dependent on the uniformity of size of the individual
particles in the powder. During spraying the kinetic propelling of
the particles and its contact with fluid, including combustion
fluids and propelling fluids, often causes a classifying effect
which adversely affects the homogeneity and uniformity of the
coating, and the presence of excess fines may change the nature of
the coating, producing for example excessive oxides or the
like.
In obtaining suitable commercial flame spray powders extensive
screening and classifying techniques are generally required and
only a relatively small cut of the available powder material is
generally suitable for marketing as a flame spray powder. In most
instances powders are formed by reducing, as for example, milling a
larger mass which results in a rather wide range of particle sizes
which must then be screened to obtain operative size range cuts.
This is generally true, irrespective of the source of the mass
which is milled, including pressed, cast, calendered or extruded
masses.
One object of this invention is the production of an improved flame
spray powder. This and still further objects will become apparent
from the following description read in conjunction with the drawing
which is a flow sheet illustrating the process for producing
powders in accordance with the invention.
In accordance with the invention I have discovered that a superior
and improved flame spray powder may be produced utilizing spray
drying techniques. In accordance with the invention finely divided
flame spray material suspended in a slip or slurry of liquid,
preferably water, with a suitable binder and preferable auxiliary
agents, is atomized and the atomized suspension dried in a hot gas
stream, forming the coarser flame spray powder, the individual
particles of which are of substantially spheroid shape, have a size
between about 20 mesh and 1 micron, and are formed of a multiple
number of subparticles bound together without fusion by the spray
dried binder, and which have a crush resistance of at least 0.7
grams.
As the starting finely divided material utilized in the formation
of the slip, any of the known or conventional flame spray
materials, or any known combination thereof, may be used. In
addition to the conventional metals or alloys or metal mixtures,
which will ultimately form alloys or semialloys when flame sprayed,
there may be mentioned oxides, as for example refractory oxides,
such as alumina A1.sub.2 O.sub.3, Beryllia BeO, Ceria CeO.sub.2,
Chromia CR.sub.2 O.sub.3, cobalt oxide CoO, gallum oxide Ga.sub.2
O.sub.3, hafnia HfO.sub.2, magnesia MgO, nickel oxide NiO, tantalum
oxide TA.sub.2 O.sub.5, thoria ThO.sub.2, Titania TiO.sub.2,
yttrium oxide Y.sub.2 O.sub.3, zirconia ZrO.sub.2, vanadium oxide
VO, niobium oxide NbO, manganese oxide MnO, iron oxides Fe.sub.2
O.sub.3, zinc oxide ZnO; complex aluminates such as BaO.sup..
Al.sub.2 O.sub.3, i.e. BaO.sup.. A1.sub.2 O.sub.3, CeO.sup..
A1.sub.2 O.sub.3, CoO.sup.. A1.sub.2 O.sub.3, Gd.sub.2 O.sub.3
.sup.. A1.sub.2 O.sub.3, K.sub.2 O.sup.. A1.sub.2 O.sub.3, Li.sub.2
O.sup.. A1.sub.2 O.sub.3, Li.sub.2 O.sup.. 5 A1.sub.2 O.sub.3,
MgO.sup.. A1.sub.2 O.sub.3, NiO.sup.. A1.sub.2 O.sub.3, Sr.sub.2
O.sub.3 .sup.. A1.sub.2 O.sub.3, SrO.sup.. A1.sub.2 O.sub.3,
SrO.sup.. 2A1.sub.2 O.sub.3, 2Y.sub.2 O.sub.3 .sup.. A1.sub.2
O.sub.3, ZnO.sup.. A1.sub.2 O.sub.3 ; zirconates such as CaO.sup..
ZrO.sub.2, SrO.sup.. ZrO.sub.2, BaO.sup.. ZrO.sub.2 ; titanates
such as A1.sub.2 O.sub.3 .sup.. TiO.sub.2, 2BaO.sup.. TiO.sub.2,
CaO.sup.. TiO.sub.2, HfO.sub.2 .sup.. TiO.sub.2, 2MgO.sup..
TiO.sub.2, SrO.sup.. TiO.sub.2 ; chromites, such as CaO.sup..
Cr.sub.2 O.sub.3, CeO.sup.. Cr.sub.2 O.sub.3, MgO.sup.. Cr.sub.2
O.sub.3, FeO.sup.. Cr.sub.2 O.sub.3 ; phosphates such as A1.sub.2
O.sub.3 .sup.. P.sub.2 O.sub.5, 3BaO.sup.. P.sub.2 O.sub.5,
3CaO.sup.. P.sub.2 O.sub.5, 3SrO.sup.. P.sub.2 O.sub.5 ; and other
mixed oxides, such as La.sub.2 O.sub.3 .sup.. Fe.sub.2 O.sub.3,
MgO.sup.. Fe.sub.2 O.sub.3, 2MgO.sup.. GeO.sub.2, CaO.sup..
HfO.sub. 2, La.sub.2 O.sub.3 .sup.. 2HfO.sub.2, Nd.sub.2 O.sub.3
.sup.. 2HfO.sub.2, 6BaO.sup.. Nb.sub.2 O.sub.5, Dy.sub.2 O.sub.3
.sup.. Nb.sub.2 O.sub.5, 2MgO.sup.. SnO.sub.2, BaO.sup.. ThO.sub.2,
SrO.sup.. UO.sub.3, CaO.sup.. UO.sub.3, CeO.sub.2 .sup.. Cr.sub.2
O.sub.3 ; silicates such as 3A1.sub.2 O.sub.3 .sup.. 2SiO.sub.2
(mullite), BaO.sup.. 2SiO.sub.2, BaO.sup.. A1.sub.2 O.sub.3 .sup..
2SiO.sub.2 , BaO.sup.. TiO.sub.2 .sup.. SiO.sub.2, 2CaO.sup..
SiO.sub.2, Dy.sub.2 O.sub.3 .sup.. SiO.sub.2, Er.sub.2 O.sub.3
.sup.. SiO.sub.2, ZrO.sub.2 .sup.. SiO.sub.2 (zircon), 2MgO.sup..
SiO.sub.2 , ZrO.sup.. ZrO.sub.2 .sup.. SiO.sub.2 ; carbides, such
as titanium carbide TiC, zirconium carbide ZrC, hafnium carbide
HfC, vanadium carbide VC, niobium carbide NbC, tantalum carbides
TaC, Ta.sub.2 C, chromium carbides Cr.sub.3 C.sub.2, Cr.sub.1
C.sub.3, Cr.sub.23 C.sub.6, molybdenum carbides Mo.sub.2 C, MoC,
tungsten carbides WC, W.sub.2 C, thorium carbides ThC, THC.sub.2 ;
complex carbides, such as WC+ W.sub.2 C, ZrC+ TiC, HfC, NbC, TaC,
or VC, TiC+ HfC, TaC, NbC, or VC; VC+ NbC, TaC, or HfC; HfC+ TaC or
NbC; HbC+ TaC; W.sub.2 WC+ TaC, NbC, ZrC, TiC; WC+ TiC or ZrC; TiC+
Cr.sub.3 C.sub.2 ; TiC+ mo.sub.2 C.
Borides, such as TiB.sub.2, ZrB.sub.2, HfB or HfB.sub.2, borides of
V, borides of Nb, borides of Ta, borides of Cr, borides of Mo,
borides of W, borides of the rare earth metals;
Silicides, such as silicides of Ti eg Ti.sub.5 Si.sub.3
silicides of Zr eg Zr.sub.6 Sr.sub.5
silicides of Hf eg Hf.sub.5 Si.sub.3
silicides of V eg V.sub.3 Si or VSi.sub.2
silicides of Nb eg Nb.sub.5 Sr.sub.3 or NbSi.sub.2
silicides of TA eg Ta.sub.5 Si or TaSi.sub. 2
silicides of Mo eg MoSi.sub.2
silicides of W eg WSi.sub.2
silicides of Cr eg Cr.sub.3 Si or Cr.sub.3 Si.sub.2
silicides of B eg B.sub.4 Si or B.sub.6 Si
silicides of the rare earth metals.
Nitrides such as boron nitrides and silicon nitrides.
Sulfides such as MgS, BaS, GrS, TiS ZrS, ZrS.sub.2, HfS, VS,
V.sub.2 S.sub.3, CrS, MoS.sub.2, WS.sub.2, the various rare earth
sulfides;
Metalloid elements, such as boron, silicon, germanium.
Cermets, such as WC/Co, W.sub.2 C/Co, WC+ W.sub.2 C/Co, Cr/A1.sub.2
O.sub.3, Ni/A1.sub.2 O.sub.3, NiA1/A1.sub.2 O.sub.3,
NiA1/ZrO.sub.2, Co/ZrO.sub.2, Cr/Cr.sub.3 C.sub.2, Cr/Cr.sub.2
O.sub.3, Co/TiC, Ni/TiC, Co/WC+TiC, Cr+Mo/A1.sub.2 O.sub.3, Ni, Fe
and/or their alloys, Cu and/or its alloys such as aluminum bronze,
phosphor bronze, etc., with the disulfides or deselenides of Mo, W,
Nb, Ta, Ti, or V, or boron nitride for "self-lubricating" coatings
with very low friction coefficient.
Cermets which contain an active metal from the group composed of
Ti, Zr, Ta, Cr, etc., or hydrides or other compounds or alloys of
these active metals, which will alloy with the metal phase of the
cermet and promote adhesion of the metal phase to the refractory
phase by promoting "wetting" of the surface of the refractory
phase.
Cermets, for instance those containing a metal and a carbide as the
refractory phase, which also contain free carbon, such as high
purity graphite or the like, which will effectively reduce or
prevent oxidation of the carbide phase and reduce solutioning of
the carbide phase in the metal binder phase.
Mixtures of any desired combinations of these or any known flame
spray material may be used for any purpose, including for the
formation of synergistic composites of the type mentioned in U.S.
Pat. No. 3,254,970 or combinations which will exothermically react
to form an intermetallic compound as disclosed in the aforesaid
patent and U.S. Pat. No. 3,322,515. In addition, combinations which
when flame sprayed, will endothermically react, or combinations or
components which will decompose to form desired coating materials,
as for example carbonates, oxalates, nitrates or oxychlorides which
will decompose to form oxide coatings, as for instance those of
thorium, zirconium, magnesium or yttrium may be used. Furthermore,
mixtures of oxides and metals which react in a redox-type of
reaction, converting a metal to an oxide and an oxide to a metal,
forming metal-oxide mixtures into metal-oxide or
intermetallic-oxide or cermets or the like, as for instance
3NiO+ 2A1 3Ni+A1.sub.2 O.sub.3 or
3NiO+ 5A1 3NiAl+ A1.sub.2 O.sub.3
Cr.sub.2 O.sub.3 + 2A1 2Cr+ A1.sub.2 O.sub.3 or
Cr.sub.2 O.sub.3 + 4A1 2CrAl+ A1.sub.2 O.sub.3
Fe.sub.2 O.sub.3 + 2A1 2Fe+ A1.sub.2 O.sub.3
may be used.
There also may be mentioned mixtures of metal oxides and reducing
agents, metals and nonmetals, such as boron, silicon, nitrogen,
sulfur, phosphorus or the like. Still further, there may be
mentioned metal hydrides alone or in mixture with other materials,
such as metal oxides and the like.
These finely divided components should preferably be in the form of
fine or superfine particles having, for example, a particle size
below 200 mesh and preferably below 325 mesh, and most preferably
below 15 microns.
These fine or superfine particles are then mechanically mixed with
water or another liquid and the binder forming a suspension which
is termed a "slip." The concentration of the fine or superfine
particles in the slip may vary between about 40 weight percent and
99 weight percent, and preferably between 50 weight percent and 98
weight percent.
While water is the preferable liquid used to form the slip, due to
its ready availability, low cost, nonflammability, high evaporation
rate at relatively low temperature, relative inertness and ability
to dissolve or suspend useful binders, it is also possible to use
other liquids, such as hydrocarbon solvents, alcohols or other
organic liquids, alone or in admixture. When using, however,
flammable liquids, care must be taken to avoid combustion or
explosion in the drying.
The slip must additionally contain a binder which is capable of
ultimately binding the subparticles together into the flame spray
particles of the required strength and crush resistance.
As a binder any material which can be dissolved or suspended in the
mother liquid of the slip and which when dried will form a film
and/or adhere to the material being agglomerated, can be used as a
binder providing that the same is sufficiently hard and tenacious
to form an agglomerate of the required strength and hardness. In
general, film-forming organic resins which are soluble in the
liquid of the slip, may be used. Examples of these include
polyvinyl alcohol, gum arabic and other natural gums, carboxy
methyl cellulose salts, polyvinyl acetate, methyl cellulose, ethyl
cellulose, polyvinyl butyral dispersions, protein colloids, acrylic
resin emulsions, ethylene oxide polymers, water-soluble phenolics,
wood extracts such as sodium, ammonium, or calcium lignin
sulfonates, sodium, ammonium, potassium or propylene glycol
alginates, various flour and starches.
Empirically, a potential binder-material combination can be
selected and a small quantity of a test slip formulated, including
in the slip any additive required for specific purpose and
compatible with the binder, i.e., wetting agent, suspending agent,
deflocculents, etc., the need for which is determined by
observation during the mixing and evaluation of the slip. The
binder must not be precipitated from solution by any additive or
the solid; the solids must remain reasonably well suspended and
completely dispersed in the liquid; the slip must not gel nor
should the solids precipitate out as a solid cake; nor should there
by any unusual chemical reaction between ingredients in the slip
such as to result in the evolution of a gas.
A qualitative measure of the effectiveness of the binder in
cementing the particles to each other can be made by drying a film
of the slip on a glass microscope slide and judging the hardness
abrasion resistance of the composite film, the adhesion of the
binder to the solid particles, and, by destructively abrading the
dried film gross segregation of the binder from the solids in
drying. Relative film hardness for various binder concentrations is
very simply determined in this manner.
In addition to organic binders, inorganic binders, such as sodium
silicate, boric acid, borax, magnesium or other soluble carbonates,
nitrates, oxalates, or oxychlorides may be used.
In addition to serving strictly a binding function, binders may be
chosen to perform auxiliary functions, or to impart additional
desirable characteristics to the flame spray powder. Thus, for
example, pigments or dyes may be added to the binder or to the slip
for ultimate incorporation in the dried binder in order to permit
color coding of the flame spray powder. If the flame spray material
is prone to undesirable oxidation when flame sprayed, hydrocarbon
binders may be chosen which will produce a protective inert coating
or reducing atmosphere adjacent the melting or reacting particles
during the flame spraying in order to suppress such oxidation. If
it is desirable to add a further element or prevent loss of an
element in the flame sprayed coating, a binder may be selected
which will perform this function. Thus, a carbon-containing binder,
such as an organic binder, may be used in order to introduce carbon
to form a carbide or to prevent carbon depletion in the spraying of
the carbide. Binders which will decompose to form a reducing
atmosphere or containing reduction agents may be used in connection
with practically all metal or alloy components in order to reduce
the oxide films inherently present on the subparticle surfaces and
thus improve consolidation, bonding, alloying, or reaction between
constituents as the case may be.
The binder may additionally be chosen to rapidly decompose in the
flame generating the gas or vapor in order to, in effect, rapidly
break up the agglomerated flame spray particles in the flame into a
number of smaller consolidated, fused or reacted particles, which
often are desirable for producing denser coatings. Binders may also
be chosen which will decompose in the flame to form a protective
atmosphere adjacent the melting particles in order to minimize or
prevent hardening of susceptible metals, such as molybdenum,
tungsten, tantalum, or niobium by contaminants such as oxygen,
nitrogen, or carbon. Still further, binder materials which act as,
or which contain, fluxes such as sodium silicate, boric acid, borax
or the like, may be used to perform a fluxing function in order to
aid interparticle cohesion, adhesion to the substrate, and produce
a superior coating of lesser porosity and higher hardness.
In the case of spraying of oxides, such as ceramics, undesirable
reduction may be prevented by including an oxidation agent, such as
a nitrite, nitrate, or permangenate, in the binder or in the slip
for depositing with the binder. In general, the binder material
should be present in a concentration in the slip to form ultimate
dried binder content in the particles of up to 10.0 weight percent,
or preferably 0.1 to 5.0 weight percent. For this purpose
concentrations of up to 10.0 weight percent, or preferably from 0.1
to 5.0 weight percent are generally required in the slip, based on
the fine starting powder contained in the slip.
In addition to the fine starting powder material, the liquid and
the binder, the slip may contain auxiliary agents, such as
plasticizers, wetting agents, deflocculants, suspending agents,
preservatives, corrosion inhibitors, antifoam agents or defoamers,
deoxidants and/or oxidizing agents when required. The use of
plasticizers is preferable in connection with binder materials
which form hard, brittle films or which may tend to crack when
drying, as for example sodium carboxymethylcellulose. Examples of
plasticizers include glycerine, ethylene glycol, triethylene
glycol, dibutyl phthalate, diglycerol, ethanolamines, propylene
glycol, glycerol monochlorohydrin, polyoxyethylene aryl ether, etc.
These plasticizers are generally used in amounts of 1 weight
percent to 50 weight percent and preferably 5 weight percent to 30
weight percent, based on the dry binder materials.
Suspending agents may be desirable to prevent premature settling of
the solids in the slip. For this purpose high molecular weight
water-soluble synthetic resins or gums, as for example sodium
carboxymethylcellulose of molecular weight 200,000, methyl
cellulose of molecular weight 140,000, or polymers of ethylene
oxide of molecular weight higher than around 125,000, may be used.
In general, only relatively low concentrations ranging from a few
parts per million to a few weight percent based on the fine
starting powder contained in the slip, are required.
Deflocculating agents may be used to aid in the slip formation and
to prevent agglomeration in the slip. Examples of these include
sodium hexametaphosphate, sodium molybdate, tetrasodium
pyrophosphate, ammonium citrate, ammonium oxalate, ammonium
tartrate, ammonium chloride, monoethylamine, etc. Conventional
amounts as are used in forming suspensions and colloids may be used
which, for example, may range from zero to 1.0 weight percent, and
preferably from 0.05 to 0.2 weight percent.
Wetting agents may also be used to aid in maintaining the solid
suspension in the slip. These are the conventional synthetic
detergents, such as alkylaryl sulfonates, sulfates, soaps, and the
like, which may be used in the conventional quantities, for example
ranging from 1 p.p.m. to 10.0 weight percent.
Certain of the binder materials may be susceptible to bacterial
degradation or mold growth during storage, in which case it may be
desirable to add a preservative to the binder material prior to
incorporation in the slip, or the slip itself. Any of the known or
conventional preservatives, such as sodium benzoate, phenol, or
phenol derivatives, formaldehyde, merthiolate, etc. may be used in
the conventional amounts and generally between about 0.1 and 0.5
weight percent of the initial binder solution. It may be preferable
to use nontoxic preservatives due to the danger of decomposition in
the flame.
In connection with fine powder materials which are susceptible to
corrosion, or in connection with which the binders show a corrosive
action, the binder should additionally contain conventional
anticorrosion agents in conventional amounts.
If the slip tends to foam during its production or during handling,
conventional antifoaming agents or defoamers, may be added in the
conventional amounts, as for example from 0.1 p.p.m. to 200
p.p.m.
Other miscellaneous additives may be included in the slips for
specific effects in the production or handling of the slip the slip
or in the ultimate flame spraying of the powder produced, as for
example chemical activators which will aid in the sintering of high
melting refractory materials. Thus for example chlorine or a
chlorine-generating compound may be added to enhance the sintering
of the carbides. Hydrophobic binders may be used in connection with
MgO as water vapor enhances sintering of this material.
Conventional acids or bases may be added as buffering agents to
control the pH of the slip.
The slip, as mentioned, is simply formed by mechanically mixing the
liquid, fine powder and the additives, with sufficient agitation to
form a uniform suspension.
The slip is then pumped into a conventional spray dryer where it is
atomized and spray-dried. The heavier particles recovered from the
bottom of the tower are used as the flame spray powder while the
smaller particles which are also recovered from the spray drying
may be reconstituted into the slip and again passed through the
device.
Referring to the embodiment shown in the drawing, the slip is made
up in the mixing tank 1, as described, and pumped by the metering
pump 2 to the atomizing head 3 of the spray dryer tower 4.
Atomizing air is passed into the atomizing head 3 from the
compressor 5. The slip is atomized into the fine spray 6. Air is
pumped by the fan or ventilator 7 through the heater 8, as for
example a conventional combustion heater, into the top of the spray
tower and passes downward as is indicated at 9, drying the atomized
slip into the agglomerated flame spray particles which fall the
bottom of the tower and are collected in the collector 10. The gas
is exhausted at 11 through the cyclone separator 12, in which the
finer suspended particles are separated and recovered in the
collector 13. These finer particles may be reconstituted into the
slip by the addition of further liquids, such as water, and
repassed through the device. The spray dryer may be operated in any
of the conventional elevated temperatures and gas flow rates, as
for example drying gas inlet temperatures between about 400.degree.
F. and 800.degree. F. and preferably between 500.degree. F. and
700.degree. F. In the equipment I have used, the liquid slip is
generally evaporated at a rate between 2 and 12 gallons per hour,
and preferably between 2.5 and 8 gallons per hour, based on a
drying gas outlet temperature of 225.degree. F. to 400.degree. F.
and preferably from 250.degree. F. to 350.degree. F.
The flame spray powder in accordance with the invention has a
general overall spheroid shape. Some of the spheroids are somewhat
collapsed, i.e. toroidal or donut shaped, and the term "spheroid"
as used herein and in the claims includes this collapsed form of
the spheroid, as well as other somewhat distorted spheroid shapes.
These powders, as compared with the conventional flame spray
powders, are unusually free flowing and may be handled in all of
the conventional powder type flame spray equipment without
difficulty. The powder may be produced at a substantially lower
cost than was previously possible and quite surprisingly shows
superior characteristics when sprayed, allowing for example a
higher spray rate and a substantially improved deposit efficiency.
The invention further allows almost unlimited possibilities of
combining desired components into integral individual powder
particles, which was not previously possible. The combined
component particles in accordance with the invention show many
advantages over the prior art mixtures or conventional aggregates
or coated powders, having a uniform distribution of the
constituents and very intimate and close contact with each other.
In the spraying process this allows complete alloying, solutioning,
or reacting of the components, allowing the formation of a much
more homogeneous and uniform coating. When, for example, the
constituents of the composite particles are materials which will
form a a cermet, the ceramic and other phases of a very fine size
are uniformly distributed. Furthermore, coatings produced from the
spray dried powder particles in accordance with the invention often
show higher density and abrasion resistance than those produced by
the conventional powders of the same type. The unusual
characteristics and flowability not only allow for better handling
in the flame spray equipment but also allow for better screening
and classification in order to obtain extremely uniform size
cuts.
While the powders may generally be used as produced, with the
binders remaining soluble in the particular liquid solvent of the
slip from which they were formed, it is also possible to
insolubilize same by a curing, cross-linking, or tanning treatment.
Thus, for example the particles may initially be treated with a
dilute alcoholic solution of chromic nitrate followed by removal of
the excess solution and drying. Insolubilization may also be
effected by treatment with concentrated solutions of dichromates,
followed by exposure to actinic, such as ultraviolet light. The
dichromates may, for example, by any of the alkaline or metal
dichromates, such as ammonium, sodium, potassium or cupric.
Insolubilization may also be effected by treatment with copper
ammonium hydroxide, as for example prepared from copper sulfate,
ammonium hydroxide, and sodium hydroxide.
It is critical that the individual spray-dried powder particles in
accordance with the invention have a crush resistance of at least
0.7 grams. This crush resistance is simply measure of the weight
that individual particles will support before the same are broken,
crushed or destroyed. This crush strength is most simply determined
by placing an individual particle on anvil and determine the
maximum weight that the same will support while remaining intact. I
have found that this crush resistance can be most accurately
determined with the use of an analytical balance as follows:
The compressive strength tester is a modified analytical balance on
which the pan on one side was replaced by an anvil atop the
horizontal beam and a counterweight, the sum weight of which
exactly equalled the weight of the pan removed. A shallow
depression on the upper surface of the anvil allows precise
orientation of the particle to be tested. An adjustable platen is
mounted above and closely adjacent to the anvil surface; the height
is adjusted such that, with the particle to be tested in position,
the zero-indicating arm of the balance is at zero on the reference
scale when the particle is just contacting the platen face.
The load is then applied gradually and without shock by unwinding a
fine chain from a calibrated rotating cylinder into the other pan
of the balance, the calibrations showing the weight of chain
deposited on the pan.
Compressive failure of the particle is indicated by movement of the
zero-indicating arm relative to the reference scale. The weight of
chain required to do this is directly read from the calibrated
cylinder.
The particles must thus be substantially stronger and have a higher
crush resistance than powders produced for most powder metallurgy
purposes where the same are to be pressed into shapes or forms.
Particles, such as ceramic particles intended for initial press
forming, must have a relatively low crush resistance in order to be
pressed into a green form of uniform consistency.
In addition to being sprayed per se in any of the known or
conventional manners for flame spraying using any of the known or
conventional powder-type flame spray equipment, the powder in
accordance with the invention may, of course, be sprayed in any
desired mixture or combination with other powder produced in
accordance with the invention or any known or conventional flame
spray powder.
The following examples are given by way of illustration and not
limitation:
EXAMPLE 1
Tungsten Carbide-cobalt Cermet Powder
Tungsten carbide (WC) powder of 1.3-1.6 micron average Fisher
subsieve Size (FSS) particle size and metallic cobalt powder of 2
micron average (FSS) particle size were blended in the proportion
88 weight percent WC: 12 weight percent Co. The blend of materials
was then dry ball milled according to standard practice in the
industry, so that the cobalt was smeared onto the WC particles and
each WC particle was, in effect, clad with cobalt.
A gum arabic binder was dissolved in water to form a concentrated
solution containing 30 weight percent gum arabic and 70 weight
percent water. Phenol in the proportion of 0.05 weight percent,
based on the total weight of the solution, was added as a
preservative for the binder concentrate.
Sodium carboxy methyl cellulose of very high (approximately
200,000) molecular weight was used as a suspending agent. A
concentrated solution, 1.4 weight percent of CMC and 98.6 weight
percent of water, was prepared in advance.
Sodium hexametaphosphate (Calgon) was used as a dispersing and
deflocculating agent. A concentrated solution, 25 weight percent of
the solid in 75 weight percent of water, was prepared in
advance.
Sodium lauryl sulfate (Proctor and Gamble Orvus WA Paste, 34 weight
percent solids in H.sub.2 O) was used as a wetting agent. Because
of its high efficiency and the need in p.p.m. only, dilute solution
was prepared by dissolving 0.3 g. of the commercial paste in 100 g.
of water, resulting in a solids concentration of 0.1 g. per 100
grams of water.
A slip was formulated according to the following table, using the
prepared concentrates described above, where applicable, and in the
proportions indicated.
---------------------------------------------------------------------------
TABLE
Total Wt. Wt. Wt. Added Addition Solids Liquid %
__________________________________________________________________________
9000 g. Ball milled WC/Co blend 9000 g. 90 300 g. Binder at 30%
solids 90 g. 210 g. 1 360 g. CMC at 1.4 wt.% solids 5 g. 355 g. 36
g. Calgon at 25 wt.% solids 9 g. 27 g. 0.1 65 g. Wetting agent at
0.1 wt.% solids 0.065 65 g. 9104.07 657 360 g. Water 1017 360 10
10121 1017
__________________________________________________________________________
In blending the ingredients to form the slip, all liquids and
solutions were first weighted into the mixing tank with the mixer
running. The dry powder was then fed into the mixing tank such that
deflocculation occurred immediately, and after a short mixing time,
the slip was uniform in consistency. At this point, pH was measured
and adjusted to pH 7.4 by buffering with phosphoric acid, and
samples were taken for viscosity and specific gravity measurements.
Specific gravity was 5.5 g./m. Deflocculation of the powder was
complete so that screening of the slip was not required. The slip
was spray dried in a Laboratory Tower Spray Dryer (LT-04-1/2) as
manufactured by Bowen Engineering Inc., North Branch, New Jersey
08856. The rated capacity of this dryer was approximately 20
lb./hr. of chamber product based on drying an A1.sub.2 O.sub.3 slip
containing 60 percent to 70 percent by weight of solids together
with a suitable binder system; the chamber product consists of
approximately 75 percent of the total product, the remaining 25
percent being deposited in the cyclone collector and usually
consists of fines. Heated air was introduced in a cyclonic flow
pattern at the top of a vertical straight-cylindrical drying
chamber. The slip is atomized into droplets near the bottom of the
drying chamber and directed upwards along the vertical centerline
by a blast of compressed air. The particles travel twice through
the drying chamber - upwards against the flow of heated air and
then downward to the bottom, and then settle by gravity into a
collecting receptacle.
Approximately 10,000 grams of slip were fed by pumping into the
atomizing nozzle from which the atomized slip was propelled through
the drying chamber, to be finally collected in the chamber and
cyclone collectors as a dry powder. The following machine
parameters were used:
Slip Feed Rate Approximately 180 ml./minute Inlet Gas Temp.
550.degree. F. Outlet Gas Temp. 273.degree. F. Type Heat Direct Gas
Atomizer Type Countercurrent SW Nozzle Atomizer Description 9-02B
Atomizing Air Pressure 40 p.s.i. Atomizing Air Flow approximately
15 SCFM
approximately 6,500 g. of the 9000 g. of powder blended in the slip
was collected as finished product in the chamber and cyclone
collectors. The other 2500 g. was loss in the mixing tank, feed
tank, feed lines, density test, etc. which proportionately high
losses are peculiar to the Laboratory feed unit and the small
quantities of material processed, and could have been recovered for
reuse. The result was a free flowing powder having essentially
spheroid particles. The chamber product was 91 percent of the total
collected and had a particle size distribution as follows:
Screen Size Weight Percent
__________________________________________________________________________
+ 140 6.0 -140 + 170 4.9 -170 + 200 9.9 -200 + 230 6.9 -230 + 270
3.2 -270 + 325 14.5 -325 54.3
__________________________________________________________________________
The cyclone product was 9 percent of the total collected and was
essentially -325 mesh size. The Hall (ASTM B-213-48 (1965)) Flow
Rate of the -140 +325 mesh size cut of the chamber product was 2.96
g./second and the apparent density (not vibrated) was 3.94 g./ml.
The Hall Flow Rate of the -325 mesh cut of the chamber product was
2.99 g./second and the apparent density (not vibrated) was 3.80
g./ml. Compressive strength of -60 +80 mesh particles was 10.0
grams.
A -325 mesh cut from the chamber product was flame sprayed, using a
Metco Type 2M plasma flame spray gun, using argon plasma gas at
100p.s.i., 100 SCFH, hydrogen plasma gas at 50 p.s.i., 2.5 SCFH,
and argon carrier gas at 100p.s.i., 15 SCFH. With a Type ES nozzle,
input power was 500 amperes at 43 volts, spray distance was 3
inches, and the spray rate was 8.2 lb/hour.
The same powder was flame sprayed with the same equipment except
using a Type E nozzle and using nitrogen plasma gas at 50 p.s.i.,
150 SCFH flow, hydrogen plasma gas at 50p.s.i., 10 SCFH flow, and
nitrogen carrier gas at 50 p.s.i., 15 SCFH flow. Input power was
300 amperes at 73 volts, spray distance was 3 inches, and the spray
rate was 9.4 lb./hr.
The same powder was flame sprayed using a Metco Type 5 P
ThermoSpray gun with a type P7G nozzle, -12 powder flow meter
valve, at 4-5 spray distance, using hydrogen at 31 p.s.i., 315
SCFH, and oxygen as the combustion supporting and carrier gas at 31
p.s.i., 54 SCHFH. The spray rate was 8.7 lb./hr. of powder.
In all 3 cases above, excellent, hard, dense, adherent, and
wear-resistant coatings were deposited.
50 weight percent of the -140 +325 mesh cut of the chamber product
was blended with 50 percent of a -140 +325 mesh cut of a
conventional spheroid powder of the self-fluxing, hard-facing,
alloy type, to make a powder blend equal in proportion and
chemistry to Metco 31C, which uses conventional cobalt-bonded
tungsten carbide powder of the same chemistry and particle size
range as the spray dried material. The blended material was flame
sprayed, using a Metco Type 2 P ThermoSpray gun with a Type P7
nozzle, 2 powder flow meter valve, using acetylene at 10 p.s.i., 25
SCFH, and oxygen at 12 p.s.i., 35 SCFH, with acetylene as the
carrier gas, and at 9.5 lb./hr. After post deposition fusing, the
resultant coating was a fully fused, pore-free, homogeneous mixture
of the coating ingredients and fully fused to the substrate.
A powder similar to that of the 31C (previous example) except
containing 80 weight percent of the spray dried WC/Co powder and 20
weight percent of the self-fluxing, hard-facing powder, was flame
sprayed in the same manner as in the previous example except that,
after deposition of the coating, a subsequent overcoating of the
self-fluxing, hard-facing alloy alone was deposited in thickness
equal to 20 percent to 25 percent of the first coating. The coating
system was then fused, the overcoat material being absorbed by the
first coating during the fusing, to effectively fill all of the
pores and weld the whole to the substrate. The result was a
homogenous mixture of the coating ingredients, very high in WC
content, and fully fused to the base.
In each of the last two spraying examples cited, the result was a
coating which showed a superior grind finish, lower porosity, and
equal wear-resistance and other characteristics to its conventional
counterpart.
EXAMPLE 2
Tungsten Carbide - Cobalt Cermet Powder
Tungsten carbide powder of 1.3-1.6 micron average (FSS) particle
size and metallic cobalt powder of 2 microns average (FSS) particle
size were blended in a simple mixture, in the proportion 88 weight
percent WC: 12 weight percent Co., for incorporation in a slip as a
simple mixture of powders. The preblending was accomplished as a
convenience only in preparing powders for a number of experimental
batches; but could be added to the slip without prior mixing.
The binders, suspending agents, deflocculent (dispersing agent)
agent) and wetting agent, etc. were prepared for use in
concentrated solutions, the same as in example 1.
A slip was formulated according to the following table, using the
prepared concentrates where applicable, and in the proportions
indicated.
---------------------------------------------------------------------------
TABLE
Total Wt. Wt. Wt. Added Addition Solids Liquid %
__________________________________________________________________________
4700 g. Mixed WC/Co powder 4700 g. 157 g. Binder at 30% solids 47
g. 110 g. 1 20 g. Calgon at 25 % solids 5 g. 15 g. 190 g. CMC at
1.4 % solids 2.7 187 g. 30 g. Wetting agent at 0.1 weight percent
solids 30 g. 4754.7 g. 342 g. 491 g. Water 833 491 14.9 5587.7 g.
833
__________________________________________________________________________
The slip was blended in the same manner as described in example 1.
Specific gravity of the slip was 3.84 g./ml.
The slip was spray dried in the same equipment and in the same
manner as described in example 1.
The following machine parameters were used:
Slip Feed Rate Approximately 120 ml./min. Inlet Gas Temp.
465.degree. F. Outlet Gas Temp. 275.degree. F. Type Heat Direct Gas
Atomizer Type Countercurrent SW Nozzle Atomizer Description 9-02B
Atomizing Air Pressure 30 p.s.i. Atomizing Air Flow Approximately
15 SCFM
approximately 3,900 g. of the 4,700 g. of powder blended in the
slip was recovered as finished product in the chamber and cyclone
collectors. The result was a free-flowing powder having essentially
spheroid particles. The chamber product comprised 84 percent of the
total collected and had a particle size distribution as
follows:
Screen Size Weight Percent
__________________________________________________________________________
+140 15.7 -140 + 170 6.8 170 + 200 12.5 -200 + 230 5.5 -230 + 270
3.5 -270 + 325 14.5 -325 41.5
__________________________________________________________________________
The cyclone product comprised 16 percent of the total collected and
was essentially -325 mesh size. The Hall Flow Rate of the -140+ 325
mesh size cut of the chamber product was 1.95 g./second and the
apparent density (not vibrated) was 2.62 g./ml. Compressive
strength of - 60+ 80 mesh particles was 17.0 grams.
A -325 mesh cut from the chamber product was flame sprayed with the
Metco Type 2M plasma flame spray gun, using the argon/hydrogen and
nitrogen/hydrogen plasma gases, and with the Metco Type 5P
ThermoSpray gun as described in example 1. In all three cases
excellent hard, dense, adherent, and wear-resistant coatings were
deposited.
50/50 and 80/20 weight percent mixtures of the spray dried WC/Co
powder and conventional self-fluxing, hard-facing alloy powders
were blended and flame sprayed according to the procedure described
in example 1. The results were essentially identical. The sprayed
coatings as compared to conventional sprayed coatings of the same
material had smaller pores and more uniform distribution of
deposited particles and crystallites.
EXAMPLE 3
Self-Fluxing, Hard-Facing Alloy Powder
The binders, suspending agents, wetting agents, and deflocculent
were prepared for use in concentrated solutions and/or dispersions
as described in example 1, or used dry. The plasticizer, glycerin,
was a liquid as received.
A slip was formulated according to the following table, using the
prepared constituents where applicable, and in the proportions
indicated. The "powder" was of the following composition:
Ferrosilicon 8.0 weight percent Chromium Boron 18.2 weight percent
Blocking Chrome 1.5 weight percent Electrolytic Chrome 4.0 weight
percent Graphite 0.94 weight percent Nickel Balance
TABLE
Total Wt. Wt. Wt. Added Addition Solid Liquid %
__________________________________________________________________________
2100 g. "Powder" 2100 g. 78 330 g. CMC at 10% solids 33 g. 297 g.
20 g. Glycerin 20 g. 15 g. Wetting agent at 0.1 weight percent
solids 15 g. 2 g. Ammonium Tartrate, dry 2 g. 2135 332 270 g. Water
602 270 22 2737 602
__________________________________________________________________________
The ingredients for the slip were blended together in the manner
described in example 1. Specific gravity of the slip was 3.03
g./ml.
The slip was spray dried in the same equipment and in the same
manner as described in example 1. The following machine parameters
were used:
Slip Feed Rate 90 ml./minute Inlet Gas Temp. 510.degree. F. Outlet
Gas Temp. 300.degree. F. Type Heat Direct Gas Atomizer Type
Countercurrent SW Nozzle Atomizer Description 9-02B Atomizing Air
Pressure 30 p.s.i. Atomizing Air Flow Approximately 15 SCFM
approximately 1,100 g. of the 2,100 g. of powder blended in the
slip were recovered as finished product in the chamber and cyclone
collectors. The result was a free-flowing powder having essentially
spheroid particles. The chamber product comprised 81 percent of the
total product and had a particle size distribution as follows:
Particle Size Weight Percent
__________________________________________________________________________
+140 29.8 -140 +170 7.0 -170 +200 8.1 -200 +230 5.7 -230 +270 3.9
-270 +325 10.5 -325 36.2
__________________________________________________________________________
The cyclone product comprised 19 percent of the total product and
was essentially -325 mesh. The Hall Flow Rate of the -140+ 325
particle size cut of the chamber product was 1.24 g./second and the
apparent density (not vibrated) was 1.66 g./ml. The Hall Flow Rate
of the -325 mesh cut of the chamber product was 0.86 g./second and
the apparent density (not vibrated) was 1.68 g./ml. Compressive
strength of -60+ 80 mesh particles was 6.0 grams.
The - 140+325 cut of the chamber product was flame sprayed, using a
Metco Type 5P ThermoSpray gun with a Type P7G nozzle, -11 powder
flow meter valve, at 7 inches spray distance using acetylene as the
combustible and carrier gas at 12 p.s.i., 33 SCFH, and oxygen at 21
p.s.i., 60 SCFH. The spray rate was 9.2 lb./hr. After deposition of
the coating on the mild steel substrate, which previously had been
grit-blasted to improve adhesion of the as-sprayed coating, the
whole was heated to around 1,900-2,000.degree. F. to fuse the
particles in the coating to each other and the coating to the
substrate. Melting and coalescence of the coating was apparent by
the formation of a layer of slag on the surface. Upon and during
cooling to room temperature, the slag layer spalled off exposing
the bright, smooth surface of the hard, wear-resistant overlay
which was welded to the substrate.
The -325 cut of the chamber product was flame sprayed the same as
the previous - 140+325 cut except that a Type P7B nozzle was used
and cooling air surrounded the flame of the gun. Spray rate was 7
lb./hr. Upon heating the deposited layer to around
1,900-2,000.degree. F. to fuse the coating particles to each other
and to the substrate, melting and coalescence was apparent by the
formation of a thin layer of slag on the surface which coalesced
into beads and permitted an excellent "shine" to be observed. The
result was a smooth, even layer of a hard, wear-resistant overlay
which was welded to the substrate.
The composition of the alloy fused to the substrate surface was
typically:
C 0.7- 1.0 wt. % Cr 16- 18 Si 3.5-4.5 wt. % Ni+Co Balance B 2.75-
3.75 wt. % Others 1.0 Max. Fe 3.5-4.5 wt. %
EXAMPLE 4
Composite Mullite Powder
Fine Mullite, 3A1.sub.2 O.sub.3 .sup. . 2SiO.sub.2, can be formed
into particles suitable for flame spraying by the spray drying
method, by agglomerating fine particles of mullite per se. It can
also be formed as a composite by combining available and cheap
commodity raw materials, such as superfine molochite and high
purity A1.sub.2 O.sub.3 in the correct proportion in the spray
dried powder. Molochite is a naturally occurring mineral of the
following typical composition:
SiO.sub.2 54-55 percent
A1.sub.2 O.sub.3 42-43 percent
Others 1.5- 2 percent
Mullite, theoretically, is 71.80 weight percent A1.sub.2 O.sub.3
and 28.20 weight percent SiO.sub.2. Therefore 50.8 weight percent
molochite and 49.2 weight percent A1.sub.2 O.sub.3 should result in
the theoretical chemistry of mullite.
The binders, suspending agents, deflocculants, wetting agents, etc.
were prepared in concentrated solutions, the same as in example
1.
A slip was formulated according to the following table, using the
prepared concentrates where applicable, and in the proportions
indicated:
TABLE
Total Wt. Wt. Wt. Added Addition Solids Liquid % 1016 g. Superfine
Molochite 1016 g. 70 984 g. Al.sub.2 O.sub.3 984 g. 67 g. Polyvinyl
Alcohol at 30 % solids 20 g. 47 g. 1 12 g. Daxad - 30 at 25% solids
3 g. 9 g. 0.15 2023 56 808 g. Water 867 808 30 2890 864
__________________________________________________________________________
The slip was blended in the same manner as described in example 1.
Specific gravity of the slip was 1.7 g./ml.
The slip was spray dried in the same equipment and in the same
manner as described in example 1. The following machine parameters
were used:
Slip Feed Rate Approximately 110 ml./minute Inlet Gas Temperature
600.degree. F. Outlet Gas Temperature 300.degree. F. Type Heat
Direct Gas Atomizer Type Countercurrent SW Nozzle Atomizer
Description 9-02 B Atomizing Air Pressure 50 p.s.i. Atomizing Air
Flow Approximately 15 SCFM
approximately 1,400 g. of the 2,000 g. of powders blended in the
slip were recovered as finished product in the chamber and cyclone
collectors. The result was a free-flowing powder having essentially
spheroid particles, each one of which was an homogenous mixture of
molochite and A1.sub.2 O.sub.3 in the proportions blended in the
slip. The chamber product comprised 79 percent of the total product
and had a particle size distribution as follows:
Screen Size Weight %
__________________________________________________________________________
+200 46 -200 +325 28 -325 26
__________________________________________________________________________
The cyclone product comprised 21 percent of the total product and
had a particle size distribution as follows:
Screen Size Weight %
__________________________________________________________________________
+200 9 -200 +325 14 -325 77
__________________________________________________________________________
Compressive strength of -60.degree. 80 mesh particles was 2.5
grams.
Various particle size cuts of the chamber product were flame
sprayed with the Metco Type 2 P and Type 5 P ThermoSpray Guns, and
with the Metco Type 2 M plasma flame gun. The following table lists
the operating parameters: ##SPC1##
The following table compares spray rates and deposit efficiencies
for spray dried composite mullite powder as compared with Metco
XP1146 conventional mullite powder. The conventional material was
heavily contaminated with metal, and the spray dried mullite
coatings produced were vastly superior to the conventional mullite
coatings. ##SPC2##
Optimum particle size based on the spray rates and deposit
efficiencies for ThermoSpray equipment is either -325 or -270 mesh,
and for plasma flame is -230 or -270 mesh. The poor flowability of
the conventional powder (based on spray rate for equivalent feed
conditions) is also readily apparent from the data shown in the
above table. With plasma flame, the spray dry spray rate was 2.8
times that of the conventional material and deposit efficiency,
even at the higher rate, is 1.46 times that of the conventional
material. With the ThermoSpray 2 P, feed rate was 3.2 times that of
the conventional material and deposit efficiency is slightly more
than twice that of the conventional material. With ThermoSpray 5 P,
feed rate was up to 5 times that of the conventional material and
deposit efficiency is more than twice that of the conventional
material, even at the vastly higher spray rate.
EXAMPLE 5
Nicket-Aluminum Exothermic Composites
Nickel-aluminum composites corresponding to the known Metco 404
(nominally aluminum clad with 80 weight percent Ni) and Metco 450
powder (nominally Ni clad with 5 weight percent Al) can be
manufactured using this method. Ni-Al powders containing 5 weight
percent Al and 7.5 weight percent Al have been manufactured by
spray drying. The spray dried composites result in the formation of
an homogenous reaction product by virtue of the homogenous mixture
of very fine particles.
Carbonyl nickel, 3-5 microns average particle size, and high purity
spheroid Al powder, 3.5-4.5 microns, were blended in the slips in
the proportion required to produce the desired composites. While
the 7.5 weight percent Al powder is used as a specific example, it
is understood that the Ni:Al proportion can be anything between
99.5 weight percent Al and 0.5 weight percent Al, depending on the
reaction product and the properties desired.
The binders, suspending agents, deflocculent, wetting agent, etc.,
were prepared for use in concentrated solutions, the same as in
example 1.
A slip was formulated according to the following table, using the
prepared concentrates where applicable, and in the proportions
indicated:
TABLE
Total Wt. Wt. Wt. Added Addition Solids Liquid %
__________________________________________________________________________
3700 g. Carbonyl Nickel 3700 g. 300 g. Spheroid Al 300 g. 36 g.
PVAc at 55 wt. % solids 20 g. 16 g. 0.5 37 g. PVAc at 55 wt. %
solids 20 g. 17 g. 0.5 16 g. Calgon at 25 wt. % solids 4 g. 12 g.
40 g. CMC at 1.4 wt. % solids 0.5 g. 40 g. 4044. 85 g. 600 g. Water
685 600 14.5 4729 685
__________________________________________________________________________
The slip was blended in the same manner as described in example 1.
Specific gravity of the slip was 2.93 g./ml.
The slip was spray dried in the same equipment and in the same
manner as described in example 1.
The following machine parameters were used:
Slip Feed Rate Approximately 150 ml./minute Inlet gas temperature
550.degree. F. Outlet gas temperature 300.degree. F. Type Heat
Direct gas Atomizer Type Countercurrent SW Nozzle Atomizer
Description 9-02 B Atomizing Air Pressure 25 p.s.i. Atomizing Air
Flow Approximately 15 SCFM
approximately 3,500 g. of the 4,000 g. of powder blended in the
slip were recovered as finished product in the chamber and cyclone
collectors. The result was a free-flowing powder having essentially
spheroid particles. The chamber product comprised 92.5 percent of
the total collected and had a particle size distribution as
follows:
Mesh Size Weight Percent
__________________________________________________________________________
+140 21.3 -140 +170 10 -170 +200 12.5 -200 +230 2 -230 +270 9 -270
+325 17 -325 28.5
__________________________________________________________________________
The cyclone product comprised 7.5 percent of the total and was
essentially -325 mesh.
Compressive strength of -60+ 80 mesh particles was 3.6 grams.
The -170.degree. 325 cut of the chamber product was flame sprayed
with a Metco Type 2 P ThermoSpray gun, using a Type P7 nozzle,
acetylene as the combustible and carrier gas at 10 p.s.i., 25 SCFH,
and oxygen at 12 p.s.i., 35 SCFH. Spray rate was approximately 6
lb./hr. The nickel and aluminum particles in the composite particle
combined exothermically in the flame to produce an homogenous
particle consisting of the nickel aluminides, the heat generated
aiding in making the particles self-bonding to the clean, smooth
surface of the steel substrate. There was practically no "smoke"
produced in spraying the spray-dried powder. In the standarized
*
EXAMPLE 6
Nickel-aluminum Exothermic Composites
Example 5 was repeated except that the Ni and Al were combined in
the proportion 5 weight percent Al: 95 weight percent Ni, with
identical result.
Compressive strength of -60+ 80 mesh particles was 3.1 grams.
EXAMPLE 7
Molybdenum Powder
Molybdenum powder of less than 8 microns maximum, approximately 5
microns average particle size, was agglomerated by spray drying
into a powder, from which particle sizes desirable for spraying
could be separated.
The binders, suspending agents, deflocculent, etc. were prepared in
concentrated solutions for use the same as in example 1. A slip was
formulated according to the following table, using the prepared
concentrates, where applicable, and in the proportions indicated:
---------------------------------------------------------------------------
TABLE
Total Wt. Wt. Wt. Added Addition Solids Liquid %
__________________________________________________________________________
4000 g. Molybdenum Powder 4000 g. 87.5 133 g. Gum Arabic at 30 %
solids 40 g. 93 g. 1 16 g. Calgon at 25 % solids 4 g. 12 g. 0.1 40
g. Polyox at 1/2 wt. % solids 0.2 40 0.012 4044.2 145 g. 440 g.
Water 585 440 g. 12.5 4629 585 g.
__________________________________________________________________________
The slip was blended in the same manner as described in example 1.
Specific gravity of the slip was 4.50 g./ml.
The slip was spray dried in the same equipment and in the same
manner as described in example 1. The following machine parameters
were used:
Slip Feed Rate 120 ml./minute Inlet Gas Temperature 450.degree. F.
Outlet Gas Temperature 275.degree. F. Type Heat Direct Gas Atomizer
Type Countercurrent SW Nozzle Atomizer Description 9-02 B Atomizing
Air Pressure 20 p.s.i. Atomizing Air Flow Approximately 15 SCFM
approximately 2,600 g. of the 4,000 g. of powder blended in the
slip were recovered as finished product in the chamber and cyclone
collectors. The result was a free-flowing powder having essentially
spheroid particles. The chamber product comprised 90 percent of the
total product collected and had a particle size distribution as
follows:
Screen Size Weight Percent
__________________________________________________________________________
+140 271/2 -140 +170 101/2 -170 +200 12 -200 +270 12 -270 +325
131/2 -325 241/2
__________________________________________________________________________
The cyclone product comprised 10 percent of the total product
collected and had a particle size distribution as follows:
Screen Size Weight Percent
__________________________________________________________________________
+140 Trace -140+ 170 Trace -170+ 200 Trace -200++270 Trace -270+
325 64 -325 351/2
The Hall Flow Rate of the -170+ 325 cut of the chamber product was
2.25 g./second and the apparent density (not vibrated) was 2.8
g./ml. The -325 cut of the chamber product did not flow smoothly
without vibration, so an accurate test of the flow rate could not
be made; the apparent density (not vibrated) was 2.48 g./ml.
Compressive strength of the -60+ 80 mesh particles was 1.3
grams.
The -170+ 325 cut of this and other similar molybdenum powders were
flame sprayed with the Metco 2P and Metco Type 5P ThermoSpray Gun
and the Metco Type 2M plasma flame gun, using spray parameters
previously described.
Some of the other Mo powders manufactured using the spray dry
equipment included, in addition to the 1 weight percent gum arabic
binder, another with 1.6 weight percent gum arabic binder, one-half
weight percent, 1 weight percent, 2 weight percent, 3 weight
percent polyvinyl alcohol binder, and 1 weight percent sugar
binder.
The following table shows spray rates and deposit efficiencies
achieved with several types of equipment flame spraying spray dried
and conventional molybdenum powders: ##SPC3##
The following table shows pertinent data regarding the effect of
binder proportion on the Hall Flow Rate, Apparent Density, Spray
Rate and Deposit Efficiency for a group of powders. Spray tests
were with the Type 2P ThermoSpray gun, -170+ 325 mesh powder, and
deposit efficiencies have been corrected for binder burnout.
##SPC4##
EXAMPLE 8
Zirconia Powder
Lime stabilized zirconia (ZrO.sub.2) powder, containing
approximately 5 weight percent of CaO to stabilize the crystal
structure in thermal cycling, of less than 10 microns maximum
particle size and approximately 3 microns average particle size,
was agglomerated by spray drying into a powder from which particle
sizes desirable for flame spraying could be separated. While the
"prealloyed" powder is used in this example, it is understood that
the spray dried particles could contain ZrO.sub.2 plus CaO in the
form of one of its many compounds, including calcium zirconate in
the correct proportion, such that the CaO content of the
agglomerated and sprayed powder would be the desired amount.
The binders, suspending agents, deflocculents, etc. were prepared
in concentrated solutions for use the same as in example 1. A slip
was formulated according to the following table, using the prepared
concentrates where applicable, and in the proportions
indicated.
Total Wt. Wt. Wt. Added Addition Solids Liquid %
__________________________________________________________________________
3000 g. Zirconia Powder 3000 g. 72 100 g. PVA at 30% Solids 30 g.
70 g. 1 12 g. Calgon at 25% Solids 3 g. 9 g. 0.1 7.5 g. CMC (dry)
7.5 0.25 3040.5 79 g. 1103 g. Water 1182 1103 28 4222 1182
__________________________________________________________________________
The slip was blended in the same manner as described in example 1.
Specific gravity of the slip was 2.04 g./ml.
The slip was spray dried in the same equipment and in the same
manner as described in example 1. The following machine parameters
were used:
Slip Feed Rate Approximately 150 ml./minute Inlet Gas Temperature
500.degree. F. Outlet Gas Temperature 275.degree. F. Type Heat
Direct Gas Atomizer Type Countercurrent SW Nozzle Atomizer
Description 9- 02B Atomizing Air Pressure 40 p.s.i. Atomizing Air
Flow Approximately 15 SCFM
approximately 2,150 g. of the 3,000 g. of powder blended in the
slip were recovered as finished product in the chamber and cyclone
collectors. The result was a free flowing powder having essentially
spheroid particles. The chamber product comprised 81 percent of the
total product collected and had a particle size distribution as
follows:
Screen Size Weight Percent
__________________________________________________________________________
+140 14.5 -140 + 170 8 -170 + 200 10.5 -200 + 270 12.5 -270 + 325
20.5 -325 34
__________________________________________________________________________
The cyclone product comprised 19 percent of the total product
collected and was essentially -325 mesh.
The Hall Flow Rate of the -200+ 325 cut of the chamber product was
1.08 g./second and the apparent density was 1.35 g./ml. (not
vibrated). The -325 cut of the chamber product did not flow
smoothly through the meter orifice of the Hall Flow Test Apparatus
without vibration, so an accurate test of the flow rate could not
be made; the apparent density (not vibrated) was 1.35 g./ml.
Compressive strength of the -60+ 80 mesh particles was 3.5
grams.
The -200+ 325 and the -325 cuts of the chamber product powder were
flame sprayed, using the Metco Type 2P ThermoSpray gun and with the
Metco Type 2M plasma flame system using spray parameters described
in the previous examples. Spray rates and deposit efficiencies
resulting from the test work and a comparison with tests using
identical equipment and spray parameters with conventional Metco
201 (-325+ 15 microns) and Metco 201B (-200+ 325) zirconia powders
are shown in the following table:
ThermoSpray Plasma Flame Type 2P Type 2M
__________________________________________________________________________
Spray Deposit Spray Deposit Rate Efficiency Rate Efficiency lb./hr.
% lb./hr. %
__________________________________________________________________________
Spray Dried -325 2.4 93* 4.2 89* Metco 201 2 80 4.0 60 Spray Dried
-200 + 325 1.7 90* 6.6 85* 2.5 81* Metco 201B Not normally con- 4.5
65 197 sidered sprayable
__________________________________________________________________________
Spray rates and deposit efficiencies with spray dried powders have
been consistently better than their conventional counterparts where
direct comparisons have been made. In addition hardness and
abrasion-resistance of the spray dry powder coatings has been
consistently better.
One run each of zirconia powder using 1 weight percent and 2 weight
percent of polyvinyl alcohol binder was made and flame spray tested
in direct comparison with each other. When flame sprayed into
water, dried and microscopically examined, the 2 weight percent PVA
bonded powder was observed to have significantly more fully fused
hollow particles than the 1 weight percent PVA bonded powder. In
the preliminary coating evaluation, the coating produced with 1
weight percent PVA bonded powder was apparently denser and more
abrasion-resistant. In addition, with identical ThermoSpray Type 2P
gun and spray parameters, a higher deposit efficiency was achieved
with the 1 weight percent PVA bonded powder:
Spray Spray Rate Deposit Rate Deposit lb./hr. Eff. % lb./hr. Eff. %
__________________________________________________________________________
1 wt.% PVA Binder 2.4 93* 4.2 89* 2 wt.% PVA Binder 2.4 92* 4.4
83*
EXAMPLE 9
The slip from example 1 was spray dried in a pilot plant size spray
dryer as manufactured by Bowen Engineering Inc., North Branch, New
Jersey 08856. The rated capacity of this dryer is 100 lbs./hour of
chamber product based on drying an A1.sub.2 O.sub.3 slip containing
60 percent to 70 percent by weight of solids together with a
suitable binder system. The results were the same.
EXAMPLE 10
Example 4 is repeated except that the subparticles of flame spray
material suspended in the slip consisted of 70 weight percent of a
mixture of MgO and 2 weight percent of TiO.sub.2 based on the
MgO.
Compressive strength of the -60+ 80 mesh powder particles is
greater than 0.7 grams.
The powder is flame sprayed in the same manner as in example 4. The
result is a dense, adherent, abrasion-resistant coating consisting
of essentially MgO but in which the TiO.sub.2 combined with the MgO
in the flame, permitting the deposition by enhancing the melting
and coalescence of the MgO subparticles.
EXAMPLE 11
Example 7 was repeated except that 0.2 weight percent ammonium
alginate replaced the gum arabic as the binder.
The results were essentially the same except that the ammonium
alginate being more protective and by providing a more reducing
atmosphere, the particle hardness was less by approximately 100
Knoop hardness because a higher purity material was deposited and
particle boundary oxides in the coating were significantly
reduced.
EXAMPLE 12
Example 11 was repeated except that 0.1 weight percent of sodium
nitrite based on the solids contained in the slip was added as an
oxidizing agent. pH of the slip was buffered to 7.0, using sodium
hydroxide before the addition of the nitrite to prevent
decomposition of the nitrite and evolution of the toxic gas.
Compressive strength of the -60+ 80 mesh particles was greater than
0.7 grams.
The powder was flame sprayed in the same manner as example 11. The
action of the oxygen supplied by the oxidizer on its decomposition
in flame spraying was to harden the particles of molybdenum from
KHN.sub.50 386 to KHN.sub.50 549 by virtue of intersticial
containment in the molybdenum particles.
EXAMPLE 13
Example 4 is repeated except that 3 weight percent of Molybdate
Orange YE-428-D*
The results are the same except that the powder produced is colored
orange, which aided in identifying it.
EXAMPLE 14
Example 8 is repeated except that A1.sub.2 O.sub.3 with sodium
silicate as the binder replaced the ZrO.sub.2 and the PVA
BINDER.
The results are essentially the same except that the sodium
silicate decomposed in the flame, the decomposition products
including SiO.sub.2 acting to bind the A1.sub.2 O.sub.3 particles
together.
EXAMPLE 15
Example 8 is repeated except that Cr.sub.2 O.sub.3 with sodium
carboxymethyl cellulose as the binder replaced the ZrO.sub.2 and
the PVA binder.
The compressive strength of the -60+ 80 mesh particles is greater
than 0.7 grams.
The results are essentially the same.
EXAMPLE 16
Example 15 is repeated except that 15 weight percent of a
borosilicate glass based on the Cr.sub.2 O.sub.3 was included in
the slip.
The result is essentially the same except that the borosilicate
glass effectively bonded the subparticles of Cr.sub.2 O.sub.3 to
each other during flame spraying and aided in improving particle to
particle cohesion in the coating, resulting in a harder, denser,
more abrasion-resistant coating.
EXAMPLE 17
Example 8 is repeated except that NiO with methyl cellulose as the
binder replaced the ZrO.sub.2 and its binder in the slip.
The results are essentially identical.
EXAMPLE 18
Example 8 is repeated except that CeO.sub.2 replaced the ZrO.sub.2
in the slip.
The results are essentially the same.
EXAMPLE 19
Example 8 is repeated except that TiO.sub.2 replaced the ZrO.sub.2
in the slip.
The results are essentially the same.
EXAMPLE 20
Example 2 is repeated except that boron carbide B.sub.4 C replaced
the tungsten carbide and aluminum replaced the cobalt.
The results are essentially the same.
EXAMPLE 21
Example 2 is repeated except that chromium carbide Cr.sub.3 C.sub.2
replaced the tungsten carbide and a nickel-chrome alloy replaced
the cobalt.
The results are essentially the same.
EXAMPLE 22
Example 5 is repeated except that chromium replaced the nickel
incorporated in the slip in example 5.
The results are essentially the same.
EXAMPLE 23
Example 4 was repeated except that aluminum oxide A1.sub.2 O.sub.3
and Titania TiO.sub.2 replaced the solids in the slip in that
example.
The results are essentially the same.
While the invention has been described in detail with reference to
certain specific embodiments, various changes and modifications
which fall within the spirit of the invention and scope of the
appended claims will become apparent to the skilled artisan. The
invention is therefore only intended to be limited by the appended
claims or their equivalents wherein I have endeavored to claim all
inherent novelty.
* * * * *