CN100582284C - Porous coated member and manufacturing method thereof using cold spray - Google Patents
Porous coated member and manufacturing method thereof using cold spray Download PDFInfo
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- CN100582284C CN100582284C CN200580004854A CN200580004854A CN100582284C CN 100582284 C CN100582284 C CN 100582284C CN 200580004854 A CN200580004854 A CN 200580004854A CN 200580004854 A CN200580004854 A CN 200580004854A CN 100582284 C CN100582284 C CN 100582284C
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- 239000007921 spray Substances 0.000 title description 23
- 238000004519 manufacturing process Methods 0.000 title description 2
- 239000000843 powder Substances 0.000 claims abstract description 84
- 229910052751 metal Inorganic materials 0.000 claims abstract description 53
- 239000002184 metal Substances 0.000 claims abstract description 47
- 238000000034 method Methods 0.000 claims abstract description 46
- 239000000203 mixture Substances 0.000 claims abstract description 40
- 229910052782 aluminium Inorganic materials 0.000 claims abstract description 17
- 229910052718 tin Inorganic materials 0.000 claims abstract description 17
- 229910052725 zinc Inorganic materials 0.000 claims abstract description 17
- 229910052749 magnesium Inorganic materials 0.000 claims abstract description 13
- 238000005507 spraying Methods 0.000 claims abstract description 13
- 150000002739 metals Chemical class 0.000 claims abstract description 11
- 238000000576 coating method Methods 0.000 claims description 151
- 239000011248 coating agent Substances 0.000 claims description 144
- 239000007789 gas Substances 0.000 claims description 47
- 239000004594 Masterbatch (MB) Substances 0.000 claims description 45
- 238000007669 thermal treatment Methods 0.000 claims description 24
- 230000005496 eutectics Effects 0.000 claims description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 6
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims description 6
- 229910052786 argon Inorganic materials 0.000 claims description 3
- 239000001307 helium Substances 0.000 claims description 3
- 229910052734 helium Inorganic materials 0.000 claims description 3
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims description 3
- 229910052757 nitrogen Inorganic materials 0.000 claims description 3
- 229910045601 alloy Inorganic materials 0.000 claims description 2
- 239000000956 alloy Substances 0.000 claims description 2
- 239000000463 material Substances 0.000 abstract description 20
- 239000011247 coating layer Substances 0.000 abstract description 4
- 239000011148 porous material Substances 0.000 abstract 1
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 25
- 229910052799 carbon Inorganic materials 0.000 description 25
- 239000011777 magnesium Substances 0.000 description 17
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- 229910018134 Al-Mg Inorganic materials 0.000 description 4
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- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
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- RSWGJHLUYNHPMX-UHFFFAOYSA-N Abietic-Saeure Natural products C12CCC(C(C)C)=CC2=CCC2C1(C)CCCC2(C)C(O)=O RSWGJHLUYNHPMX-UHFFFAOYSA-N 0.000 description 2
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- 229910018140 Al-Sn Inorganic materials 0.000 description 2
- 229910018564 Al—Sn Inorganic materials 0.000 description 2
- LYCAIKOWRPUZTN-UHFFFAOYSA-N Ethylene glycol Chemical compound OCCO LYCAIKOWRPUZTN-UHFFFAOYSA-N 0.000 description 2
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- KHPCPRHQVVSZAH-UHFFFAOYSA-N trans-cinnamyl beta-D-glucopyranoside Natural products OC1C(O)C(O)C(CO)OC1OCC=CC1=CC=CC=C1 KHPCPRHQVVSZAH-UHFFFAOYSA-N 0.000 description 2
- 239000002351 wastewater Substances 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 229910000861 Mg alloy Inorganic materials 0.000 description 1
- 229920003171 Poly (ethylene oxide) Polymers 0.000 description 1
- DHKHKXVYLBGOIT-UHFFFAOYSA-N acetaldehyde Diethyl Acetal Natural products CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 description 1
- 125000002777 acetyl group Chemical class [H]C([H])([H])C(*)=O 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- SNAAJJQQZSMGQD-UHFFFAOYSA-N aluminum magnesium Chemical compound [Mg].[Al] SNAAJJQQZSMGQD-UHFFFAOYSA-N 0.000 description 1
- 229910002056 binary alloy Inorganic materials 0.000 description 1
- 239000006227 byproduct Substances 0.000 description 1
- 239000012159 carrier gas Substances 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 238000010288 cold spraying Methods 0.000 description 1
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- 238000005516 engineering process Methods 0.000 description 1
- 238000007667 floating Methods 0.000 description 1
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- 229910052739 hydrogen Inorganic materials 0.000 description 1
- WGCNASOHLSPBMP-UHFFFAOYSA-N hydroxyacetaldehyde Natural products OCC=O WGCNASOHLSPBMP-UHFFFAOYSA-N 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000004570 mortar (masonry) Substances 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
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- 230000003647 oxidation Effects 0.000 description 1
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- 239000002904 solvent Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
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- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
- A62B7/00—Respiratory apparatus
- A62B7/02—Respiratory apparatus with compressed oxygen or air
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
-
- A—HUMAN NECESSITIES
- A62—LIFE-SAVING; FIRE-FIGHTING
- A62B—DEVICES, APPARATUS OR METHODS FOR LIFE-SAVING
- A62B7/00—Respiratory apparatus
- A62B7/10—Respiratory apparatus with filter elements
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C24/00—Coating starting from inorganic powder
- C23C24/02—Coating starting from inorganic powder by application of pressure only
- C23C24/04—Impact or kinetic deposition of particles
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/023—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/028—Including graded layers in composition or in physical properties, e.g. density, porosity, grain size
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/18—After-treatment
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F21—LIGHTING
- F21V—FUNCTIONAL FEATURES OR DETAILS OF LIGHTING DEVICES OR SYSTEMS THEREOF; STRUCTURAL COMBINATIONS OF LIGHTING DEVICES WITH OTHER ARTICLES, NOT OTHERWISE PROVIDED FOR
- F21V33/00—Structural combinations of lighting devices with other articles, not otherwise provided for
- F21V33/0064—Health, life-saving or fire-fighting equipment
- F21V33/0068—Medical equipment
Abstract
Disclosed is a coated member on which a porous metal coating layer is formed and a method of producing the same. The method comprises providing the mother material, feeding powder having a metal composition, which includes at least two different metals selected from the group consisting of Al, Mg, Zn, and Sn and which is expressed by xA-(1-x)B (O<x<l, where x is a weight ratio of A and B), onto the mother material, supplying high pressure gas to the powder, applying the metal powder on the mother material by spraying the metal powder using the high pressure gas through an supersonic nozzle, and heat-treating the coated mother material to form the porous coating layer. In the method, it is possible to freely control the pore size and porosity of the coated member. Accordingly, it is available to various members for thermal and mechanical applications.
Description
Technical field
The present invention relates generally to coated component and this porous coating member manufacturing method that is formed with porous coating on it, more specifically, the void distribution of the method that the present invention relates to use the low temperature spraying method on the surface of masterbatch, to form porous coating and its floating coat and the coated component that the aperture is controlled.
Background technology
Be formed at porous coating on the parts surface and can improve the thermal characteristics and the mechanical property of parts.
For example, if form the porous coating that comprises the perforate that communicates with each other on the surface of heat exchanger, then heat exchanger has the area that contacts with ambient air of increase, thereby guarantees effective heat exchange performance.Simultaneously, according to the friction means and the relation of element on every side, need friction means to have lower intensity and hardness sometimes.Porous coating can satisfy this requirement.In addition, when masterbatch combines with kinds of materials, owing to stress appears in the dislocation of lattice at the interface.Porous coating can as buffer layer with avoid in conjunction with the time stress.
Can adopt various coating processes as the method that on the surface of the parts that are used for heat application and machine applications, forms metallic coating traditionally.About this point, described method can exemplify out electrochemical plating, hot dip process method or hot spray process.Yet these methods have limitation in application facet, perhaps can produce heat affecting or make the masterbatch thermal distortion masterbatch.In addition, use aforesaid method in fact to be difficult to the porosity and the void distribution of artificial control coating.
And, in such as corrosive atmospheres such as waste water or seawater, coat heat-conducting metal coating on the pipeline of conventional heat exchanger and can be corroded or generate tongue shape thing from the teeth outwards, thereby can not bring into play its function.Therefore, existence can not be guaranteed the problem of weather resistance.
Summary of the invention
An object of the present invention is to provide and be used for heat application and the parts of machine applications and the method for the porous coating that formation is used in these parts, these parts can be owing to heat affecting cause the masterbatch thermal distortion or damages masterbatch, and these parts can be applied to various fields.
Another object of the present invention provides the parts that are used for heat application and machine applications, porosity, aperture and void distribution that can the control surface coating in described parts, and provide and form the porous coating parts that are used in the method for the porous coating in these parts and use this method to make.
A further object of the present invention provides the method that forms the porous coating with high thermal conductivity, the externally medium-term and long-term use of corrosive atmosphere of this porous coating.
To achieve these goals, the invention provides the method that on masterbatch, forms porous coating.This method comprises provides masterbatch, the powder feeding that will have following metal composition is to described masterbatch, described metal is formed and is comprised at least two kinds of different metals being selected from the group be made up of Al, Mg, Zn and Sn and with xA-(1-x) B (0＜x＜1, x is the weight ratio of A) expression, to the powder supplies high pressure gas, by coming the metallize powder and metal-powder be coated on the masterbatch through superonic flow nozzzle with high pressure gas, and to heat-treating to form porous coating through the masterbatch of coating.
According to an embodiment of the invention, in aforesaid method, A is Al, and B comprises the metallic element that is selected from the group of being made up of Mg, Zn and Sn.In addition, preferably through having temperature between the fusing point of metal of high melt point in the eutectic temperature of A and B and A and B under, the thermal treatment of the masterbatch of coating carries out.Particularly, thermal treatment is carried out at about 200 ℃～650 ℃.
In addition, powder feed comprises that also change x is to change the composition of powder.
And the present invention also provides a kind of metallic coating parts.These metallic coating parts comprise metal masterbatch and the coating that is formed on the metal masterbatch, and described coating comprises at least two kinds of metallic elements and represents with xA-(1-x) B (x is the weight ratio of A).A and B are the different metals that is selected from the group of being made up of Al, Mg, Zn and Sn, when on the thickness direction in coating when mobile x in the scope of 0＜x＜1, change, and coating porosity changes according to the variation of x.
According to an embodiment of the invention, in above-mentioned parts, x increases or reduces when the thickness direction of coating moves, and the porosity of coating is with the increase of x or reduce and increase or reduce.In addition, A is Al, and B is any one metal that is selected from the group of being made up of Mg, Zn and Sn, reduces and the porosity of coating increases at the interface x when coatingsurface moves from metal masterbatch and coating.
And the present invention also provides a kind of metallic coating parts.These metallic coating parts comprise metal masterbatch and the coating that is formed on the metal masterbatch, and described coating comprises at least two kinds of metallic elements and represents with A-B.A and B are the different metals that is selected from the group of being made up of Al, Mg, Zn and Sn, and the A or the B that are selected from above-mentioned group when the thickness direction along coating moves change, and the porosity of coating changes according to the variation of A or B.
In the present invention, coating can comprise the perforate that interconnects each other to small part, and preferred aperture is present in the top of coating in specific Application Areas.
In addition, the invention provides the method that on masterbatch, forms the porous carbon coating.This method comprises provides masterbatch, supply with the coalescent carbon dust of organic binder bond, and to carbon dust supply high pressure gas, and by using high pressure gas to spray carbon dust and carbon dust is coated on the masterbatch through superonic flow nozzzle.
In aforesaid method, being used to make the organic binder bond of carbon dust alligatoring can be at least a material that is selected from the group of being made up of polyvinyl alcohol (PVA), rosin, resin, polyvinyl butyral acetal (PVB) and polyoxyethylene glycol (PEG).The content of organic binder bond is preferably 10 weight %～30 weight % with respect to carbon.
In addition, in aforesaid method, can be in addition coating be carried out step at 400 ℃～500 ℃ of burn off organic binder bonds.
Description of drawings
Fig. 1 is the synoptic diagram that is used to form the low temperature paint finishing 100 of coating in the present invention;
Fig. 2 a and 2b show the schema that forms porous coating according to the embodiment of the present invention;
Fig. 3 is the sectional view that comprises the coated component 200 of the coating with variable composition according to the embodiment of the present invention;
Fig. 4 is according to the embodiment of the present invention, has the optical microscope photograph in cross section of coating of the composition of 0.5Al-0.5AlMg after thermal treatment;
Fig. 5 is according to the embodiment of the present invention, has the optical microscope photograph in cross section of coating of the composition of 0.3Al-0.7AlMg after thermal treatment;
Fig. 6 is according to the embodiment of the present invention, the optical microscope photograph in the cross section of the coating of lamination Al/AlMg/Al/AlMg/Al composition successively after thermal treatment;
Fig. 7 is according to the embodiment of the present invention, the optical microscope photograph in the cross section of the coating of lamination 0.667Al-0.333Mg/0.5Al-0.5Mg composition successively after thermal treatment;
Fig. 8 is according to the embodiment of the present invention, has the optical microscope photograph in cross section of coating of the composition of 0.5Al-0.5Sn after thermal treatment;
Fig. 9 is according to the embodiment of the present invention, the optical microscope photograph in the cross section of the coating of lamination 0.667Al-0.333Sn/0.5Al-0.5Sn composition successively after thermal treatment;
Figure 10 is according to the embodiment of the present invention, the optical microscope photograph in the cross section of the coating of lamination 0.667Al-0.333Zn/0.5Al-0.5Zn composition successively after thermal treatment;
Figure 11 is according to another embodiment of the present invention, forms the schema of porous carbon coating; With
Figure 12 a and 12b are by the cross section of the carbon coating of the operation formation of Figure 11 and the electron micrograph on surface.
Embodiment
Below, will describe the present invention with reference to the accompanying drawings.
Fig. 1 be among the present invention powder quick go up to form the synoptic diagram of the low temperature spray equipment 100 of coating at base material (S).
Spray equipment 100 quickens to be used to form the powder of coating it is coated on the base material (S) with subsonic speed or supersonic speed.About this point, spray equipment 100 comprises gas compressor 110, gas heater 120, powder feeder 130 and spray nozzle 140.
Utilization is by the powder that is about 1 μ m～50 μ m that the atmospheric pressurized gas of 5 normal atmosphere (atm)～20 is provided by powder feeder 130 through spray nozzle 140 sprayings with about 300mm/s～1200mm/s speed that is about of gas compressor 110 supplies.The powder and the base material (S) that together spray with gas collide.In this, when the collision of powder and base material (S), the kinetic energy of powder makes powder generation viscous deformation, and the bonding strength with base material is provided, and forms thus to have very highdensity coating.
In device 100, thereby the gas heater 120 that is arranged in the pressurized gas induction trunk is to be used to add hot compressed gas improves the spraying rate of spray nozzle with the kinetic energy that increases pressurized gas auxiliary unit.In addition, as shown in FIG., thereby the part pressurized gas can by gas compressor 110 air inlets to powder feeder 130 well with powder supplies to spray nozzle 140.
The pressurized gas that is used for device 100 can be enumerated some commercial gas as an example, for example helium, nitrogen, argon gas or air, and gases used kind can suitably be selected according to the spraying rate and the economic benefit of spray nozzle 140.
In the United States Patent (USP) 5,305,414 of Anatoly P.Alkimov etc., disclosed the operation and the structure of this device in detail, omitted description of them at this.
Fig. 2 a shows to use the schema that forms coating with reference to figure 1 described spray equipment on masterbatch or base material.
According to Fig. 2 a, method of the present invention start from powder feeder 130 supply by spray equipment 100 comprise two or more metal metal-powder step (S210) and by gas compressor 110 step of compressed gas supplying (S220) under high pressure.
In the step (S210) of supplying powder, the powder that comprises two or more metal comprises the mixture or the sosoloid of at least two kinds of metals that are selected from the group of being made up of Al, Mg, Zn and Sn, or both mixtures.In addition, selected metal differs from one another among the present invention.For example, if a kind of metal that is selected from above-mentioned group comprises Al, then the composition of metal-powder can be a binary system, for example Al-Mg, Al-Zn or Al-Sn; Ternary system, for example Al-Mg-Zn; Or has a system that surpasses three kinds of metals.In addition, except cited metal, also can use Ti, Si, Mn, Cr, Fe, Co, Ni or Cu and can not deviate from spirit of the present invention.
In the present invention, can provide the powder that comprises metal ingredient with the form of sosoloid.For example, can provide the metal-powder that contains Al-Mg with the form of AlMg sosoloid (being so-called aluminum magnesium alloy (Magal)).In addition, can provide the powder that contains metal ingredient with the mixture of solid-solution powder and single powder.For example, metal-powder can be the mixture of Al powder and AlMg powder.Because it is dangerous that the metal-powder that contains Mg is handled, for example, can cause blast, therefore provide conveniency to guarantee to handle as sosoloid.
When using coating of the present invention in the parts with hot purposes and mechanical purposes, owing to compare with its proportion, metal-powder has good relatively thermal characteristics and mechanical property, and as thermal conductivity or intensity, therefore preferred its is included in widely used Al or Al alloy in the machine part.
In the step (S220) that pressurized gas is provided of the present invention, gas can be the above-mentioned helium that exemplifies, nitrogen, argon gas or air.Gas is compressed to pressure with gas compressor to be about 5 normal atmosphere～20 normal atmosphere and to supply then.If desired, can be when being heated to about 200 ℃～500 ℃ with heating unit (as the gas heater 120 of Fig. 1) compressed gas supplying.Yet even add hot compressed gas according to present embodiment, because the proportion of gas is very low, the temperature variation of metal-powder also is negligible.Thereby the different of spraying step of the present invention and conventional spray paint method are that spraying is to carry out at low temperatures, and in the conventional spray paint method with powder heating and coating under fusing point or higher temperature.
Simultaneously, as mentioned above, part pressurized gas used in the step (S220) of compressed gas supplying can be with acting on the carrier gas of supplying metal powder continuously and stably.
Below, use superonic flow nozzzle to spray the mixture (S230) of pressurized gas and metal-powder.Flow velocity through the gas-powdered mixture of nozzle spraying depends on the temperature and pressure of gas and the particle diameter and the proportion of powder.Particle diameter is about the speed spraying of gas-powdered mixture of 1 μ m～50 μ m with about 300m/s～1200m/s under the pressure and temperature condition of feeding gas.
Metal-powder that sprays under high speed and masterbatch collision are to form high density coatings.Spray step (S230) and have the coating of desired thickness, then the coating that forms is thus heat-treated (S240) until formation.In the present invention, preferred heat treated temperature is about 200 ℃～650 ℃.Be equal to or higher than the fusing fully that 650 ℃ thermal treatment temp causes metallic coating, and coating can not melt almost under 200 ℃ or lower temperature, causes producing negligible thermal effectiveness.
The high density coatings that is formed on the masterbatch is heat-treated step (S240) to obtain porosity.And by the aftermentioned embodiment as can be known, the variation of the composition of the metal-powder that is coated with is depended in the porosity of porous coating and aperture.Aspect this, " variation of the composition " variation of the amount of comprising as used herein and the variation of employed metal.
About with reference to the described coating process of the present invention of figure 2a, Fig. 2 b has shown the method that forms porous coating, thereby this method comprises the step (S250) of the void distribution of the composition control coating that changes metal-powder.
According to this method, in the step (S240) of using nozzle to spray, in the process that forms coating, change the composition of powder.For example, after the powder that will consist of 0.5Al-0.5Mg (wherein the weight ratio of Al: Mg is 1: 1) is supplied the scheduled time, this ratio is controlled to be 1: 2, or the supply powder that comprises Al-Zn replaces comprising the powder of Al-Mg, wherein the ratio of Al: Zn is 1: 1, forms the coating that has vertical composition gradient or comprise heterogeneity thus.
Can realize the variation of powder constituent by typical process well known to those skilled in the art.For example, can be supplied to successively in the powder feeder having the different powder of forming, perhaps, be used to store a plurality of powder feeder in preparation with different powder of forming after, can utilize valve to select to comprise the powder feeder of powder with required composition.
Fig. 3 is the sectional view that comprises the coated component 200 of the coating that forms through described operation.
According to Fig. 3, be that the Al-Zn layer 230 that 2: 1 Al-Zn layer 210, Al-Zn layer 220 that weight ratio is 1: 1 and weight ratio are 1: 2 is formed at masterbatch (S) with weight ratio, on Al.According to embodiments of the present invention described later, if coating is heat-treated, then Zn content increases, and aperture and porosity increase thus.Therefore, if heat-treat being coated with the parts with powder of forming shown in Fig. 3, then can form such coated component, wherein porosity and/or volume of voids are along with increasing away from masterbatch.Above-mentioned void distribution is an ideal, and reason is that it helps the formation stable coating at the interface between coating and masterbatch.In addition, in above-mentioned structure,, can be the perforate that communicates with each other therefore in the hole that the coating outmost surface forms because porosity and volume of voids increase.Especially, perforate plays an important role in the heat exchange properties of improving masterbatch.
As mentioned above, with reference to the variation of the void distribution of figure 3 described coatings can be by changing composition amount or obtain by the kind that changes composition.In other words, by lamination Al-Mg, Al-Zn and Al-Sn layer successively on masterbatch, can make wherein porosity and/or aperture along with the coated component that increases away from the interface.
Figure 11 is the schema that shows another embodiment formation porous carbon coating according to the present invention.
According to Figure 11, the carbon dust that at first median size is less than or equal to 10 μ m mixes (S310) with at least a tackiness agent that is selected from the group of being made up of PVA, PVB, PEG, resin and rosin.According to the kind of tackiness agent, use The suitable solvent, promptly organic solvent such as water or alcohol mixes.
Subsequently, dry gained slurry to be making the carbon dust cake, and this cake is pulverized and sorting, makes carbon dust with the particle diameter (as the median size of 50 μ m～200 μ m) that is suitable for the nozzle spraying (S320～S340) thus.Afterwards, use organic binder bond to make carbon dust coalescent so that it compares chap with the original size of powder.
Below, use with reference to figure 1 described low temperature spray equipment through nozzle with the gained carbon dust be about 4kgf/cm
2～7kgf/cm
2Thereby high pressure gas together spray and on masterbatch, form coating (S350).In addition, carry out the burn off process from coating, to remove organic binder bond at about 400 ℃～500 ℃.
The present invention may be better understood by following preferred embodiment.
The physical properties of used metal is as described in Table 1 in the following example 1～7.
Table 1
| Metal | Fusing point (℃) | Density (g/cm 2) |
| Al | 660.2 | 2.699 |
| Mg | 650 | 1.74 |
| Zn | 419.46 | 7.133 |
| Sn | 231.9 | 7.298 |
The spraying condition of the nozzle among the embodiment 1～7 is as follows:
Nozzle: standard Laval type
Bore: 4mm * 6mm
Trunnion spacing: 1mm
Pressurized gas: kind: air
Pressure: 7 normal atmosphere
Temperature: 330 ℃
The size of the powder of being supplied:＜44 μ m (325 order)
To comprise weight ratio be 50: 50 Al powder and the mix powder of AlMg powder (that is, 0.5Al-0.5AlMg) (eutectic temperature is about 400 ℃) under 7 normal atmosphere, send in the spray nozzle to coat on the aluminium base with air.
The about 620 ℃ thermal treatments of the gained coating being carried out 1 hour.To use the observation by light microscope cross section through heat treated base material cutting and polishing.Fig. 4 has described the photo of the cut surface of gained base material.
According to Fig. 4, can find out that coating is combined on the Al base material well.Interface between Al base material and the coating is apparent owing to the hole of being sealed in the coating (black part).Do not observe hole during coating, but after thermal treatment, generated hole.
Embodiment 2
The weight of AlMg in increasing mix powder so that metal-powder have the composition of 0.3Al-0.7AlMg, with embodiment 1 in make coating under the identical condition.Coating is heat-treated, use the observation by light microscope cross section, the result as shown in Figure 5.
Compare with Fig. 4, can find out that by Fig. 5 the size of hole increases, even and with the naked eye also can confirm the increase of porosity.
Embodiment 3
So that Al powder/AlMg powder/Al powder/AlMg powder/Al powder successively the mode of lamination form coating.Remaining coating condition is identical with embodiment 1.Subsequently, 620 ℃ of thermal treatments of the gained coating being carried out 1 hour.
Fig. 6 is the optical microscope photograph that shows through the cross section of heat treated base material.As shown in the figure, in the Al layer, almost do not observe hole, but in the AlMg layer, frequently observe hole.
Embodiment 4
Be coated with the Al base material with the mix powder that consists of 0.667Al-0.333Mg, and then be coated with the another kind of mix powder that consists of 0.5Al-0.5Mg.Remaining coating condition is identical with embodiment 1.Subsequently, the gained coating carried out 1 hour thermal treatment, and use the observation by light microscope cross section at about 620 ℃.
Fig. 7 is the optical microscope photograph in this cross section.Can find out that by Fig. 7 the porosity of the coating layer portion (outmost surface) that consists of 0.5Al-0.5Mg is higher than the porosity of the coating layer portion (interface) that consists of 0.667Al-0.333Mg.Thereby the porosity that can find out coating increases with the increase of Mg content.In addition, by the shape and the porosity in hole, the hole that can infer outmost surface is the perforate that communicates with each other.As mentioned above, communicate with each other and increased contact area with ambient air to its inner hole that distributes by the outmost surface of coating.Thereby, especially, can be used in and require the excellent heat exchange or the purposes of heat-radiating properties.
Embodiment 5
Mix powder coating Al base material with the Al that consists of 0.5Al-0.5Sn and Sn.Remaining coating condition is identical with embodiment 1.
At about 650 ℃ the gained coating carried out 1 hour thermal treatment, the observation by light microscope cross section is used in the polishing back.Fig. 8 is the optical microscope photograph in this cross section.As shown in Figure 7, in coating, observe very many holes.Shape and porosity according to the hole judge that the hole seemingly communicates with each other.
Embodiment 6
By with embodiment 1 in the coating of identical operation consist of the mix powder of 0.667Al-0.333Sn, coating subsequently consists of the another kind of mix powder of 0.5Al-0.5Sn.620 ℃ with gained coating thermal treatment 1 hour, use the cross section of observation by light microscope through polishing.
Fig. 9 is the photo in cross section.Interface portion that relatively scribbles 0.667Al-0.333Sn and the outmost surface part that scribbles 0.5Al-0.5Sn can be found out in outmost surface part aperture obviously higher and porosity is higher.Thereby the increase that can find out Sn content has promoted the generation in hole.
Embodiment 7
To consist of the mix powder coating Al base material of 0.667Al-0.333Zn, be coated with the another kind of mix powder that consists of 0.5Al-0.5Zn then.The coating condition is identical with embodiment 1.Subsequently, the gained coating about 620 ℃ of thermal treatments 1 hour, is used the observation by light microscope cross section, the result as shown in Figure 10.
Can find out owing to added Zn and coating, formed many holes from Figure 10.In addition, can find out with interface portion and compare, partly exist very huge hole and porosity higher in outmost surface with high Zn content with relatively low Zn content.Thereby, can find out that aperture and porosity increase along with the increase of Zn content.
Can find out that by embodiment 1～7 Mg, the Zn and the Sn that together are added in the coating with Al help forming hole after the thermal treatment in coating.And aperture and porosity increase with the increase of addition.The hole communicates with each other, thereby becomes perforate when the content of Mg, Zn and Sn increases.
The present inventor infers that its reason is as follows.Yet it is in order to understand the present invention rather than to attempt as the basis that limits the scope of the invention that following informative description is provided.
Mg, the Zn and the Sn that together add with Al form the eutectic liquid phase jointly with Al under thermal treatment temp, and the Al partial melting.When having above-mentioned liquid phase, the combination in hole relatively easily realizes, thereby increased can be with the hole that is observed visually.
Simultaneously, the byproduct gas (as hydrogen) that generates of the Al and the reaction of airborne moisture by fusing can think to form the reason in hole.It is believed that fusing point is lower than the Mg of Al, Sn and Zn and Al and causes above-mentioned reaction under thermal treatment temp.
About Another reason, the variation owing to density forms the hole when the alloy of metal-powder is made by its partial melting by inference.
This supposition conforms to true, promptly as described above in Example, and adds Mg and compares by adding Zn or Sn and can form relative more hole.Its reason is that the melt temperature (231.9 ℃) of the melt temperature (419.46 ℃) of Zn or Sn is lower than the melt temperature (650 ℃) of Mg.
Consider above-mentioned reason, in the present invention, thermal treatment temp must be higher than the eutectic temperature of two kinds of metals that will be mixed with each other at least.The term of Shi Yonging " eutectic temperature " comprises peritectic temperature herein.Yet, because metal-powder may contain a spot of impurity, therefore can the generating unit fractional melting in the temperature that is equal to or less than eutectic temperature.In addition, in the present invention, thermal treatment temp must be able to not be higher than the fusing point of the pure Al with peak melting point.Its reason is that coating will lose structural stability in this case.
Embodiment 8
On copper (Cu) plate, form carbon coating.The carbon dust that with median size is 5 μ m～10 μ m mix with the PVA of about 15 weight % and dry with preparation carbon cake after, it is pulverized and sub-elects the carbon granule that particle diameter is less than or equal to 150 μ m in mortar.Under temperature and pressure same with the above-mentioned embodiment, the carbon dust that sub-elects is sprayed on the copper coin, forms carbon coating thus.
Figure 12 a and 12b are the electron micrographs that is formed at the cross section and the surface of the carbon coating on the copper coin.Can find out with reference to the accompanying drawings and on copper coin, form porous carbon coating with excellent bond strength.
Industrial applicibility
Method of the present invention has the existing advantage of low temperature spraying process. In other words, owing to do not carry out high-temperature process, therefore farthest suppressed the oxidation of masterbatch or coating, and can not occur because the infringement to masterbatch that heat affecting causes. In addition, can guarantee very high coating speed and be highly susceptible to controlling the thickness of coating.
Especially, the Mg that together uses with Al in coating process of the present invention, Sn and Zn have the fusing point that is lower than Al. Thereby because heat treatment carries out under the temperature of the fusing point that is equal to or less than Al, so the present invention can be applied to comprise Al or Al alloy as the most of parts that are used for hot purposes and mechanical purposes of masterbatch, and can not damage masterbatch.
In addition, in coating process of the present invention, can change the composition of coating to change the porosity of coating. Therefore, can form easily porous coating required in the various industrial circles by said method.
And, in coated component made according to the method for the present invention, can freely control aperture and porosity. Thereby, can use at the various parts that are used for hot purposes and mechanical purposes.
In addition, in carbon coating made according to the method for the present invention, permitted mushy loose structure owing to have, thereby can guarantee high thermal conductivity, and carbon as more stable than metal in seawater or the waste water, thereby is suitable for use as the parts that are used for hot purposes in corrosive atmosphere at corrosive atmosphere.
Claims (13)
1. method that on masterbatch, forms porous coating, this method comprises:
Masterbatch is provided;
To have powder feeding that following metal forms to described masterbatch, described metal is formed and is comprised at least two kinds of different metals being selected from the group be made up of Al, Mg, Zn and Sn and represent with xA-(1-x) B, 0＜x＜1 wherein, and x is the weight ratio of A;
To the powder supplies high pressure gas, the pressure of described high pressure gas is 5 normal atmosphere～20 normal atmosphere;
By spraying described metal-powder and described metal-powder be coated on the described masterbatch through superonic flow nozzzle with described high pressure gas; With
To heat-treating through the masterbatch of coating, wherein through having temperature between the fusing point of metal of higher melt in the eutectic temperature of A and B and A and B under, the thermal treatment of the masterbatch of coating carries out to form porous coating.
2. the method for claim 1 wherein has the powdered alloy that powder that described metal forms comprises at least two kinds of metals that are selected from above-mentioned group.
3. the method for claim 1, wherein A is Al, B comprises the metallic element that is selected from the group of being made up of Mg, Zn and Sn.
4. the method for claim 1, the supply of wherein said high pressure gas comprises:
Gas is compressed; With
Compressed gas is carried out preheating.
5. the method for claim 1 is wherein carried out at 200 ℃～650 ℃ through the thermal treatment of the masterbatch of coating.
6. the method for claim 1, the supply of wherein said powder also comprise and change x to change the composition of described powder.
7. the method for claim 1, wherein said gas comprises any one gas that is selected from the group of being made up of helium, nitrogen, argon gas and air.
8. metallic coating parts, these metallic coating parts comprise:
The metal masterbatch; With
Be formed at the coating on the described metal masterbatch, described coating comprises at least two kinds of metallic elements and represents that with xA-(1-x) B wherein x is the weight ratio of A,
Wherein, A and B are the different metals that is selected from the group of being made up of Al, Mg, Zn and Sn, when on the thickness direction in described coating when mobile x in the scope of 0＜x＜1, change, the porosity of described coating changes according to the variation of x.
9. metallic coating parts as claimed in claim 8, wherein x increases or reduces when the thickness direction of described coating moves, and the porosity of described coating is with the increase of x or reduce and increase or reduce.
10. metallic coating parts as claimed in claim 9, wherein A is Al, B is any one metal that is selected from the group of being made up of Mg, Zn and Sn, from the interface of described metal masterbatch and described coating during to described coating surperficial mobile x reduce and the porosity of described coating increases.
11. metallic coating parts, these metallic coating parts comprise:
The metal masterbatch; With
Be formed at the coating on the described metal masterbatch, described coating comprises at least two kinds of metallic elements and represents with A-B,
Wherein, A and B are the different metals that is selected from the group of being made up of Al, Mg, Zn and Sn, and the A or the B that are selected from above-mentioned group when the thickness direction along described coating moves change, and the porosity of described coating changes according to the variation of A or B.
12. as claim 8 or 11 described metallic coating parts, wherein said coating comprises the perforate that communicates with each other to small part.
13. metallic coating parts as claimed in claim 12, wherein said perforate is present in the top of described coating.
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| KR1020040009441A KR20050081252A (en) | 2004-02-13 | 2004-02-13 | Porous metal coated member and manufacturing method thereof using cold spray |
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| EP (1) | EP1718781A4 (en) |
| JP (1) | JP2007522346A (en) |
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| US6372299B1 (en) * | 1999-09-28 | 2002-04-16 | General Electric Company | Method for improving the oxidation-resistance of metal substrates coated with thermal barrier coatings |
| RU2183695C2 (en) * | 2000-08-25 | 2002-06-20 | Общество С Ограниченной Ответственностью Обнинский Центр Порошкового Напыления | Method of applying coatings |
| US6444259B1 (en) * | 2001-01-30 | 2002-09-03 | Siemens Westinghouse Power Corporation | Thermal barrier coating applied with cold spray technique |
| JP2003082476A (en) * | 2001-06-26 | 2003-03-19 | Toshiba Corp | Corrosion and wear resistant turbine member and manufacturing method |
| US20030039856A1 (en) * | 2001-08-15 | 2003-02-27 | Gillispie Bryan A. | Product and method of brazing using kinetic sprayed coatings |
| RU2205897C1 (en) | 2001-12-26 | 2003-06-10 | Общество С Ограниченной Ответственностью Обнинский Центр Порошкового Напыления | Coating method |
| JP3613255B2 (en) * | 2002-03-22 | 2005-01-26 | 独立行政法人産業技術総合研究所 | Deposition equipment |
| US6592947B1 (en) * | 2002-04-12 | 2003-07-15 | Ford Global Technologies, Llc | Method for selective control of corrosion using kinetic spraying |
-
2004
- 2004-02-13 KR KR1020040009441A patent/KR20050081252A/en not_active Application Discontinuation
-
2005
- 2005-02-11 CN CN200580004854A patent/CN100582284C/en not_active Expired - Fee Related
- 2005-02-11 JP JP2006553054A patent/JP2007522346A/en active Pending
- 2005-02-11 US US10/589,184 patent/US20070240603A1/en not_active Abandoned
- 2005-02-11 WO PCT/KR2005/000387 patent/WO2005078150A1/en active Application Filing
- 2005-02-11 EP EP05721848A patent/EP1718781A4/en not_active Withdrawn
- 2005-02-11 KR KR1020067013942A patent/KR100794295B1/en active IP Right Grant
Also Published As
| Publication number | Publication date |
|---|---|
| JP2007522346A (en) | 2007-08-09 |
| EP1718781A4 (en) | 2009-03-18 |
| KR20060114363A (en) | 2006-11-06 |
| WO2005078150A1 (en) | 2005-08-25 |
| CN1918316A (en) | 2007-02-21 |
| EP1718781A1 (en) | 2006-11-08 |
| KR20050081252A (en) | 2005-08-18 |
| KR100794295B1 (en) | 2008-01-14 |
| US20070240603A1 (en) | 2007-10-18 |
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