Method of producing thermal spray powder, manufacture apparatus of thermal spray powder, and thermal spray powder produced by the producing method

Patent metadata

Field	Value
Publication number	US-10150707-B2
Application number	US-201515329696-A
Country	US
Kind code	B2
Filing date	Aug 25, 2015
Priority date	Sep 5, 2014
Publication date	Dec 11, 2018
Grant date	Dec 11, 2018

Abstract

A method for producing a thermal spray powder includes: a preparing step of preparing a powder mixture containing a first particle made from zirconia-based ceramic containing a first additive agent and a second particle made from zirconia-based ceramic containing a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm; and a secondary-particle producing step of producing a plurality of secondary particles each of which includes the first particle and the second particle sintered with each other.

First claim

The invention claimed is:

1. A method for producing a thermal spray powder, comprising:
a preparing step of preparing a powder mixture comprising a first particle made from a zirconia-based ceramic comprising a first additive agent of yttrium oxide and a second particle made from a zirconia-based ceramic comprising a second additive agent of ytterbium oxide, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm; and
a secondary-particle producing step of producing a plurality of secondary particles each of which comprises the first particle and the second particle sintered with each other.

2. A method for producing a thermal spray powder, comprising:
a preparing step of preparing a powder mixture comprising a first particle made from a zirconia-based ceramic comprising a first additive agent and a second particle made from a zirconia-based ceramic comprising a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm;
a secondary-particle producing step of producing a plurality of secondary particles each of which comprises the first particle and the second particle sintered with each other; and
a secondary-particle classifying step of obtaining a powder having a 10% cumulative particle diameter of not less than 20 μm and not more than 150 μm from the secondary particles obtained in the secondary-particle producing step.

3. The method for producing a thermal spray powder according to claim 1 ,
wherein the powder mixture has a 10% cumulative particle diameter of not more than 5 μm.

4. The method for producing a thermal spray powder according to claim 1 ,
wherein the secondary-particle producing step comprises:
a powder agglomeration step of producing a plurality of intermediate particles each comprising the first particle and the second particle by a spray dry method, and
a heat treatment step of performing heat treatment on the intermediate particles to obtain the secondary particles.

5. The method for producing a thermal spray powder according to claim 1 , further comprising a secondary-particle classifying step of obtaining a powder having a 10% cumulative particle diameter of not less than 20 μm and not more than 150 μm from the secondary particles obtained in the secondary-particle producing step.

6. The method for producing a thermal spray powder according to claim 1 , wherein the preparing step further comprises:
a non-adhering particle recovery step of recovering a plurality of first non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the first additive agent, and a plurality of second non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the second additive agent; and
a powder crushing step of crushing the plurality of first non-adhering particles and the plurality of second non-adhering particles collectively.

7. The method for producing a thermal spray powder according to claim 2 ,
wherein the first additive agent is yttrium oxide, and
wherein the second additive agent is ytterbium oxide.

8. The method for producing a thermal spray powder according to claim 2 ,
wherein the powder mixture has a 10% cumulative particle diameter of not more than 5 μm.

9. The method for producing a thermal spray powder according to claim 2 ,
wherein the secondary-particle producing step comprises:
a powder agglomeration step of producing a plurality of intermediate particles each comprising the first particle and the second particle by a spray dry method, and
a heat treatment step of performing heat treatment on the intermediate particles to obtain the secondary particles.

10. The method for producing a thermal spray powder according to claim 2 ,
wherein the preparing step further comprises:
a non-adhering particle recovery step of recovering a plurality of first non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the first additive agent, and a plurality of second non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the second additive agent; and
a powder crushing step of crushing the plurality of first non-adhering particles and the plurality of second non-adhering particles collectively.

11. A method for producing a thermal spray powder comprising:
(i) a preparing step comprising:
preparing a powder mixture comprising a first particle made from a zirconia-based ceramic comprising a first additive agent and a second particle made from a zirconia-based ceramic comprising a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm;
a non-adhering particle recovery step of recovering a plurality of first non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the first additive agent, and a plurality of second non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the second additive agent; and
a powder crushing step of crushing the plurality of first non-adhering particles and the plurality of second non-adhering particles collectively; and
(ii) a secondary-particle producing step of producing a plurality of secondary particles each of which comprises the first particle and the second particle sintered with each other.

12. The method for producing a thermal spray powder according to claim 11 ,
wherein, in the non-adhering particle recovery step, a plurality of third non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from metal is recovered along with the plurality of first non-adhering particles and the plurality of second non-adhering particles, and
wherein the method further comprises a selecting step of separating the plurality of third non-adhering particles from the plurality of first non-adhering particles and the second non-adhering particles.

13. The method for producing a thermal spray powder according to claim 11 , further comprising:
a secondary-particle classifying step of obtaining a powder having a 10% cumulative particle diameter of not less than 20 μm and not more than 150 μm from the secondary particles obtained in the secondary-particle producing step,
wherein the preparing step further comprises an irregular-particle recovery step of recovering irregular particles excluded in the secondary-particle classifying step, and
wherein, in the powder crushing step, the plurality of first non-adhering particles, the plurality of second non-adhering particles, and the irregular particles are crushed collectively.

14. The method for producing a thermal spray powder according to claim 11 ,
wherein, in the non-adhering particle recovery step, the plurality of first non-adhering particles and the plurality of second non-adhering particles are recovered by a dust collector.

15. The method for producing a thermal spray powder according to claim 11 ,
wherein the first additive agent is yttrium oxide, and
wherein the second additive agent is ytterbium oxide.

16. The method for producing a thermal spray powder according to claim 11 ,
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Assignees

• Mitsubishi Hitachi Power Sys

Inventors

• Torigoe Taiji
• Nagano Ichiro
• Okajima Yoshifumi
• Okada Ikuo
• Mega Masahiko
• Uemura Yoshitaka
• Okaya Naotoshi
• Sakuma Shusuke

Classifications

• B22F1/00

  Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties · CPC title

• C23C4/073

  containing MCrAl or MCrAlY alloys, where M is nickel, cobalt or iron, with or without non-metal elements · CPC title

• F05D2300/21

  Oxide ceramics · CPC title

• C23C28/3455

  with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer · CPC title

• C09D5/036

  Stabilisers (organic stabilisers for paints C09D7/48) · CPC title