Thermal spray powder, method of forming abradable thermal spray coating using the same, and abradable thermal spray coating

Patent metadata

Field	Value
Publication number	US-10301713-B2
Application number	US-201715471488-A
Country	US
Kind code	B2
Filing date	Mar 28, 2017
Priority date	Mar 31, 2016
Publication date	May 28, 2019
Grant date	May 28, 2019

Abstract

There is provided a thermal spray powder for forming an abradable thermal spray coating. The thermal spray powder includes NiCr alloy particles and synthetic mica particles. The synthetic mica particles are contained at 40 volume % or less with respect to a total volume of the thermal spray powder.

First claim

What is claimed is:

1. A thermal spray powder for forming an abradable thermal spray coating, comprising:
NiCr alloy particles;
synthetic mica particles; and
h-BN particles, wherein
the synthetic mica particles are contained at 30 volume % or less with respect to a total volume of the thermal spray powder, and
the h-BN particles are contained at 15 volume % or less with respect to the total volume of the thermal spray powder.

2. The thermal spray powder according to claim 1 , wherein
the synthetic mica particles are contained at 20 volume % or more with respect to the total volume of the thermal spray powder.

3. The thermal spray powder according to claim 1 , wherein
the synthetic mica particles are particles made of fluorine phlogopite.

4. The thermal spray powder according to claim 1 , wherein
the NiCr alloy particles contain Cr at 20 to 50 mass %.

5. The thermal spray powder according claim 1 , wherein
the NiCr alloy particles contain Al at 0.1 to 5 mass %.

6. An abradable thermal spray coating, comprising:
NiCr alloy particles;
synthetic mica particles; and
h-BN particles, wherein
the synthetic mica particles are contained at 40 volume % or less with respect to a total volume of powders contained in the abradable thermal spray coating, and
the h-BN particles are contained at 15 volume % or less with respect to the total volume of the thermal spray powder.

7. The abradable thermal spray coating according to claim 6 , wherein
the synthetic mica particles are contained at 20 volume % or more with respect to the total volume of powders contained in the abradable thermal spray coating.

8. The abradable thermal spray coating according to claim 6 , wherein
the synthetic mica particles include shells on surfaces of the synthetic mica particles, the shells being formed by a solidification of melted synthetic mica particles.

9. The thermal spray powder according to claim 1 , wherein
the synthetic mica particles are contained at 10 volume % or more with respect to the total volume of the thermal spray powder, and the h-BN particles are contained at 5 volume % or more with respect to the total volume of the thermal spray powder.

10. The abradable thermal spray coating according to claim 6 , wherein
the synthetic mica particles are contained at 10 volume % or more with respect to the total volume of the thermal spray powder, and the h-BN particles are contained at 5 volume % or more with respect to the total volume of the thermal spray powder.

11. A method of forming an abradable thermal spray coating using the thermal spray powder according to claim 1 , comprising:
forming the abradable thermal spray coating while some of the synthetic mica particles contained in the thermal spray powder remain in a solid phase state.

12. The forming method according to claim 11 , wherein
forming of the abradable thermal spray coating using the thermal spray powder is performed by gas flame thermal spraying.

13. The forming method according to claim 12 , wherein
at least one of conditions including (i) a supply flow rate of a combustion gas supplied to a thermal spray gun, (ii) an air pressure of air supplied to the thermal spray gun, (iii) a thermal spray distance between a base material on which the abradable thermal spray coating is formed and the thermal spray gun, and (iv) a supply rate of the thermal spray powder to the base material is adjusted so that some of the synthetic mica particles remain in a solid phase state.

Assignees

• Toyota Motor Co Ltd

Inventors

• Miyamoto Noritaka
• Kurase Masahiro
• Hotta Toshio
• Koyama Mototsugu
• Yamamoto Eisuke

Classifications

• C23C4/04

  characterised by the coating material · CPC title

• C09D1/00

  Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances · CPC title

• C23C4/06

  Metallic material · CPC title

• C09D1/02

  alkali metal silicates · CPC title

• C23C4/129 Primary

  Flame spraying · CPC title