Method of manufacturing laminate and laminate

Patent metadata

Field	Value
Publication number	US-10315388-B2
Application number	US-201515308717-A
Country	US
Kind code	B2
Filing date	May 29, 2015
Priority date	Jun 11, 2014
Publication date	Jun 11, 2019
Grant date	Jun 11, 2019

Abstract

A method of manufacturing a laminate in which a spray coating film made of a material different from a base material is laminated on the base material includes: a base material heating step of heating the base material; an intermediate layer forming step of forming, on a surface of the heated base material, an intermediate layer made of a material different from the base material and the spray coating film; and a spray coating film forming step of forming the spray coating film on a surface of the intermediate layer.

First claim

The invention claimed is:

1. A method of manufacturing a laminate in which a spray coating film made of a material different from a base material is laminated on the base material, the method comprising:
heating a base material made of a metal or an alloy;
forming, on a surface of the heated base material, an intermediate layer made of a material different from the base material and the spray coating film, wherein the intermediate layer is made of a metal or an alloy and has a thermal expansion coefficient between those of the base material and the spray coating film;
lowering a temperature of the base material until stress in the intermediate layer becomes compressive stress, after the forming of the intermediate layer; and
forming the spray coating film on a surface of the intermediate layer in a state where a temperature of the base material is lowered at the lowering operation,
wherein the spray coating film is formed of a ceramic-based material, or a mixed material of metal and ceramics.

2. The method of manufacturing a laminate according to claim 1 , wherein compressive stress is accumulated in the intermediate layer at the time of start of the spray coating film forming step.

3. The method of manufacturing the laminate according to- claim 1 , wherein, in the base material heating step, the base material is heated in a range from ⅕ or higher of a melting point of the base material to the melting point or lower of the base material.

4. The method of manufacturing the laminate according to- claim 1 , wherein, in the intermediate layer forming step, the intermediate layer is formed so that porosity of the intermediate layer is 3% or more.

5. The method of manufacturing the laminate according to- claim 1 , wherein, in the intermediate layer forming step, the intermediate layer is formed so that a thickness of the intermediate layer is in a range from 100 μm or more to 800 μm or less.

6. The method of manufacturing the laminate according to- claim 1 , wherein, in the intermediate layer forming step, powders of material of the intermediate layer and a gas are accelerated toward the surface of the heated base material, and the powders are sprayed and deposited on the surface of the base material, while being kept in a solid phase state.

7. The method of manufacturing the laminate according to- claim 1 , wherein, in the intermediate layer forming step, the material of the intermediate layer is thermally sprayed onto the surface of the heated base material.

Assignees

• Nhk Spring Co Ltd

Inventors

• Hirano Satoshi
• Futakuchiya Jun
• Ishioka Yasuaki
• Ito Naoki
• Itami Yohei

Classifications

• C23C28/321

  with at least one metal alloy layer · CPC title

• C23C4/123

  Spraying molten metal · CPC title

• C23C28/345

  with at least one oxide layer · CPC title

• B32B15/043 Primary

  of metal (B32B15/01 takes precedence) · CPC title

• C23C4/11

  Oxides · CPC title