Pre-formulated powder feedstock

Patent metadata

Field	Value
Publication number	US-10329656-B2
Application number	US-201415317792-A
Country	US
Kind code	B2
Filing date	Sep 18, 2014
Priority date	Sep 18, 2014
Publication date	Jun 25, 2019
Grant date	Jun 25, 2019

Abstract

A powder composition adapted for use in suspension thermal spray coating processes. The powder includes agglomerated and/or non-agglomerated particles having at least one dispersing agent deposited thereon. The composition results in a homogeneous, stable suspension when combined with a liquid carrier for use in suspension thermal spray coating processes.

First claim

What is claimed is:

1. A powder composition adapted for use in suspension thermal spray coating processes, wherein the powder composition comprises primary particles having at least one dispersing agent deposited thereon, the composition resulting in a homogeneous, stable suspension when combined with a liquid carrier use in suspension thermal spray processes, wherein the dispersing agent is 2-[2-(2-methoxyethoxy) ethoxy] acetic acid, and the primary particles comprise at least one of: oxides of aluminum, zirconium, titanium, chromium, manganese cobalt, yttrium, lanthanum, lanthanum strontium, manganese, manganese cobalt iron, dysprosium; carbides of titanium, tantalum, tungsten, chromium, vanadium, nickel; lanthanum strontium manganite, pure metal and/or alloys based on nickel, cobalt iron, chromium, aluminum, copper; yttrium fluoride, lanthanum strontium cobalt ferrite, zirconia gadolinia ytterbia yttria, gadolinium zirconate, lanthanum strontium maganate, lanthanum strontium cobalt ferrite; zirconia stabilized with magnesia, calcia, dysprosia, yttria, ceria, vtterbia; ytterbium zirconate, strontium, and mixtures and/or composites thereof.

2. The composition of claim 1 , wherein the primary particles are agglomerated and/or non-agglomerated.

3. The composition of claim 1 , wherein the primary particles are up to about 10 microns in size.

4. The composition of claim 1 , wherein the primary particles are up to about 2 microns in size.

5. The composition of claim 1 , wherein the primary particles are up to about 0.1 micron in size.

6. The composition of claim 1 , wherein the primary particles are about 0.1 to about 1 micron in size.

7. The composition of claim 1 , wherein the dispersing agent is present in an amount of up to about 5% by weight.

8. The composition of claim 1 , wherein the dispersing agent is present in an amount of about 0.1% to about 1% by weight.

9. The composition of claim 1 , wherein the powder composition additionally contains a binder deposited on the primary particles.

10. The composition of claim 9 , wherein the binder is polyvinyl alcohol.

11. The composition of claim 9 , wherein the binder is present in an amount up to about 5% by weight.

12. The composition of claim 9 , wherein the binder is present in an amount up to about 0.2% by weight.

13. The composition of claim 9 , wherein the binder is present in an amount of about 0.01% to about 0.2% by weight.

14. The composition of claim 1 , wherein the liquid carrier is an organic liquid.

15. The composition of claim 1 , wherein the liquid carrier is one or more of a ketone, alcohol, glycol, and or aliphatic hydrocarbons.

16. The composition of claim 1 , wherein the liquid carrier is one or more of water, acetone, methyl alcohol, ethyl alcohol, isopropyl alcohol, ethylene glycol, hexane, and/or octane.

17. The composition of claim 1 , additionally containing sufficient liquid to be in paste form.

18. A homogenous, stable suspension used in suspension spray coating processes, wherein the suspension comprises (a) a powder composition comprising primary particles having at least one dispersing agent thereon and (b) a liquid carrier; the dispersing agent is a polymer salt, an inorganic salt, a non-ionic organic compound, and/or acid or base that produces dispersion effect through pH adjustment and is present in an amount of up to about 10% by weight; the liquid carrier is a liquid selected form the group consisting of water, a ketone, an alcohol, a glycol, an aliphatic hydrocarbon, and combinations thereof; and the primary particles comprise at least one of: oxides of aluminum, zirconium, titanium, chromium, manganese cobalt, yttrium, lanthanum, lanthanum strontium, manganese, manganese cobalt iron, dysprosium; carbides of titanium, tantalum, tungsten, chromium, vanadium, nickel; lanthanum strontium manganite, pure metal and/or alloys based on nickel, cobalt iron, chromium, aluminum, copper; yttrium fluoride, lanthanum strontium cobalt ferrite, zirconia gadolinia ytterbia yttria, gadolinium zirconate, lanthanum strontium maganate, lanthanum strontium cobalt ferrite; zirconia stabilized with magnesia, calcia, dysprosia, yttria, ceria, vtterbia; ytterbium zirconate, strontium, and mixtures and/or composites thereof.

19. A homogenous, stable suspension used in suspension spray coating processes, wherein the suspension comprise (a) a powder composition comprising primary particles having at least one dispersing agent deposited thereon, wherein the dispersing agent is 2-[2-(2-methoxyethoxy) ethoxy] acetic acid and is present in an amount of up to about 10% by weight, and (b) a liquid carrier[[; the dispersing agent is 2-[2-(2-methoxyethoxy) ethoxy] acetic acid, and is present in an amount of up to about 10% by weight and]] wherein the liquid carrier is an organic liquid.

20. The suspension of claim 19 , wherein the powder composition additionally contains a binder deposited on the primary particles.

21. The suspension of claim 18 , wherein the liquid carrier is acetone, methyl alcohol, isopropyl alcohol, ethylene glycol, hexane, and/or octane.

22. The suspension of claim 18 , wherein the primary particles are agglomerated and/or non-agglomerated.

23. The suspension of claim 18 , wherein the primary particles are up to about 10 microns in size.

24. The suspension of claim 18 , wherein the primary particles are up to about 2 microns in size.

25. The suspension of claim 18 , wherein the primary particles are up to about 0.1 micron in size.

26. The suspension of claim 18 , wherein the primary particles are about 0.1 to about 1 micron in size.

27. The suspension of claim 18 , wherein the dispersing agent is 2-[2-(2-methoxyethoxy) ethoxy] acetic acid.

28. The suspension of claim 18 , wherein the dispersing agent is present in an amount of up to about 5% by weight.

29. The suspension of claim 18 , wherein the dispersing agent is present in an amount of about 0.1% to about 1% by weight.

30. The suspension of claim 18 , wherein the powder composition additionally contains a binder deposited on the primary particles.

31. The suspension of claim 30 , wherein the binder is polyvinyl alcohol.

32. The suspension of claim 30 , wherein the binder is present in an amount up to about 5% by weight.

33. The suspension of claim 30 , wherein the binder is present in an amount up to about 0.2% by weight.

34. The suspension of claim 30 , wherein the binder is present in an amount of about 0.01% to about 0.2% by weight.

35. The suspension of claim 18 , wherein the liquid carrier is an organic liquid.

36. The suspension of claim 35 , wherein the organic liquid is one or more of a ketone, alcohol, glycol, and or aliphatic hydrocarbons.

Assignees

• Oerlikon Metco Us Inc

Inventors

• Callen Brian
• Liu Jing
• Nestler Montia
• Stelmack Eugene
• Runte Mathias

Classifications

• C23C4/134

  Plasma spraying · CPC title

• B22F1/0062

  Operations & Transport · mapped topic

• B22F1/0096

  Operations & Transport · mapped topic

• C09D1/00

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

• C23C4/04 Primary

  characterised by the coating material · CPC title