Process for producing a layer

Patent metadata

Field	Value
Publication number	US-10415141-B2
Application number	US-201515323351-A
Country	US
Kind code	B2
Filing date	Jun 30, 2015
Priority date	Jul 3, 2014
Publication date	Sep 17, 2019
Grant date	Sep 17, 2019

Abstract

A process for producing a layer or a body built up of layers. A process gas which has a pressure of >10 bar is accelerated in a convergent-divergent nozzle and a coating material which is formed by particles and is composed of Mo, W, an Mo-based alloy or a W-based alloy is injected into the process gas. The particles are at least partly present as aggregates and/or agglomerates. It is possible to produce dense layers and components in this way. We also describe layers and components having a microstructure with cold-deformed grains having a high aspect ratio.

First claim

The invention claimed is:

1. A process for producing a layer or a body built up of layers, the process comprising:
providing a coating material formed of particles selected from the group consisting of Mo, W, an Mo-based alloy, a W-based alloy, and an Mo—W alloy, wherein greater than 50% of all of the particles are present as aggregates and/or agglomerates;
providing the aggregates and/or agglomerates with an average surface area, which is measured by BET, of greater than 0.05 m 2 /g, and wherein the aggregates and/or agglomerates have an average porosity, which is determined by quantitative image analysis, of greater than 10% by volume;
providing a process gas at a pressure of greater than 10 bar;
accelerating the process gas in a convergent-divergent nozzle and injecting the coating material into the process gas before, in or after the convergent-divergent nozzle; and
depositing the coating material to form the layer or the body built up of layers.

2. A process for producing a layer or a body built up of layers, the process comprising: providing a coating material formed of particles selected from the group consisting of Mo, Wo, an Mo-based alloy, a W-based alloy, and an Mo-W alloy, wherein the particles are at least partly present as aggregates and/or agglomerates and wherein the particles at least partly have an average porosity, determined by quantitative image analysis, of >10% by volume; providing a process gas at a pressure of greater than 10 bar; accelerating the process gas in a convergent-divergent nozzle and injecting the coating material into the process gas before, in or after the convergent-divergent nozzle; and depositing the coating material to form the layer or the body built up of layers.

3. The process according to claim 1 , which comprises providing the aggregates and/or agglomerates with an average nanohardness HIT 0.005/30/1/30 of ≤10 GPa.

4. The process according to claim 1 , which comprises providing the coating material at least partly in granulate form.

5. The process according to claim 1 , which comprises providing the coating material with spherical particles having an average porosity, which is determined by quantitative image analysis, of <10% by volume.

6. The process according to claim 1 , wherein the coating material comprises hard material particles.

7. The process according to claim 1 , wherein the coating material has a bimodal or multimodal particle size distribution.

8. The process according to claim 1 , which comprises passing the process gas through a heater.

9. The process according to claim 7 , wherein the heater has, at least in regions, a temperature of >800° C.

10. The process according to claim 1 , which comprises providing the process gas with a nitrogen content of >50% by volume.

11. The process according to claim 1 , which comprises providing the coating material with >80 at. % of at least one element selected from the group consisting of Mo and W.

12. The process according to claim 1 , which comprises introducing thermal energy into the coating material before and/or during impingement on a substrate body or a previously produced layer.

13. The process according to claim 12 , wherein the introducing step comprises injecting the thermal energy by way of electromagnetic waves and/or by way of induction.

14. The process according to claim 1 , which comprises depositing the coating material on a substrate body to form an adhering layer having an average layer thickness of >10 μm on impingement on the substrate body.

15. The process according to claim 1 , which comprises producing a body made up of a multiplicity of layers.

Assignees

• Plansee Se

Inventors

• O'Sullivan Michael
• Kathrein Martin
• Leichtfried Gerhard
• Hosp Thomas
• Lang Bernhard
• Sprenger Dietmar

Classifications

• B05B7/16

  incorporating means for heating {or cooling} the material to be sprayed {(spraying by means of explosions B05B7/0006)} · CPC title

• B05B7/14

  designed for spraying particulate materials (B05B7/16 takes precedence) · CPC title

• B05B7/0025

  with a compressed gas supply · CPC title

• B01J19/10

  employing sonic or ultrasonic vibrations · CPC title

• B01J2/06

  in a liquid medium · CPC title