Wear-resistant Cu—Ni—Sn coating

Patent metadata

Field	Value
Publication number	US-10626489-B2
Application number	US-201715792295-A
Country	US
Kind code	B2
Filing date	Oct 24, 2017
Priority date	Oct 24, 2016
Publication date	Apr 21, 2020
Grant date	Apr 21, 2020

Abstract

The present disclosure relates to a method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process. Briefly, a copper-nickel-tin alloy feedstock is converted into a powder or droplet form, then sprayed onto a substrate to form a coating thereon.

First claim

The invention claimed is:

1. A method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process, the steps comprising:
applying heat to a copper-nickel-tin alloy provided as a feedstock in the shape of a wire;
mixing the heated copper-nickel-tin alloy with a carrier gas to form a copper-nickel-tin alloy mixture; and
spraying the resulting copper-nickel-tin alloy mixture upon a substrate to provide a spinodal outer coating thereon.

2. The coating method of claim 1 , wherein the copper-nickel-tin alloy is about 8 wt % to about 22 wt % nickel, about 4 wt % to about 10 wt % tin, and the remaining balance is copper.

3. The coating method of claim 1 , wherein the thermal spray process is a cold spray, plasma spray, warm spray, detonation spray, high-velocity oxy fuel spray, or arc spray process.

4. The coating method of claim 1 , wherein the spraying occurs at a pressure of about 20 bar to about 40 bar.

5. The coating method of claim 1 , wherein the alloy mixture has a temperature of about 350° C. to about 700° C.

6. The coating method of claim 1 , wherein the coating has a thickness of about 100 micrometers to about 2000 micrometers.

7. The coating method of claim 1 , wherein the alloy mixture is sprayed at a velocity of 50 m/s to 1500 m/s.

8. A method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process, the steps comprising:
applying heat to a copper-nickel-tin alloy;
mixing the heated copper-nickel-tin alloy with a carrier gas to form a copper-nickel-tin alloy mixture; and
spraying the resulting copper-nickel-tin alloy mixture upon a substrate to provide a spinodal outer coating thereon, wherein the spraying occurs at a pressure of about 20 bar to about 40 bar.

9. The coating method of claim 8 , wherein the copper-nickel-tin alloy is about 8 wt % to about 22 wt % nickel, about 4 wt % to about 10 wt % tin, and the remaining balance is copper.

10. The coating method of claim 8 , wherein the thermal spray process is a cold spray, plasma spray, warm spray, detonation spray, high-velocity oxy fuel spray, or arc spray process.

11. The coating method of claim 8 , wherein the alloy mixture has a temperature of about 350° C. to about 700° C.

12. The coating method of claim 8 , wherein the coating has a thickness of about 100 micrometers to about 2000 micrometers.

13. The coating method of claim 8 , wherein the alloy mixture is sprayed at a velocity of 50 m/s to 1500 m/s.

14. A method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process, the steps comprising:
applying heat to a copper-nickel-tin alloy;
mixing the heated copper-nickel-tin alloy with a carrier gas to form a copper-nickel-tin alloy mixture; and
spraying the resulting copper-nickel-tin alloy mixture upon a substrate to provide a spinodal outer coating thereon, wherein the coating has a thickness of about 100 micrometers to about 2000 micrometers.

15. The coating method of claim 14 , wherein the copper-nickel-tin alloy is about 8 wt % to about 22 wt % nickel, about 4 wt % to about 10 wt % tin, and the remaining balance is copper.

16. The coating method of claim 14 , wherein the thermal spray process is a cold spray, plasma spray, warm spray, detonation spray, high-velocity oxy fuel spray, or arc spray process.

17. The coating method of claim 14 , wherein the spraying occurs at a pressure of about 20 bar to about 40 bar.

18. The coating method of claim 14 , wherein the alloy mixture has a temperature of about 350° C. to about 700° C.

19. The coating method of claim 14 , wherein the alloy mixture is sprayed at a velocity of 50 m/s to 1500 m/s.

20. A method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process, the steps comprising:
applying heat to a copper-nickel-tin alloy;
mixing the heated copper-nickel-tin alloy with a carrier gas to form a copper-nickel-tin alloy mixture; and
spraying the resulting copper-nickel-tin alloy mixture upon a substrate to provide a spinodal outer coating thereon, wherein the alloy mixture is sprayed at a velocity of 50 m/s to 1500 m/s.

21. The coating method of claim 20 , wherein the copper-nickel-tin alloy is about 8 wt % to about 22 wt % nickel, about 4 wt % to about 10 wt % tin, and the remaining balance is copper.

22. The coating method of claim 20 , wherein the thermal spray process is a cold spray, plasma spray, warm spray, detonation spray, high-velocity oxy fuel spray, or arc spray process.

23. The coating method of claim 20 , wherein the spraying occurs at a pressure of about 20 bar to about 40 bar.

24. The coating method of claim 20 , wherein the alloy mixture has a temperature of about 350° C. to about 700° C.

25. The coating method of claim 20 , wherein the coating has a thickness of about 100 micrometers to about 2000 micrometers.

Assignees

• Materion Corp

Inventors

• Grensing Fritz C
• Kusner Robert E
• Krus David J
• Nielsen William D
• Ziegler Karl

Classifications

• C23C4/08 Primary

  containing only metal elements (C23C4/073 takes precedence) · CPC title

• F16C33/121

  Use of special materials · CPC title

• C22C9/06

  with nickel or cobalt as the next major constituent · CPC title

• F16C2223/42

  by spraying the coating material, e.g. plasma spraying · CPC title

• C23C24/04

  Impact or kinetic deposition of particles · CPC title