Thermal spray material

Patent metadata

Field	Value
Publication number	US-11293696-B2
Application number	US-201515500417-A
Country	US
Kind code	B2
Filing date	Jun 30, 2015
Priority date	Aug 8, 2014
Publication date	Apr 5, 2022
Grant date	Apr 5, 2022

Abstract

Provided is a thermal spray material capable of, when used in a thermal spray operation for repairing a furnace wall of an industrial furnace or for other purposes, maintaining good post-repetition bondability with respect to a target surface to thereby prevent peel-off of a resulting thermally sprayed deposit, and improving initial ignitability while suppressing dust-generating property. The thermal spray material comprised a basic compound comprising at least one of a Ca component and an Mg component, a metal Si powder, and a silica-based or alumina-silica based powder. A content rate of a fraction constituting the basic compound and having a particle size of 0.15 mm or less is 30 mass % or more with respect to 100 mass % of the basic compound, and a content rate of a fraction constituting the metal Si powder and having a particle size of 20 μm or less is from 10 mass % to 25 mass % with respect to 100 mass % of the thermal spray material. Further, (the content rate (mass %) of the fraction constituting the metal Si powder and having a particle size of 20 μm or less, with respect to 100 mass % of the thermal spray material)/(a content rate (mass %) of the fraction constituting the basic compound and having a particle size of 0.15 mm or less, with respect to 100 mass % of the thermal spray material) is from 0.8 to 10, and a content rate of a fraction constituting the metal Si powder and having a particle size of 10 μm or less is 60 mass % or more with respect to 100 mass % of the metal Si powder.

First claim

The invention claimed is:

1. A thermal spray material capable of being sprayed onto a target surface using oxygen or oxygen-containing gas as a carrier gas and melt-adhered to the target surface by means of heat generated based on combustion of a metal Si powder, the thermal spray material containing:
a basic compound comprising at least one of a Ca component and an Mg component, in an amount of 4.5 mass % to 20 mass %;
a metal Si powder in an amount of 15 mass % to 30 mass %; and
one or more refractory powders selected from the group consisting of silica-based powders and alumina-silica based powders, in an amount of 50 mass % to 86 mass %;
wherein:
a content rate of a fraction constituting the basic compound and having a particle size of 0.15 mm or less is 30 mass % or more with respect to 100 mass % of the basic compound;
a content rate of a fraction constituting the metal Si powder and having a particle size of 20 μm or less is from 15 mass % to 25 mass % with respect to 100 mass % of the thermal spray material;
(the content rate (mass %) of the fraction constituting the metal Si powder and having a particle size of 20 μm or less, with respect to 100 mass % of the thermal spray material)/(a content rate (mass %) of the fraction constituting the basic compound and having a particle size of 0.15 mm or less, with respect to 100 mass % of the thermal spray material) is from 0.8 to 10; and
a content rate of a fraction constituting the metal Si powder and having a particle size of 10 μm or less is 60 mass % or more with respect to 100 mass % of the metal Si powder,
and wherein the content rate of the fraction constituting the basic compound and having a particle size of 0.15 mm or less is from 4 mass % to 16 mass % with respect to 100 mass % of the thermal spray material.

2. The thermal spray material as recited in claim 1 , wherein (the content rate (mass %) of the fraction constituting the metal Si powder and having a particle size of 20 μm or less, with respect to 100 mass % of the thermal spray material)/(the content rate (mass %) of the fraction constituting the basic compound and having a particle size of 0.15 mm or less, with respect to 100 mass % of the thermal spray material) is from 1 to 3.6.

Assignees

• Krosakiharima Corp

Inventors

• Honda Kazuhiro

Classifications

• F27D1/1636

  Repairing linings by projecting or spraying refractory materials on the lining · CPC title

• C04B35/66

  Monolithic refractories or refractory mortars, including those whether or not containing clay {(making or repairing of linings F27D1/16)} · CPC title

• C23C4/04 Primary

  characterised by the coating material · CPC title

• C23C4/067

  containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic · CPC title

• C23C4/10

  Oxides, borides, carbides, nitrides or silicides; Mixtures thereof · CPC title