Thermal spray slurry, thermal spray coating and method for forming thermal spray coating

Patent metadata

Field	Value
Publication number	US-2017107604-A1
Application number	US-201615297464-A
Country	US
Kind code	A1
Filing date	Oct 19, 2016
Priority date	Oct 20, 2015
Publication date	Apr 20, 2017
Grant date	—

Abstract

Provided is a thermal spray slurry capable of satisfactorily forming a thermal spray coating with superior plasma erosion resistance. The invention provides a thermal spray slurry comprising thermal spray particles and a dispersion medium. The thermal spray particles comprise a compound containing yttrium (Y) and a halogen element (X) as constituent elements, and be present in an amount of 10% by mass or more and 70% by mass or less. The viscosity of the thermal spray slurry is 300 mPa·s or less.

First claim

1 . A thermal spray slurry comprising:
thermal spray particles comprising a compound containing yttrium (Y) and a halogen element (X) as constituent elements, the thermal spray particles being present in an amount of 10% by mass or more and 70% by mass or less; and a dispersion medium; a viscosity of the thermal spray slurry is 300 mPa·s or less.

2 . The thermal spray slurry of claim 1 , wherein the halogen element (X) is fluorine, and the thermal spray particles comprise yttrium fluoride.

3 . The thermal spray slurry of claim 1 , wherein the thermal spray particles comprise a compound that further contains oxygen (O) as a constituent element.

4 . The thermal spray slurry of claim 3 , wherein the halogen element (X) is fluorine, and the thermal spray particles comprises yttrium oxyfluoride.

5 . The thermal spray slurry of claim 4 , wherein the thermal spray particles comprise at least one selected from the group consisting of Y 5 O 4 F 7 , Y 6 O 5 F 8 , Y 7 O 6 F 9 and Y 17 O 14 F 23 in an amount of at least 95% by mass.

6 . The thermal spray slurry of claim 1 , wherein the sedimentation rate of the thermal spray particles contained in the thermal spray slurry is 30 μm/second or more.

7 . The thermal spray slurry of claim 1 , further comprising a dispersant.

8 . The thermal spray slurry of claim 1 , further comprising a viscosity adjuster.

9 . The thermal spray slurry of claim 1 , further comprising an agglomerating agent.

10 . The thermal spray slurry of claim 1 , wherein the average particle diameter of the thermal spray particles is 1 nm to less than 200 nm.

11 . The thermal spray slurry of claim 1 , wherein the average particle diameter of the thermal spray particles is 200 nm to 6 μm.

12 . A thermal spray coating that is a thermal spray deposit of the thermal spray slurry of claim 1 .

13 . A method for forming a thermal spray coating, the method comprising:
thermal spraying the thermal spray slurry of claim 1 to form a thermal spray coating.

14 . The method for forming a thermal spray coating of claim 13 , wherein
the thermal spray slurry contains water as the dispersion medium, and the thermal spray coating is formed by high-velocity flame spraying.

15 . The method for forming a thermal spray coating of claim 13 , wherein
the thermal spray slurry contains an organic solvent as the dispersion medium, and the thermal spray coating is formed by plasma spraying the thermal spray slurry.

16 . The method for forming a thermal spray coating of claim 13 , wherein the thermal spray slurry is supplied to a thermal spray system by axial feed.

17 . The method for forming a thermal spray coating of claim 13 , wherein the thermal spray slurry is supplied to a thermal spray system using two feeders in such a way that a fluctuation cycles of the amounts of thermal spray slurry supplied from the two feeders are in reverse phases to one another.

18 . The method for forming a thermal spray coating of claim 13 , wherein the thermal spray slurry is sent from a feeder and first accumulated in a tank immediately equipped before the thermal spray system, and the thermal spray slurry in the tank is then supplied to the thermal spray system using natural gravity.

19 . The method for forming a thermal spray coating of claim 13 , including a step of supplying the thermal spray slurry to the thermal spray system via an electrically conductive tube.

Assignees

• Fujimi Inc

Inventors

• Ibe Hiroyuki
• Sato Kazuto
• Tsuzuki Kazuyuki
• Masuda Takaya

Classifications

• C04B2235/5445

  submicron sized, i.e. from 0,1 to 1 micron · CPC title

• C23C4/129 Primary

  Flame spraying · CPC title

• C04B2235/3225

  Yttrium oxide or oxide-forming salts thereof · CPC title

• C23C4/134

  Plasma spraying · CPC title

• C23C4/04 Primary

  characterised by the coating material · CPC title