Method of manufacturing laminate and laminate

Patent metadata

Field	Value
Publication number	US-2017145552-A1
Application number	US-201515308717-A
Country	US
Kind code	A1
Filing date	May 29, 2015
Priority date	Jun 11, 2014
Publication date	May 25, 2017
Grant date	—

Abstract

A method of manufacturing a laminate in which a spray coating film made of a material different from a base material is laminated on the base material includes: a base material heating step of heating the base material; an intermediate layer forming step of forming, on a surface of the heated base material, an intermediate layer made of a material different from the base material and the spray coating film; and a spray coating film forming step of forming the spray coating film on a surface of the intermediate layer.

First claim

1 . A method of manufacturing a laminate in which a spray coating film made of a material different from a base material is laminated on the base material, the method comprising:
a base material heating step of heating the base material; an intermediate layer forming step of forming, on a surface of the heated base material, an intermediate layer made of a material different from the base material and the spray coating film; and a spray coating film forming step of forming the spray coating film on a surface of the intermediate layer.

2 . The method of manufacturing a laminate according to claim 1 , wherein compressive stress is accumulated in the intermediate layer at the time of start of the spray coating film forming step.

3 . The method of manufacturing a laminate according to claim 1 , further comprising:
a base material lowering step of lowering a temperature of the base material until stress in the intermediate layer becomes compressive stress, after the intermediate layer forming step.

4 . The method of manufacturing the laminate according to claim 1 , wherein, in the base material heating step, the base material is heated in a range from ⅕ or higher of a melting point of the base material to the melting point or lower of the base material.

5 . The method of manufacturing the laminate according to claim 1 , wherein, in the intermediate layer forming step, the intermediate layer is formed so that porosity of the intermediate layer is 3% or more.

6 . The method of manufacturing the laminate according to claim 1 , wherein, in the intermediate layer forming step, the intermediate layer is formed so that a thickness of the intermediate layer is in a range from 100 μm or more to 800 μm or less.

7 . The method of manufacturing the laminate according to claim 1 , wherein, in the intermediate layer forming step, powders of material of the intermediate layer and a gas are accelerated toward the surface of the heated base material, and the powders are sprayed and deposited on the surface of the base material, while being kept in a solid phase state.

8 . The method of manufacturing the laminate according to claim 1 , wherein, in the intermediate layer forming step, the material of the intermediate layer is thermally sprayed onto the surface of the heated base material.

9 . A laminate comprising:
a base material; an intermediate layer made of a material different from the base material; and a spray coating film which is made of a material different from the base material and the intermediate layer, and is formed on a surface of the intermediate layer, wherein compressive stress is accumulated in the intermediate layer at room temperature.

10 . The laminate according to claim 9 , wherein porosity of the intermediate layer is 3% or more.

11 . The laminate according to claim 9 , wherein a thickness of the intermediate layer is in a range from 100 μm or more to 800 μm or less.

12 . The laminate according to claim 9 , wherein the base material is made of a metal or an alloy, and the spray coating film is made of ceramic or cermet.

13 . The laminate according to claim 9 , wherein the intermediate layer is formed by accelerating powders of the material different from the base material and a gas toward a surface of the base material, and by spraying and depositing the powders onto the surface of the base material, while being kept in a solid phase state.

14 . The laminate according to claim 9 , wherein the intermediate layer is formed by thermally spraying a material different from the base material onto the surface of the base material.

Assignees

• Nhk Spring Co Ltd

Inventors

• Hirano Satoshi
• Futakuchiya Jun
• Ishioka Yasuaki
• Ito Naoki
• Itami Yohei

Classifications

• C23C4/123 Primary

  Spraying molten metal · CPC title

• C23C28/02

  only coatings {only including layers} of metallic material · CPC title

• B32B15/043 Primary

  of metal (B32B15/01 takes precedence) · CPC title

• C23C24/04

  Impact or kinetic deposition of particles · CPC title

• B32B2255/06

  on metal layer · CPC title