Coating method using special powdered coating materials and use of such coating materials

Patent metadata

Field	Value
Publication number	US-9580787-B2
Application number	US-201214234872-A
Country	US
Kind code	B2
Filing date	Jul 25, 2012
Priority date	Jul 25, 2011
Publication date	Feb 28, 2017
Grant date	Feb 28, 2017

Abstract

The invention relates to the use of a particle-containing powdered coating material in a coating method selected from the group consisting of cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying, wherein the particles have a relative deformability factor V m of at most 0.1 and the relative deformability factor is defined according to Formula (I):

V
m

=

d

D
50

,

(
I
)

wherein d is the average smallest thickness of the particles, measured vertical to and in the middle half of the longitudinal axis of the particles, and D 50 is the average diameter of the volume-averaged particle-size distribution.

The invention furthermore relates to a method for coating.

First claim

The invention claimed is:

1. A process for producing a coating on a substrate, comprising:
introducing a particle-containing powdered coating material in a coating method selected from the group consisting of cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying for coating a substrate, wherein the particles have a relative deformability factor V m of at most 0.1 and the relative deformability factor is defined according to Formula (I):

V
m

=

d

D
50

,

(
I
)

wherein d is the average smallest thickness of the particles, measured vertical to and in the middle half of the longitudinal axis of the particles, and D 50 is the average diameter of the volume-averaged particle-size distribution.

2. The process according to claim 1 , wherein the relative deformability factor is defined according to Formula (II) taking into account the Mohs hardness of the particles relative to the Mohs hardness of silver:

V
m

=

d

D
50

·

H
X

H
Ag

,

(
II
)

wherein H X is the Mohs hardness of the particles and H Ag is the Mohs hardness of silver.

3. The process according to claim 1 , wherein the relative deformability factor of the powdered coating material is at most 0.01.

4. The process according to claim 1 , wherein the particles of the powdered coating material have a technical elastic limit of more than 45 N/mm 2 .

5. The process according to claim 1 , wherein the melting point, measured in [K], of the particles of the coating material is at most 60% of the temperature, measured in [K], of the medium utilized in the coating method directed onto the substrate.

6. The process according to claim 1 , wherein the particles comprise metal particles, and the metal is selected from the group consisting of silver, gold, platinum, palladium, vanadium, chromium, manganese, cobalt, germanium, antimony, aluminum, zinc, tin, iron, copper, nickel, titanium, silicon, alloys and mixtures thereof.

7. The process according to claim 1 , wherein the coating method is selected from the group consisting of flame spraying and non-thermal plasma spraying.

8. The process according to claim 1 , wherein the powdered coating material has a particle-size distribution with a D 50 value from a range of from 1.5 to 84 μm.

9. The process according to claim 1 , wherein the powdered coating material has a particle-size distribution with a D 10 value from a range of from 3.7 to 26 μm, a D 50 value from a range of from 6 to 49 μm and a D 90 value from a range of from 12 to 86 μm.

10. The process according to claim 1 , wherein the span of the powdered coating material is at most 2.9, wherein the span is defined according to Formula (III):

Span
=

D
90

-

D
10

D
50

.

(
III
)

11. The process according to claim 1 , wherein the particles of the powdered coating material are at least partially coated.

12. A method for coating a substrate selected from the group consisting of cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying and non-thermal plasma spraying,
the method comprising:
(a) introducing a particle-containing powdered coating material into a medium directed onto a substrate to be coated by cold gas spraying, flame spraying, high-speed flame spraying, thermal plasma spraying or non-thermal plasma spraying, wherein the particles have a relative deformability factor V m of at most 0.1 and the relative deformability factor is defined according to Formula (I):

V
m

=

d

D
50

,

(
I
)

wherein d is the average smallest thickness of the particles, measured vertical to and in the middle half of the longitudinal axis of the particles, and D 50 is the average diameter of the volume-averaged particle-size distribution; and
(b) depositing the powdered coating material onto the substrate.

13. The method according to claim 12 , wherein the coating method is selected from the group consisting of flame spraying and non-thermal plasma spraying.

14. The method according to claim 12 , wherein the powdered coating material is conveyed as an aerosol.

15. The method according to claim 12 , wherein the medium directed onto the substrate is air or has been produced from air.

16. The process according to claim

Assignees

• Höfener Sebastian
• Rupprecht Markus
• Wolfrum Christian
• Reis Andreas
• Eckart Gmbh

Inventors

• Höfener Sebastian
• Rupprecht Markus
• Wolfrum Christian
• Reis Andreas

Classifications

• C23C24/04

  Impact or kinetic deposition of particles · CPC title

• C23C4/12

  characterised by the method of spraying · CPC title

• C23C4/129

  Flame spraying · CPC title

• C23C4/08 Primary

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

• C23C4/10

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