Coated metallic powder and method of making the same

Patent metadata

Field	Value
Publication number	US-9682425-B2
Application number	US-63368609-A
Country	US
Kind code	B2
Filing date	Dec 8, 2009
Priority date	Dec 8, 2009
Publication date	Jun 20, 2017
Grant date	Jun 20, 2017

Abstract

A metallic powder is disclosed. The metallic powder includes a plurality of metallic powder particles. Each powder particle includes a particle core. The particle core includes a core material comprising Mg, Al, Zn or Mn, or a combination thereof, having a melting temperature (T P ). Each powder particle also includes a metallic coating layer disposed on the particle core. The metallic coating layer includes a metallic coating material having a melting temperature (T C ). The powder particles are configured for solid-state sintering to one another at a predetermined sintering temperature (T S ), and T S is less than T P and T C .

First claim

The invention claimed is:

1. A metallic powder comprising a plurality of metallic powder particles disposed in a powder compact, each powder particle comprising:
a particle core, the particle core comprises a core material comprising Mg, Al, Zn or Mn, or a combination thereof; and
a metallic coating layer disposed on the particle core and comprising a metallic coating material, wherein the metallic coating layer comprises a plurality of coating layers, and wherein a first coating layer comprises Al, a second coating layer comprises Al, Zn, Mn, Mg, Mo, W, Cu, Fe, Si, Ca, Co, Ta, Re, or Ni, or an oxide, nitride or carbide thereof, or a combination of any of the aforementioned second coating layer materials, and a third coating layer comprises Al, Zn, Mn, Mg, Mo, W, Fe, Si, Ca, Co, Ta, Re, or Ni, or a combination thereof, wherein the first coating layer has a chemical composition that is different than a chemical composition of the second coating layer, and the chemical composition of the second coating layer is different than a chemical composition of the third layer, and wherein the powder compact of the powder particles is selectively and controllably dissolvable in a predetermined wellbore fluid comprising potassium chloride, hydrochloric acid, calcium chloride, calcium bromide or zinc bromide.

2. The metal powder of claim 1 , wherein the particle core has a diameter of about 5 μm to about 300 μm.

3. The metal powder of claim 1 , wherein the core material is a binary Mg—Zn, Al—Zn, Mg—Mn, Zn—Mn alloy, or a tertiary Mg—Zn—Y alloy.

4. The metal powder of claim 1 , wherein the core material is a tertiary Mg—Al—X alloy, wherein X is Zn, Mn, Si, Ca or Y, or a combination thereof.

5. The metal powder of claim 4 , wherein the Mg—Al—X alloy comprises, by weight, up to about 85% Mg, up to about 15% Al and up to about 5% X.

6. The metal powder of claim 1 , wherein the core material further comprises a rare earth element.

7. The metal powder of claim 6 , wherein the rare earth element comprises, by weight, less than about 5% of the particle core.

8. The metal powder of claim 1 , wherein the metallic coating material has a chemical composition and the core material has a chemical composition that is different than the chemical composition of the coating material.

9. The metal powder of claim 1 , wherein the coating layer has a thickness of about 25 nm to about 2500 nm.

10. The metal powder of claim 1 , further comprising a fourth coating layer that is disposed on the third coating layer.

11. The metal powder of claim 1 , wherein the fourth coating layer comprises Al, Mn, Fe, Co or Ni, or a combination thereof, and wherein the chemical composition of the third coating layer is different than a chemical composition of the fourth coating layer.

12. A metallic powder comprising a plurality of metallic powder particles, each powder particle comprising:
a particle core, the particle core comprises a core material comprising a metal having a standard oxidation potential less than Zn, ceramic, glass, or carbon, or a combination thereof; and
a metallic coating layer disposed on the particle core and comprising a metallic coating material, wherein the metallic coating layer comprises a plurality of coating layers, and wherein a first coating layer comprises Al, a second coating layer comprises Al, Zn, Mn, Mg, Mo, W, Cu, Fe, Si, Ca, Co, Ta, Re, or Ni, or an oxide, nitride or carbide thereof, or a combination of any of the aforementioned second coating layer materials, and a third coating layer comprises Al, Zn, Mn, Mg, Mo, W, Fe, Si, Ca, Co, Ta, Re, or Ni, or a combination thereof, wherein the first coating layer has a chemical composition that is different than a chemical composition of the second coating layer, and the chemical composition of the second coating layer is different than a chemical composition of the third layer, and wherein the second coating layer is configured to provide at least one of enhanced interlayer adhesion, enhanced strength of the overall metallic coating layer, or limited interlayer diffusion.

13. The metallic powder of claim 12 , wherein the metallic coating material has a chemical composition and the core material has a chemical composition that is different than the chemical composition of the coating material.

14. A method of making a metal powder, comprising:
forming a metal powder comprising a plurality of powder particles of a binary Mg—Zn, Mg—Mn, Al—Zn, Al—Mn, or Zn—Mn alloy, or a tertiary Mg—Zn—Y alloy, or a tertiary Mg—Al—X alloy, wherein X is Zn, Mn, Si, Ca, or Y, or a combination thereof, as a core material for use as a plurality of particle cores; and
depositing a metallic coating layer on each of the plurality of particle cores, wherein the metallic coating layer comprises a plurality of coating layers, and wherein a first coating layer comprises Al, a second coating layer comprises Al, Zn, Mn, Mg, Mo, W, Cu, Fe, Si, Ca, Co, Ta, Re, or Ni, or an oxide, nitride or carbide thereof, or a combination of any of the aforementioned second coating layer materials, and a third coating layer comprises Al, Zn, Mn, Mg, Mo, W, Fe, Si, Ca, Co, Ta, Re, or Ni, or a combination thereof, wherein the first coating layer has a chemical composition that is different than a chemical composition of the second coating layer, and the chemical composition of the second coating layer is different than a chemical composition of the third layer, and wherein the second coating layer is configured to provide at least one of enhanced interlayer adhesion, enhanced strength of the overall metallic coating layer, or limited interlayer diffusion.

15. The method of claim 14 , wherein forming the metal powder comprises vacuum spray forming or inert gas spray forming.

16. The method of claim 14 , wherein depositing the coating layer comprises depositing the coating material by fluidized bed chemical vapor deposition.

17. The method of claim 14 , wherein depositing the metallic coating layer comprises depositing the first coating layer comprising Al or Ni, or a combination thereof, on the particle core.

Assignees

• Xu Zhiyue
• Agrawal Gaurav
• Salinas Bobby
• Baker Hughes Inc

Inventors

• Xu Zhiyue
• Agrawal Gaurav
• Salinas Bobby

Classifications

• B22F1/17

  Metallic particles coated with metal · CPC title

• B22F1/16 Primary

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• Y10T428/2991

  Coated · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title