Spray coating film, engine having the spray coating film and film-forming method of the spray coating film

Patent metadata

Field	Value
Publication number	US-9840982-B2
Application number	US-201514943701-A
Country	US
Kind code	B2
Filing date	Nov 17, 2015
Priority date	Nov 21, 2014
Publication date	Dec 12, 2017
Grant date	Dec 12, 2017

Abstract

A spray coating film has a first spray coating film formed on a surface of an aluminum substrate and a second spray coating film formed on a surface of the first spray coating film. In the first spray coating film, an inorganic material with a layered crystalline structure is dispersed in a Ni-based alloy material, and an area ratio of the inorganic material is in a range from 40% to 80% relative to the sectional area of the first spray coating film. The second spray coating film is a porous film composed of ZrO 2 —SiO 2 based ceramic containing 30% to 50% by mass of SiO 2 , and the second spray coating film has an area ratio of pores of 30% to 80% relative to the sectional area of the second spray coating film.

First claim

What is claimed is:

1. A spray coating film comprising:
a first spray coating film formed on a surface of an aluminum substrate; and
a second spray coating film formed on a surface of the first spray coating film,
wherein, in the first spray coating film, an inorganic material with a layered crystalline structure is dispersed in a Ni-based alloy material, and an area ratio of the inorganic material is in a range of from 40% to 80% relative to a cross section in a film thickness direction of the first spray coating film,
wherein the second spray coating film is a porous film composed of ZrO 2 —SiO 2 based ceramic containing 30% to 50% by mass of SiO 2 , and the second spray coating film has an area ratio of pores of 30% to 80% relative to a cross section in a film thickness direction of the second spray coating film, and
wherein the inorganic material with a layered crystalline structure is composed of at least one of bentonite or graphite.

2. An engine having the spray coating film according to claim 1 , wherein the engine has a cylinder head as the aluminum substrate, and the spray coating film is formed on a wall surface of the cylinder head that forms a combustion chamber.

3. A film-forming method of a spray coating film having a first spray coating film formed on a surface of an aluminum substrate and a second spray coating film formed on a surface of the first spray coating film, comprising:
a step of forming the first spray coating film by spray coating a surface of the aluminum substrate with a mixed powder, obtained by mixing an inorganic powder composed of an inorganic material with a layered crystalline structure and a Ni alloy powder composed of a Ni-based alloy material, in such a manner that an area ratio of the inorganic material is in a range of from 40% to 80% relative to a cross section in a film thickness direction of the first spray coating film; and
a step of forming the second spray coating film by spray coating a surface of the first spray coating film with a ZrO 2 —SiO 2 powder composed of ZrO 2 —SiO 2 based ceramic containing 30% to 50% by mass of SiO 2 , in such a manner that the second spray coating film has an area ratio of pores of 30% to 80% relative to a cross section in a film thickness direction of the second spray coating film,
wherein the inorganic powder is composed of at least one of bentonite or graphite.

4. The film-forming method of a spray coating film according to claim 3 , wherein the ZrO 2 —SiO 2 powder has an average particle size in a range from 1 to 10 μm.

5. The film-forming method of a spray coating film according to claim 3 , wherein the ZrO 2 —SiO 2 powder is a powder obtained by granulating particles having an average particle size of 1 μm or less.

6. The film-forming method of a spray coating film according to claim 3 , wherein the mixed powder is a granulation powder obtained by granulating inorganic particles that constitute the inorganic powder and Ni alloy particles that constitute the Ni alloy powder.

7. A method of manufacturing an engine by using the film-forming method of a spray coating film according to claim 3 , wherein the spray coating film is formed on a wall surface of a cylinder head that forms a combustion chamber, wherein the cylinder head serves as the aluminum substrate.

Assignees

• Toyota Motor Co Ltd

Inventors

• Shimoda Kenji
• Hamaguri Toshiaki
• Nishio Kazuaki
• Nakata Hiromichi

Classifications

• C23C4/067

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

• C23C28/3455

  with a refractory ceramic layer, e.g. refractory metal oxide, ZrO2, rare earth oxides or a thermal barrier system comprising at least one refractory oxide layer · CPC title

• F01L3/04

  Coated valve members or valve-seats · CPC title

• C23C4/12 Primary

  characterised by the method of spraying · CPC title

• C23C4/11

  Oxides · CPC title