CA2035160A1 - Ceramic spray coating material - Google Patents
Ceramic spray coating materialInfo
- Publication number
- CA2035160A1 CA2035160A1 CA002035160A CA2035160A CA2035160A1 CA 2035160 A1 CA2035160 A1 CA 2035160A1 CA 002035160 A CA002035160 A CA 002035160A CA 2035160 A CA2035160 A CA 2035160A CA 2035160 A1 CA2035160 A1 CA 2035160A1
- Authority
- CA
- Canada
- Prior art keywords
- weight
- spray
- coating material
- mold
- ceramic
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
- C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
- C23C4/10—Oxides, borides, carbides, nitrides or silicides; Mixtures thereof
- C23C4/11—Oxides
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Physics & Mathematics (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Continuous Casting (AREA)
- Molds, Cores, And Manufacturing Methods Thereof (AREA)
Abstract
ABSTRACT
A ceramic spray, e.g. for coating on the inner surface of a casting mold, comprises zirconia and yttria of a purity of at least 99.6%.
A ceramic spray, e.g. for coating on the inner surface of a casting mold, comprises zirconia and yttria of a purity of at least 99.6%.
Description
~3~6~
CERAMIC SPRAY COATING MATERIAL
~ he present invention relates to a cera~ic spray coating material comprising zirconia and yttria~ , There is a continuous casting mold conventionally known from Japanese Patent Publication No.5819~86, which has an Ni-plating layer formed on an inner ~old surface and a Co-Mo-Cr alloy layer spray-coated thereon and comprising 45 to 65% ~y weight of Co, 20 to 40% ~y weight of Mo and the balance of Cr. If such continuous casting mold is used as a casting mold for a usual discontinuous casting process, e.g., a low pressure casting or gravity casting process, a disadvantage ~is encountered: A gas cannot be sufficiently eliminated during casting and hence, a blow (ruggedness) may be produced, resulting in an inferior surface profile of a molded product.
For the purpose of overcoming such disadvantage, the applicant has proposed, in Japanese Patent application No.228343/89, a powdered metal spra~-coating material which comprises 40 to 60% hy weight of Ni, 20 to 40% by weight of Co, 15 to 25% by weight of Cr and 0.1 to 1.0% by weight of Y, wherein a porous ceramic layer of ZrO2/Y2O3 is provided on the metal spray-coating material.
However, the porous ceramic layer spray-coated on the inner surface of a mold may be peeled off in long term runs of 30,000 shots or more of castin~, and therefore, .it has ~ ~ 3 ~ 3. 6 ~
been desired to provide a further increased bonding force to the metal spray-coated layer.
Thereupon, the applicant has made ~etalled studies for a ceramic spray-coating material with a further increased bonding force and consequently has found that the above disadvantage can be avoided by increasing the purity of a ceramic spray-coating material of ZrO2/Y203.
Therefore, the present invention provides a ceramic spray coating material comprising zirconia and yttria, wherein the purity of a mixture of zirconia and yttria is ¦
99.6% by weight or more.
The ceramic spray-coating material according to the present invention has very good bonding force, as compared to the prior art material.
The composition of the ceramiG spray-coating material according to the present invention comprises 98 to 85% by weight of ZrO2 and 2 to 15% by weight of Y203. The particles of the spray-coating material may be of an average particle size in a range of 20 to 40 um, but an average particle size in a range of 10 to 50 um is particularly desirable.
When used in a mold, a ceramic layer formed of such spray-coating material serves to eliminate a gas during casting and in addition thereto, to considerably improve the heat resistance and durability of the mold. In general, it is preferable that the thickness of such layer is in a range of 50 to 500 um.
The ceramic spray-coating material according to the ~ 2 present invention will now be described as being used, by way of an example~ in a convenient production of a discontinuous castiny mold of a copper alloy. An Ni-plating layer is formed on an inner surface of the copper alloy mold in a usual manner to a thickness of 50 to 300 um, perferably 100 to 200 um. If necessary, a powder alloy of Ni/Co/Cr/Y as described in Japanese Patent Application No.228343/89 may be applied onto the Ni-plating layer, with cooling with a water-cooling device provided within the mold, to a thickness of 50 to 600 um, preferably 200 to 300 um by plasma spray-coating at a temperature of about 10,000 to about 5,000C or by jet coating at a temperature of about 2,700C. Then, a ceramic coating layer of the above-described composition with a high purity (of 99.6% by weight or more) is applied to a thickness of 50 to 500 um, preferably 200 to 300 um by a spray coating under a similar condition. A large number of open pores are produced in the ceramic layer and render -the ceramic layer porous. The pores providing the porosity are of a size small as they can be observed by a microscope, rather than a size as large as they will causes a ruggedness on a surface of a molded product.
The copper alloy mold made in this manner has the porous ceramic layer havin~ open pores which serve to contain a gas generated during casting and to guide the gas outside and hence, any adverse a~fec-tion due to the gas cannot be exerted to the surface of a molde product. In other words, no blow ~ruggedness) is produced.
When the ceramic layer is employed in a copper alloy mold, the mold has higher durability and wear resistance, ~ 3~3 which enables the number of runs of casting corresponding to the number of shots, approximately 30 to 50% more than the nu~ber of runs of 30,000 shots when a lower purity ceramic layer is used, e.g., 40,000 shots or more, without need for applying a soft facing material to the inner surface o~ the mold.
The present invention will now be described in more detail by way of Example and Comparative Example.
Example 1 An Ni plating layer having a thickness of 200 ~m is provided, by electro-plating, on an inner surface of a mold made of a copper alloy containing V.15% by weight of zirconium and having a coefficient of thermal conductivity of 7. Then, an alloy comprising 57.SS% by weight of Ni, 25%
by weight of Co, 17% by weight of Cr and 0.45~ by weight of Y is spray-coated at 8,000C by a plasma spray~coating process to form a coating film of 150 ~m.
A ceramic mixture having a purity of 9~.~l1% by weight and comprising 91.41% by weight of ZrO2, 8.3% by weight of Y203, 0.08% by weight of SiO2, 0.03% by weight of Fe203 and 0.18% by weight of impurities is applied onto the thus--formed Ni/Co/Cr/Y alloy coating film to a thickness of 250 um by a similar spray-coating process. The spray-coating temperature in this spray-coating is of 8,000 C. A large number of very small pores are present in the cerami~ layer, thereby providing a porosity.
When the permanent mold made in this manner was used in casting of a magnesium alloy casing for an automobile engine while being cooled to a temperature of 3S0 to 400 C, and even if 40,000 shots were conducted, any change on the surface of the mold was still not observed and the surface profile of a molded product was good.
Comparative ~xample 1 A permanen' mold is made i~ the same manner as in Example 1, except for use of a ceramic mixture having a purity of 98.93 and comprising 90.7~% by weight of ZrO2, 8.15% by weight of Y203, O . 38% by weight of A1203, 0.20% by weight of SiO2, 0.11% by weight of Fe2O3 and 0-38% by weight of impurities. The resulting permanent mold had its ceramic layer peeled off at 30,451 runs.
CERAMIC SPRAY COATING MATERIAL
~ he present invention relates to a cera~ic spray coating material comprising zirconia and yttria~ , There is a continuous casting mold conventionally known from Japanese Patent Publication No.5819~86, which has an Ni-plating layer formed on an inner ~old surface and a Co-Mo-Cr alloy layer spray-coated thereon and comprising 45 to 65% ~y weight of Co, 20 to 40% ~y weight of Mo and the balance of Cr. If such continuous casting mold is used as a casting mold for a usual discontinuous casting process, e.g., a low pressure casting or gravity casting process, a disadvantage ~is encountered: A gas cannot be sufficiently eliminated during casting and hence, a blow (ruggedness) may be produced, resulting in an inferior surface profile of a molded product.
For the purpose of overcoming such disadvantage, the applicant has proposed, in Japanese Patent application No.228343/89, a powdered metal spra~-coating material which comprises 40 to 60% hy weight of Ni, 20 to 40% by weight of Co, 15 to 25% by weight of Cr and 0.1 to 1.0% by weight of Y, wherein a porous ceramic layer of ZrO2/Y2O3 is provided on the metal spray-coating material.
However, the porous ceramic layer spray-coated on the inner surface of a mold may be peeled off in long term runs of 30,000 shots or more of castin~, and therefore, .it has ~ ~ 3 ~ 3. 6 ~
been desired to provide a further increased bonding force to the metal spray-coated layer.
Thereupon, the applicant has made ~etalled studies for a ceramic spray-coating material with a further increased bonding force and consequently has found that the above disadvantage can be avoided by increasing the purity of a ceramic spray-coating material of ZrO2/Y203.
Therefore, the present invention provides a ceramic spray coating material comprising zirconia and yttria, wherein the purity of a mixture of zirconia and yttria is ¦
99.6% by weight or more.
The ceramic spray-coating material according to the present invention has very good bonding force, as compared to the prior art material.
The composition of the ceramiG spray-coating material according to the present invention comprises 98 to 85% by weight of ZrO2 and 2 to 15% by weight of Y203. The particles of the spray-coating material may be of an average particle size in a range of 20 to 40 um, but an average particle size in a range of 10 to 50 um is particularly desirable.
When used in a mold, a ceramic layer formed of such spray-coating material serves to eliminate a gas during casting and in addition thereto, to considerably improve the heat resistance and durability of the mold. In general, it is preferable that the thickness of such layer is in a range of 50 to 500 um.
The ceramic spray-coating material according to the ~ 2 present invention will now be described as being used, by way of an example~ in a convenient production of a discontinuous castiny mold of a copper alloy. An Ni-plating layer is formed on an inner surface of the copper alloy mold in a usual manner to a thickness of 50 to 300 um, perferably 100 to 200 um. If necessary, a powder alloy of Ni/Co/Cr/Y as described in Japanese Patent Application No.228343/89 may be applied onto the Ni-plating layer, with cooling with a water-cooling device provided within the mold, to a thickness of 50 to 600 um, preferably 200 to 300 um by plasma spray-coating at a temperature of about 10,000 to about 5,000C or by jet coating at a temperature of about 2,700C. Then, a ceramic coating layer of the above-described composition with a high purity (of 99.6% by weight or more) is applied to a thickness of 50 to 500 um, preferably 200 to 300 um by a spray coating under a similar condition. A large number of open pores are produced in the ceramic layer and render -the ceramic layer porous. The pores providing the porosity are of a size small as they can be observed by a microscope, rather than a size as large as they will causes a ruggedness on a surface of a molded product.
The copper alloy mold made in this manner has the porous ceramic layer havin~ open pores which serve to contain a gas generated during casting and to guide the gas outside and hence, any adverse a~fec-tion due to the gas cannot be exerted to the surface of a molde product. In other words, no blow ~ruggedness) is produced.
When the ceramic layer is employed in a copper alloy mold, the mold has higher durability and wear resistance, ~ 3~3 which enables the number of runs of casting corresponding to the number of shots, approximately 30 to 50% more than the nu~ber of runs of 30,000 shots when a lower purity ceramic layer is used, e.g., 40,000 shots or more, without need for applying a soft facing material to the inner surface o~ the mold.
The present invention will now be described in more detail by way of Example and Comparative Example.
Example 1 An Ni plating layer having a thickness of 200 ~m is provided, by electro-plating, on an inner surface of a mold made of a copper alloy containing V.15% by weight of zirconium and having a coefficient of thermal conductivity of 7. Then, an alloy comprising 57.SS% by weight of Ni, 25%
by weight of Co, 17% by weight of Cr and 0.45~ by weight of Y is spray-coated at 8,000C by a plasma spray~coating process to form a coating film of 150 ~m.
A ceramic mixture having a purity of 9~.~l1% by weight and comprising 91.41% by weight of ZrO2, 8.3% by weight of Y203, 0.08% by weight of SiO2, 0.03% by weight of Fe203 and 0.18% by weight of impurities is applied onto the thus--formed Ni/Co/Cr/Y alloy coating film to a thickness of 250 um by a similar spray-coating process. The spray-coating temperature in this spray-coating is of 8,000 C. A large number of very small pores are present in the cerami~ layer, thereby providing a porosity.
When the permanent mold made in this manner was used in casting of a magnesium alloy casing for an automobile engine while being cooled to a temperature of 3S0 to 400 C, and even if 40,000 shots were conducted, any change on the surface of the mold was still not observed and the surface profile of a molded product was good.
Comparative ~xample 1 A permanen' mold is made i~ the same manner as in Example 1, except for use of a ceramic mixture having a purity of 98.93 and comprising 90.7~% by weight of ZrO2, 8.15% by weight of Y203, O . 38% by weight of A1203, 0.20% by weight of SiO2, 0.11% by weight of Fe2O3 and 0-38% by weight of impurities. The resulting permanent mold had its ceramic layer peeled off at 30,451 runs.
Claims
WHAT IS CLAIMED IS
A ceramic spray coating material comprising zirconia and yttria, wherein the purity of a mixture of zirconia and yttria is 99.6% by weight or more.
A ceramic spray coating material comprising zirconia and yttria, wherein the purity of a mixture of zirconia and yttria is 99.6% by weight or more.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2-16153 | 1990-01-29 | ||
| JP2016153A JPH03223455A (en) | 1990-01-29 | 1990-01-29 | Ceramic thermal spraying material |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA2035160A1 true CA2035160A1 (en) | 1991-07-30 |
Family
ID=11908562
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002035160A Abandoned CA2035160A1 (en) | 1990-01-29 | 1991-01-29 | Ceramic spray coating material |
Country Status (3)
| Country | Link |
|---|---|
| EP (1) | EP0444394A3 (en) |
| JP (1) | JPH03223455A (en) |
| CA (1) | CA2035160A1 (en) |
Families Citing this family (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPH05132752A (en) * | 1991-06-13 | 1993-05-28 | T-P Kogyo Kk | Method for thermally spraying ceramic on casting mold |
| NL1007830C2 (en) * | 1997-12-18 | 1999-06-21 | Hoogovens Staal Bv | Mold for continuous casting of metal and method for continuous casting therewith. |
| FI107789B (en) * | 1999-02-03 | 2001-10-15 | Outokumpu Oy | Casting mold for producing a cooling element and forming cooling element in the mold |
| AUPP939099A0 (en) * | 1999-03-23 | 1999-04-15 | Cast Centre Pty Ltd | Die coatings for gravity and low pressure diecasting |
| US8603930B2 (en) | 2005-10-07 | 2013-12-10 | Sulzer Metco (Us), Inc. | High-purity fused and crushed zirconia alloy powder and method of producing same |
| US7723249B2 (en) * | 2005-10-07 | 2010-05-25 | Sulzer Metco (Us), Inc. | Ceramic material for high temperature service |
| US7799716B2 (en) * | 2006-03-03 | 2010-09-21 | Sulzer Metco (Us), Inc. | Partially-alloyed zirconia powder |
| JP5765567B2 (en) * | 2010-08-05 | 2015-08-19 | アイシン精機株式会社 | Die casting mold parts |
| JP6266093B2 (en) * | 2014-04-07 | 2018-01-24 | 三菱電機株式会社 | Heat exchanger and air conditioner |
| CN112759950B (en) * | 2020-10-28 | 2022-03-11 | 北京理工大学 | A kind of YSZ/graphene composite sealing coating and preparation method thereof |
Family Cites Families (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JPS5887273A (en) * | 1981-11-18 | 1983-05-25 | Hitachi Ltd | Parts having ceramic coated layer and their production |
| JPS5895678A (en) * | 1981-12-01 | 1983-06-07 | 工業技術院長 | Heat resistant ceramic coating method |
| US4485151A (en) * | 1982-05-06 | 1984-11-27 | The United States Of America As Represented By The Administrator Of The National Aeronautics And Space Administration | Thermal barrier coating system |
| JPH0715141B2 (en) * | 1982-11-26 | 1995-02-22 | 株式会社東芝 | Heat resistant parts |
| JPS61250161A (en) * | 1985-04-30 | 1986-11-07 | Riken Corp | Cylinder liner |
-
1990
- 1990-01-29 JP JP2016153A patent/JPH03223455A/en active Pending
-
1991
- 1991-01-02 EP EP19910100015 patent/EP0444394A3/en not_active Withdrawn
- 1991-01-29 CA CA002035160A patent/CA2035160A1/en not_active Abandoned
Also Published As
| Publication number | Publication date |
|---|---|
| JPH03223455A (en) | 1991-10-02 |
| EP0444394A2 (en) | 1991-09-04 |
| EP0444394A3 (en) | 1991-10-02 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| EEER | Examination request | ||
| FZDE | Discontinued | ||
| FZDE | Discontinued |
Effective date: 20001120 |