US3338688A - Low smoking nickel aluminum flame spray powder - Google Patents
Low smoking nickel aluminum flame spray powder Download PDFInfo
- Publication number
- US3338688A US3338688A US401969A US40196964A US3338688A US 3338688 A US3338688 A US 3338688A US 401969 A US401969 A US 401969A US 40196964 A US40196964 A US 40196964A US 3338688 A US3338688 A US 3338688A
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- US
- United States
- Prior art keywords
- nickel
- aluminum
- powder
- flame spray
- boron
- 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.)
- Expired - Lifetime
Links
- 239000000843 powder Substances 0.000 title claims description 43
- 239000007921 spray Substances 0.000 title claims description 27
- NPXOKRUENSOPAO-UHFFFAOYSA-N Raney nickel Chemical compound [Al].[Ni] NPXOKRUENSOPAO-UHFFFAOYSA-N 0.000 title description 8
- 230000000391 smoking effect Effects 0.000 title description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical group [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 35
- 229910052782 aluminium Inorganic materials 0.000 claims description 28
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 claims description 28
- 239000002245 particle Substances 0.000 claims description 18
- QDWJUBJKEHXSMT-UHFFFAOYSA-N boranylidynenickel Chemical compound [Ni]#B QDWJUBJKEHXSMT-UHFFFAOYSA-N 0.000 description 25
- 229910052759 nickel Inorganic materials 0.000 description 14
- 238000000576 coating method Methods 0.000 description 12
- 239000011248 coating agent Substances 0.000 description 10
- 239000000463 material Substances 0.000 description 10
- 239000000779 smoke Substances 0.000 description 10
- 239000011230 binding agent Substances 0.000 description 8
- 239000002131 composite material Substances 0.000 description 8
- 239000002966 varnish Substances 0.000 description 8
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 6
- 229910052796 boron Inorganic materials 0.000 description 6
- 238000005507 spraying Methods 0.000 description 6
- 239000010410 layer Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
- 238000001035 drying Methods 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 238000000034 method Methods 0.000 description 2
- 229910052750 molybdenum Inorganic materials 0.000 description 2
- 239000011733 molybdenum Substances 0.000 description 2
- 229910000907 nickel aluminide Inorganic materials 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 235000019198 oils Nutrition 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N phenol group Chemical group C1(=CC=CC=C1)O ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000011347 resin Substances 0.000 description 2
- 229920005989 resin Polymers 0.000 description 2
- 229910000521 B alloy Inorganic materials 0.000 description 1
- 239000004593 Epoxy Substances 0.000 description 1
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 206010000496 acne Diseases 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 230000000996 additive effect Effects 0.000 description 1
- 229920000180 alkyd Polymers 0.000 description 1
- HSFWRNGVRCDJHI-UHFFFAOYSA-N alpha-acetylene Natural products C#C HSFWRNGVRCDJHI-UHFFFAOYSA-N 0.000 description 1
- YYCNOHYMCOXPPJ-UHFFFAOYSA-N alumane;nickel Chemical class [AlH3].[Ni] YYCNOHYMCOXPPJ-UHFFFAOYSA-N 0.000 description 1
- CHLJYJMHKCYDMM-UHFFFAOYSA-N alumane;nickel Chemical compound [AlH3].[Ni].[Ni] CHLJYJMHKCYDMM-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 239000011247 coating layer Substances 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 239000007771 core particle Substances 0.000 description 1
- 229920001971 elastomer Polymers 0.000 description 1
- 125000002534 ethynyl group Chemical group [H]C#C* 0.000 description 1
- 238000010285 flame spraying Methods 0.000 description 1
- 239000000446 fuel Substances 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 239000004922 lacquer Substances 0.000 description 1
- 230000007775 late Effects 0.000 description 1
- 239000004816 latex Substances 0.000 description 1
- 229920000126 latex Polymers 0.000 description 1
- 235000021388 linseed oil Nutrition 0.000 description 1
- 239000000944 linseed oil Substances 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 239000002923 metal particle Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- -1 polyethylene Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 238000007788 roughening Methods 0.000 description 1
- 239000005060 rubber Substances 0.000 description 1
- 238000000935 solvent evaporation Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 239000006188 syrup Substances 0.000 description 1
- 235000020357 syrup Nutrition 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
- B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
- B23K35/24—Selection of soldering or welding materials proper
- B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
- B23K35/3033—Ni as the principal constituent
-
- 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
- C23C4/06—Metallic material
- C23C4/067—Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12181—Composite powder [e.g., coated, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
- Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]
- Y10T428/2991—Coated
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31678—Of metal
- Y10T428/31714—Next to natural gum, natural oil, rosin, lac or wax
Definitions
- the initial nickel particles which constitute the core or nucleus of the composite powders in accordance with the invention should have a size and shape approximating that desired in the end powders as described above.
- the invention more particularly re- 10 lates to a nickel aluminum composite flame spray powder
- the nickel core or nucleus particles are then coated with which may be flame-sprayed to form a self-bonding coatthe aluminum and nickel boron, the coating being effected ing
- the aluminum and the nickel boron are de- In flame spraying the surface or base, such as the posited in finely divided form in a binder on the nickel metal surface or base being coated by the flame spray particles.
- the aluminum and nickel boron preferably in as finely ration such as a severe mechanical roughening in order divided form as possible, as for example a size of -325 to ensure a satisfactory bond of the sprayed coating. mesh, are mixed in the required proportions with a Certain materials, as for example molybdenum, will howbinder or lacquer so as, in elfect, to form a paint in 7 ever adequately bond to a clean surface without this spewhich the aluminum and nickel boron particles correcial surface preparation and of course subsequently apspond to the pigment.
- the paint is then used to coat the plied sprayed layers will adequately bond to the initially i kel o e rti le and allow d to set or dry.
- applied sprayed coating as one flame-sprayed layer bonds The binder material may be any known or conventional to a previously applied layer without difficulty. Materials, binder material which may be used for forming a coating such as molybdenum, which will bond to a base Without or for bonding particles together or to a surface.
- the the conventional surface preparation are referred to in binder is preferably a varnish containing a resin as the the flame spray art as self-bonding.
- a further self-bondvarnish solids may contain a resin which does not ihg flame spray material is a Composite Composed of depend on solvent evaporation in order to form a dried nickel and aluminum which will exothermically react r set film,
- the varnish may thus contain a catalyzed when p y forming a nickel ahlmihide intefresin as the varnish solids.
- binders which metallic.
- the known Self-bonding flame p y materials generate or alkyd varnishes, varnishes containing drying oils, such a C nsid rable am llnt f Smoke d g praying and this as tuna oil and linseed oil, rubber and latex binders and presents a problem if adequate ventilating facilities are th 1ik not Provided, as for example Where Special exhausting The coating of the nickel core component with the facilities, such as an exhaust booth, are not available.
- One object of this invention is a Self-bonding fl example, from 5 95% boron, andpr'efer'ably from 7 25% spray powder which will generate substantially less smoke by i ht of boron, and most preferably about 18% by When p y than the Prior art Powders and Still retaln Weight boron.
- the nickel boron powder most preferably ahigh bond strength.
- a further object of this invention is an aluminum coated i nickel flame P Y Powder which is Self-bonding When The powders are sprayed in the COHVCIllIlOI'IEII manner, sprayed and which will generate substantially less smoke using a powder type flame spray gun, though it is also than the conventional nickel aluminum composite powders ibl t bi h Same i th f f a wlre While retaining a high bond Strength rod, using plastic or a similar binding, as for example These and Still furth r Objects Will become apparent polyethylene which decomposes in a heating zone of the fro the following desel'iptiohi gun.
- the spraying is in all respects efiected in the convem known nickel alllminum composlte flame spray-powder; tional manner previously utilized for self-bonding flame laandcyvill retain hlgh bond strength or even show lncrease p y material, and in particular nickel aluminum n stren
- the com posite flame spray powder in accordance with posfltes Due jfi ifigg a gc ad zl dz riiii il ii i the invention comprises nickel particles coated with $111 e Prepara 1 f g 1 to 6% by weight f aluminum and 1 to 2% by required thou h, of course conventiona sur ace prepara- Weight nickel boron, based on the total of aluminum, e ut'lhzed 1f deslmd-
- the Powder m accfrdance nickel boron and nickel in the particles with the invention may be flame-sprayed
- the nickel and aluminum When sprayed, the nickel and aluminum exothermically react, forming a nickel aluminide intermetallic.
- EXAMPLE 1 Finely divided aluminum powder (325 mesh) was admixed with 20% by weight of nickel boron powder based on aluminum, consisting of a foundry alloy containing 18% by weight of boron and having a particle size between about l-20 microns. The powder blend was then admixed with a conventional phenolic varnish having approximately 10% solid contents so as to form a mixture having the consistency of heavy syrup and containing about 60% by weight of the metal particles.
- 100 grams of the varnish powder mixture is then added to about 900 grams of nickel powder having a size between about 200- 325 mesh and the two are thoroughly mixed, with the mixing continued until the varnish dries leaving a fairly free-flowing powder in which all of the nickel core particles are clad with a dry film which contains the aluminum particles and nickel boron particles.
- the powder is then warmed to about 250 F. to ensure complete drying.
- the powder is then screened and hand-milled to reduce the same to a 100 mesh powder.
- the end powder consists approximately of 5% aluminum, 1% nickel boron, the balance nickel.
- the powder is flame-sprayed on a mild am plate which has been surface cleaned by smooth grinding.
- the spraying is effected at a distance of 6 from the plate, using a powder type flame spray gun as described in US. Patent 2,961,335 of Nov. 22, 1960 and sold by Metco, Inc., of Westbury, N.Y., under the trade name Thermospray powder gun.
- the spraying is effected at a rate of 5 to 10 lbs. of powder per hour, using acetylene gas as the fuel, at a pressure of 10 lbs. p.s.i. gauge and a flow rate of cu. ft./hr., and oxygen as the oxidizing gas at a pressure of 12 lbs. p.s.i. gauge and a flow rate of cu. ft./hr.
- acetylene gas as the fuel
- oxygen as the oxidizing gas
- the coating is self-bonded, has excellent oxidation resistant characteristics even at high
- Example 1 was repeated except that three batches of powder were made up containing 3, 4 and 5% by weight of aluminum, respectively, each containing 1% by weight of nickel boron. Each of the powder batches was sprayed as described in Example 1 and the amount of smoke generated was determined on the basis of the amount of time it took for the smoke to fill a booth having a volume of 36 cu. ft. The bond strength of the coatings produced for each of the batches was also tested in the conventional manner by spraying on the end face of a mild steel rod of approximately 1" diameter, grinding the sprayed coating smooth, and cementing a second, similar rod to the ground steel and pulling the two rods apart in tension and determining the force necessary to lift the coating.
- Example 1 may be repeated, using in place of the nickel boron foundry alloy, nickel boron alloys containing from 5-95 and preferably 7-25 boron.
- a flame spray powder comprising particles having a nickel core coated with about 2 /2 to 6% by weight of aluminum and /2 to 2% nickel boron based on the total of nickel, aluminum and nickel boron.
- we spray powder comprising pa rti c les h aying a n igkel gore coated with ⁇ binder containing aluminum particles and nickel borompart icles, said aluminum par ticles being present in amount of 2 /2 to 6% by Weight based on the total of aluminum, nickel and nickel boron, said nickel boron particles being present in amount of about /2 to 2% by weight based on the total of the aluminum, nickel and nickel boron.
- a flame spray powder according to claim 5 in which said niekel b o'foni present in amount of about 1% by weight.
- the improvement which comprises spraying a flame spray powder comprising particles having g pickel core cop tec l a minor amount of aluminum and nickel boron. w
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Materials Engineering (AREA)
- Plasma & Fusion (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Coating By Spraying Or Casting (AREA)
- Laminated Bodies (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Paints Or Removers (AREA)
Description
. idea- 570. oa 3.338.688 an 3,338,688 Patented Aug. 29, 1967 i United States Patent "ice example, should have a size between --60 mesh and +3 microns, and preferably 140 mesh and +10 microns, the mesh sizes being US. Standard Screen Mesh sizes. Most preferably the powder should be as uniform as pos- 5 sible in grain size, with the individual grains not vary- SPRAY POWDER Frank N. Longo, Mineola, N.Y., assignor to Metco Inc., Westbury, N.Y., a corporation of New Jersey No Drawing. Filed Oct. 6, 1964, Ser. No. 401,969 8 Claims. (Cl. 29192) This invention relates to a low smoking nickel aluminum nickel particles should have the general over-all shape and size of conventional flame spray powders and thus, for
ing by more than 240 microns and preferably 75 microns.
The initial nickel particles which constitute the core or nucleus of the composite powders in accordance with the invention should have a size and shape approximating that desired in the end powders as described above.
flame spray powder. The invention more particularly re- 10 lates to a nickel aluminum composite flame spray powder The nickel core or nucleus particles are then coated with which may be flame-sprayed to form a self-bonding coatthe aluminum and nickel boron, the coating being effected ing With the generation of considerably less smoke than by any known coating process, as for example described the previously known self-bonding nickel aluminum flame in copending application Ser. No. 343,705, filed Feb. 10, spray powders or other self-bonding flame spray ma- 1964. terials. Preferably the aluminum and the nickel boron are de- In flame spraying the surface or base, such as the posited in finely divided form in a binder on the nickel metal surface or base being coated by the flame spray particles. technique, must generally have a special surface prepa- The aluminum and nickel boron, preferably in as finely ration such as a severe mechanical roughening in order divided form as possible, as for example a size of -325 to ensure a satisfactory bond of the sprayed coating. mesh, are mixed in the required proportions with a Certain materials, as for example molybdenum, will howbinder or lacquer so as, in elfect, to form a paint in 7 ever adequately bond to a clean surface without this spewhich the aluminum and nickel boron particles correcial surface preparation and of course subsequently apspond to the pigment. The paint is then used to coat the plied sprayed layers will adequately bond to the initially i kel o e rti le and allow d to set or dry. applied sprayed coating as one flame-sprayed layer bonds The binder material may be any known or conventional to a previously applied layer without difficulty. Materials, binder material which may be used for forming a coating such as molybdenum, which will bond to a base Without or for bonding particles together or to a surface. The the conventional surface preparation, are referred to in binder is preferably a varnish containing a resin as the the flame spray art as self-bonding. A further self-bondvarnish solids, and may contain a resin which does not ihg flame spray material is a Composite Composed of depend on solvent evaporation in order to form a dried nickel and aluminum which will exothermically react r set film, The varnish may thus contain a catalyzed when p y forming a nickel ahlmihide intefresin as the varnish solids. Examples of binders which metallic. may be used include the conventional phenolic, epoxy, The known Self-bonding flame p y materials generate or alkyd varnishes, varnishes containing drying oils, such a C nsid rable am llnt f Smoke d g praying and this as tuna oil and linseed oil, rubber and latex binders and presents a problem if adequate ventilating facilities are th 1ik not Provided, as for example Where Special exhausting The coating of the nickel core component with the facilities, such as an exhaust booth, are not available. pain containing the aluminum and nickel boron may It has been found that the amount of smoke generated b ff t d i any know or desired manner, and it is y the nickel aluminum composites y be reduced y simply necessary to mix the two materials together and reducing the percentage of the aluminum in the cOmallow the binder to set or dry, which will result in a P but this results in a corresponding reduction 0f fairly free-flowing powder consisting of the nickel core the bond Strength of the Coating formed, and it has 110t coated with cladding of the aluminum and nickel boron. been possible to reduce the smoke to a tolerable level 4 Th i k 1 bo der may be any known powder while retaining a satisfactory bond strength. comprising afi ialjjyjlgflnjekel and boron containing for One object of this invention is a Self-bonding fl example, from 5 95% boron, andpr'efer'ably from 7 25% spray powder which will generate substantially less smoke by i ht of boron, and most preferably about 18% by When p y than the Prior art Powders and Still retaln Weight boron. The nickel boron powder most preferably ahigh bond strength. is used in a particle size range between -20 and +1 A further object of this invention is an aluminum coated i nickel flame P Y Powder which is Self-bonding When The powders are sprayed in the COHVCIllIlOI'IEII manner, sprayed and which will generate substantially less smoke using a powder type flame spray gun, though it is also than the conventional nickel aluminum composite powders ibl t bi h Same i th f f a wlre While retaining a high bond Strength rod, using plastic or a similar binding, as for example These and Still furth r Objects Will become apparent polyethylene which decomposes in a heating zone of the fro the following desel'iptiohi gun. When formed as wires, the same may have conven- In accordance with the invention I have discovfired that tional sizes and accuracy tolerances for flame spray wires a particular form of a nickel aluminum composite flame and thus for example, may Vary in Size between and spray powder containing a specific additive will produce 20 gauge. substantially less smoke when sprayed than the other The spraying is in all respects efiected in the convem known nickel alllminum composlte flame spray-powder; tional manner previously utilized for self-bonding flame laandcyvill retain hlgh bond strength or even show lncrease p y material, and in particular nickel aluminum n stren The com posite flame spray powder in accordance with posfltes Due jfi ifigg a gc ad zl dz riiii il ii i the invention comprises nickel particles coated with $111 e Prepara 1 f g 1 to 6% by weight f aluminum and 1 to 2% by required thou h, of course conventiona sur ace prepara- Weight nickel boron, based on the total of aluminum, e ut'lhzed 1f deslmd- The Powder m accfrdance nickel boron and nickel in the particles with the invention may be flame-sprayed as a bonding coat The composite of aluminum and nickel boron coated for q n ly ppli d flame spray material or any purposes where it is desiredto form the nickel aluminide coating. The composites may furthermore be sprayed in conjunction with, or in addition to, other flame spray materials conventionally used in the art.
When sprayed, the nickel and aluminum exothermically react, forming a nickel aluminide intermetallic.
The following examples are given by way of illustration and not limitation:
EXAMPLE 1 Finely divided aluminum powder (325 mesh) was admixed with 20% by weight of nickel boron powder based on aluminum, consisting of a foundry alloy containing 18% by weight of boron and having a particle size between about l-20 microns. The powder blend was then admixed with a conventional phenolic varnish having approximately 10% solid contents so as to form a mixture having the consistency of heavy syrup and containing about 60% by weight of the metal particles. 100 grams of the varnish powder mixture is then added to about 900 grams of nickel powder having a size between about 200- 325 mesh and the two are thoroughly mixed, with the mixing continued until the varnish dries leaving a fairly free-flowing powder in which all of the nickel core particles are clad with a dry film which contains the aluminum particles and nickel boron particles. The powder is then warmed to about 250 F. to ensure complete drying. The powder is then screened and hand-milled to reduce the same to a 100 mesh powder. The end powder consists approximately of 5% aluminum, 1% nickel boron, the balance nickel. The powder is flame-sprayed on a mild am plate which has been surface cleaned by smooth grinding. The spraying is effected at a distance of 6 from the plate, using a powder type flame spray gun as described in US. Patent 2,961,335 of Nov. 22, 1960 and sold by Metco, Inc., of Westbury, N.Y., under the trade name Thermospray powder gun. The spraying is effected at a rate of 5 to 10 lbs. of powder per hour, using acetylene gas as the fuel, at a pressure of 10 lbs. p.s.i. gauge and a flow rate of cu. ft./hr., and oxygen as the oxidizing gas at a pressure of 12 lbs. p.s.i. gauge and a flow rate of cu. ft./hr. During the spraying very little smoke is generated and a coating layer is built up to a thickness of between .003" and .005. The coating is self-bonded, has excellent oxidation resistant characteristics even at high temperatures, and can be used as an intermediate bonding coat.
EXAMPLE 2 Example 1 was repeated except that three batches of powder were made up containing 3, 4 and 5% by weight of aluminum, respectively, each containing 1% by weight of nickel boron. Each of the powder batches was sprayed as described in Example 1 and the amount of smoke generated was determined on the basis of the amount of time it took for the smoke to fill a booth having a volume of 36 cu. ft. The bond strength of the coatings produced for each of the batches was also tested in the conventional manner by spraying on the end face of a mild steel rod of approximately 1" diameter, grinding the sprayed coating smooth, and cementing a second, similar rod to the ground steel and pulling the two rods apart in tension and determining the force necessary to lift the coating.
Table I below indicates the results:
4 EXAMPLE 3 Example 2 was repeated exactly except that in each case the flame spray powder was formed without the nickel boron. The results obtained are shown in Table II below:
TABLE II Aluminum Bond Smoke, time to fill Content Strength" 36 cu. ft. volume (percent) (p.s.i.) (see) These figures are averages of 6 or more tests.
EXAMPLE 4 Example 1 may be repeated, using in place of the nickel boron foundry alloy, nickel boron alloys containing from 5-95 and preferably 7-25 boron.
While the invention has been described in detail with reference to certain specific embodiments, various changes and modifications which fall within the spirit of the invention and scope of the appended claims, will become apparent to the skilled artisan. The invention is, therefore, only intended to be limited by the appended claims or their equivalents wherein I have endeavored to claim all inherent novelty.
I claim:
JEIQL BEY. w la comprising parades h a nickeLcore cpated with aluminum and nickel boron.
2. A flame spray powder comprising particles having a nickel core coated with about 2 /2 to 6% by weight of aluminum and /2 to 2% nickel boron based on the total of nickel, aluminum and nickel boron.
3. A flame spray powder according to claim 2 in which said nickel boron is present in amount of about 1% by weight.
4. we spray powder comprising pa rti c les h aying a n igkel gore coated with {binder containing aluminum particles and nickel borompart icles, said aluminum par ticles being present in amount of 2 /2 to 6% by Weight based on the total of aluminum, nickel and nickel boron, said nickel boron particles being present in amount of about /2 to 2% by weight based on the total of the aluminum, nickel and nickel boron.
5. A flame sppaypowder according to claim 4 in which said inder is ayarniish:
6. A flame spray powder according to claim 5 in which said niekel b o'foni present in amount of about 1% by weight.
7. A flame spray powder according to claim 6 in which said aluminum is present in amount of about 5% by weight.
8. In the flame spray process, the improvement which comprises spraying a flame spray powder comprising particles having g pickel core cop tec l a minor amount of aluminum and nickel boron. w
References Cited UNITED STATES PATENTS 3,025,182 3/1962 Schrewelius l17105 3,141,744 7/1964- Couch et al 29194 3,254,970 6/1966 DittIiCh et a1. 2919l.2 3,305,326 2/1967 Longo 29-192 DAVID L. RECK, Primary Examiner.
R. O. DEAN, Assistant Examiner.
Claims (1)
1. A FLAME SPRAY POWDER COMPRISING PARTICLES HAVING A NICKEL CORE COATED WITH ALUMINUM AND NICKEL BORON.
Priority Applications (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US401969A US3338688A (en) | 1964-10-06 | 1964-10-06 | Low smoking nickel aluminum flame spray powder |
| GB24215/65A GB1068284A (en) | 1964-10-06 | 1965-06-08 | Flame spray material |
| DE1483468A DE1483468C3 (en) | 1964-10-06 | 1965-09-22 | Flame spray powder |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US401969A US3338688A (en) | 1964-10-06 | 1964-10-06 | Low smoking nickel aluminum flame spray powder |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| US3338688A true US3338688A (en) | 1967-08-29 |
Family
ID=23590007
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US401969A Expired - Lifetime US3338688A (en) | 1964-10-06 | 1964-10-06 | Low smoking nickel aluminum flame spray powder |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US3338688A (en) |
| DE (1) | DE1483468C3 (en) |
| GB (1) | GB1068284A (en) |
Cited By (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3410714A (en) * | 1965-10-18 | 1968-11-12 | Gen Electric | Metallizing and bonding non-metallic bodies |
| US3421972A (en) * | 1965-06-28 | 1969-01-14 | Koppers Co Inc | Process for directly bonding polytetrafluoroethylene to metal,adhesive composition used therefor and laminated product thereof |
| DE2031616A1 (en) * | 1969-07-01 | 1971-01-21 | Metco Ine Westbury (Long Island) NY (VStA) | Flame spray powder |
| US3617358A (en) * | 1967-09-29 | 1971-11-02 | Metco Inc | Flame spray powder and process |
| US3769689A (en) * | 1972-01-12 | 1973-11-06 | Nasa | Method of making pressure-tight seal for super alloy |
| US4027367A (en) * | 1975-07-24 | 1977-06-07 | Rondeau Henry S | Spray bonding of nickel aluminum and nickel titanium alloys |
| US4031278A (en) * | 1975-08-18 | 1977-06-21 | Eutectic Corporation | High hardness flame spray nickel-base alloy coating material |
| US4039318A (en) * | 1976-07-19 | 1977-08-02 | Eutectic Corporation | Metaliferous flame spray material for producing machinable coatings |
| DE2929274A1 (en) * | 1978-07-19 | 1980-01-31 | Metco Inc | SELF-ADHESIVE FLAME SPRAY POWDER FOR THE PRODUCTION OF EASILY EDITABLE COATINGS |
| DE2934446A1 (en) * | 1979-08-25 | 1981-03-12 | Verschleiß-Technik Dr.-Ing. Hans Wahl GmbH & Co, 7302 Ostfildern | Wear and corrosion resistant material or coatings - made from metal or carbide grains covered by sheath contg. boron or phosphorus |
| US4379720A (en) * | 1982-03-15 | 1983-04-12 | Marko Materials, Inc. | Nickel-aluminum-boron powders prepared by a rapid solidification process |
| US4741973A (en) * | 1986-12-15 | 1988-05-03 | United Technologies Corporation | Silicon carbide abrasive particles having multilayered coating |
| US5165609A (en) * | 1991-09-05 | 1992-11-24 | Technalum Research, Inc. | Method of producing thermally reactive powders using consumable disintegrator disks |
| US5302182A (en) * | 1991-09-05 | 1994-04-12 | Technalum Research, Inc. | Method of preparing particles with a controlled narrow distribution |
| US5312648A (en) * | 1991-09-05 | 1994-05-17 | Technalum Research, Inc. | Method for coating particles using counter-rotating disks |
| US5660934A (en) * | 1994-12-29 | 1997-08-26 | Spray-Tech, Inc. | Clad plastic particles suitable for thermal spraying |
Families Citing this family (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| RU2387736C2 (en) * | 2007-10-26 | 2010-04-27 | Учреждение Российской Академии Наук Институт Физики Прочности И Материаловедения Сибирского Отделения Ран (Ифпм Со Ран) | Powder material for gas-thermal sputtering of polymeric coatings |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3025182A (en) * | 1957-03-05 | 1962-03-13 | Kanthal Ab | Formation of corrosion-resistant metallic coatings by so-called flame-spraying techniques |
| US3141744A (en) * | 1961-06-19 | 1964-07-21 | Dwight E Couch | Wear-resistant nickel-aluminum coatings |
| US3254970A (en) * | 1960-11-22 | 1966-06-07 | Metco Inc | Flame spray clad powder composed of a refractory material and nickel or cobalt |
| US3305326A (en) * | 1963-04-23 | 1967-02-21 | Metco Inc | Self-fusing flame spray material |
-
1964
- 1964-10-06 US US401969A patent/US3338688A/en not_active Expired - Lifetime
-
1965
- 1965-06-08 GB GB24215/65A patent/GB1068284A/en not_active Expired
- 1965-09-22 DE DE1483468A patent/DE1483468C3/en not_active Expired
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3025182A (en) * | 1957-03-05 | 1962-03-13 | Kanthal Ab | Formation of corrosion-resistant metallic coatings by so-called flame-spraying techniques |
| US3254970A (en) * | 1960-11-22 | 1966-06-07 | Metco Inc | Flame spray clad powder composed of a refractory material and nickel or cobalt |
| US3141744A (en) * | 1961-06-19 | 1964-07-21 | Dwight E Couch | Wear-resistant nickel-aluminum coatings |
| US3305326A (en) * | 1963-04-23 | 1967-02-21 | Metco Inc | Self-fusing flame spray material |
Cited By (19)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3421972A (en) * | 1965-06-28 | 1969-01-14 | Koppers Co Inc | Process for directly bonding polytetrafluoroethylene to metal,adhesive composition used therefor and laminated product thereof |
| US3410714A (en) * | 1965-10-18 | 1968-11-12 | Gen Electric | Metallizing and bonding non-metallic bodies |
| US3617358A (en) * | 1967-09-29 | 1971-11-02 | Metco Inc | Flame spray powder and process |
| DE2031616A1 (en) * | 1969-07-01 | 1971-01-21 | Metco Ine Westbury (Long Island) NY (VStA) | Flame spray powder |
| US3769689A (en) * | 1972-01-12 | 1973-11-06 | Nasa | Method of making pressure-tight seal for super alloy |
| US4027367A (en) * | 1975-07-24 | 1977-06-07 | Rondeau Henry S | Spray bonding of nickel aluminum and nickel titanium alloys |
| US4031278A (en) * | 1975-08-18 | 1977-06-21 | Eutectic Corporation | High hardness flame spray nickel-base alloy coating material |
| US4118527A (en) * | 1976-07-19 | 1978-10-03 | Eutectic Corporation | Metaliferous flame spray material for producing machinable coatings |
| US4039318A (en) * | 1976-07-19 | 1977-08-02 | Eutectic Corporation | Metaliferous flame spray material for producing machinable coatings |
| DE2929274A1 (en) * | 1978-07-19 | 1980-01-31 | Metco Inc | SELF-ADHESIVE FLAME SPRAY POWDER FOR THE PRODUCTION OF EASILY EDITABLE COATINGS |
| DE2934446A1 (en) * | 1979-08-25 | 1981-03-12 | Verschleiß-Technik Dr.-Ing. Hans Wahl GmbH & Co, 7302 Ostfildern | Wear and corrosion resistant material or coatings - made from metal or carbide grains covered by sheath contg. boron or phosphorus |
| US4379720A (en) * | 1982-03-15 | 1983-04-12 | Marko Materials, Inc. | Nickel-aluminum-boron powders prepared by a rapid solidification process |
| US4741973A (en) * | 1986-12-15 | 1988-05-03 | United Technologies Corporation | Silicon carbide abrasive particles having multilayered coating |
| US5165609A (en) * | 1991-09-05 | 1992-11-24 | Technalum Research, Inc. | Method of producing thermally reactive powders using consumable disintegrator disks |
| US5302182A (en) * | 1991-09-05 | 1994-04-12 | Technalum Research, Inc. | Method of preparing particles with a controlled narrow distribution |
| US5312648A (en) * | 1991-09-05 | 1994-05-17 | Technalum Research, Inc. | Method for coating particles using counter-rotating disks |
| US5660934A (en) * | 1994-12-29 | 1997-08-26 | Spray-Tech, Inc. | Clad plastic particles suitable for thermal spraying |
| US5718970A (en) * | 1994-12-29 | 1998-02-17 | Longo; Frank N. | Thermal sprayed coating containing plastic |
| US5885663A (en) * | 1994-12-29 | 1999-03-23 | Spray-Tech, Inc. | Method for depositing a coating containing plastic on a surface |
Also Published As
| Publication number | Publication date |
|---|---|
| DE1483468C3 (en) | 1973-09-27 |
| GB1068284A (en) | 1967-05-10 |
| DE1483468A1 (en) | 1969-09-25 |
| DE1483468B2 (en) | 1973-03-08 |
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