[go: up one dir, main page]

WO2019055310A1 - Procédé et système pour favoriser l'adhérence de revêtements par pulvérisation à l'arc - Google Patents

Procédé et système pour favoriser l'adhérence de revêtements par pulvérisation à l'arc Download PDF

Info

Publication number
WO2019055310A1
WO2019055310A1 PCT/US2018/049972 US2018049972W WO2019055310A1 WO 2019055310 A1 WO2019055310 A1 WO 2019055310A1 US 2018049972 W US2018049972 W US 2018049972W WO 2019055310 A1 WO2019055310 A1 WO 2019055310A1
Authority
WO
WIPO (PCT)
Prior art keywords
arc
stream
article
spray coating
metallic
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.)
Ceased
Application number
PCT/US2018/049972
Other languages
English (en)
Inventor
Peter Joseph Yancey
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Atmospheric Plasma Solutions Inc
Original Assignee
Atmospheric Plasma Solutions Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Atmospheric Plasma Solutions Inc filed Critical Atmospheric Plasma Solutions Inc
Publication of WO2019055310A1 publication Critical patent/WO2019055310A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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
    • C23C4/02—Pretreatment of the material to be coated, e.g. for coating on selected surface areas
    • 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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/131—Wire arc spraying

Definitions

  • the present invention is directed to a method to promote adhesion of coatings on surfaces, such as promoting adhesion of arc-spray or thermal-spray coatings onto surfaces such as metallic or ceramic surfaces with use of a non-thermal plasma stream at atmospheric pressure.
  • Arc-spray or thermal spray coatings are frequently applied to article surfaces.
  • the surface to receive the arc-spray coating must be prepared to ensure adequate adhesion of the arc-spray coating.
  • surfaces are commonly roughened by way of grit blasting to create a surface more amenable to bonding to the arc-spray coating.
  • Such surface preparation processes may be complicated, costly, and inconsistent.
  • grit or media blasting requires that the user has a sufficient supply of correctly sized and shaped particulates to create a uniform blasted surface profile or texture. The blast media is often only useable once before it becomes contaminated or is fractured upon impact rendering the media ineffective for a second application.
  • the media presents an ongoing source of dusts and the spent abrasive media must be disposed of.
  • the disclosure eliminates or drastically reduces the need to use blast media to prepare the surface prior to arc-spray coating.
  • a method of surface pre-treatment applied to an article that uniformly and predictably enhances the bonding of an arc-spray coating is needed.
  • Some systems and methods describe removal of materials from substrates using an atmospheric plasma source, such as U.S. Pat. Nos. 8,133,324 to Claar, 8,981,251 to Yancey, and 8,604,379 to Yancey, each of which are incorporated by reference in entirety.
  • WIPO 2017/087991 to Yancey describes a method and device to promote adhesion of metallic surfaces, incorporated by reference in entirety.
  • the disclosure provides a method to promote adhesion of coatings on surfaces. More specifically, the disclosure describes the use of a non-thermal plasma stream at atmospheric pressure to promote adhesion of arc-spray coatings, or thermal spray coatings, onto surfaces such as metallic or ceramic surfaces. In one embodiment, both the article and the arc-spray are metallic.
  • the disclosure involves methods to promote adhesion of coatings on surfaces, such as promoting adhesion of arc-spray coatings, or thermal spray coatings, onto surfaces such as metallic or ceramic surfaces with use of a non-thermal plasma stream at atmospheric pressure.
  • the method applies a non-thermal plasma stream at atmospheric pressure to an article surface, creating an energized surface region that promotes adhesion of a coating, such as an arc-spray coating or a thermal spray coating.
  • the coating is applied onto a metallic or a ceramic surface.
  • a method to adhere an arc-spray coating to a surface of an article comprising: generating a non-thermal plasma stream, the non-thermal plasma stream at atmospheric pressure; positioning the surface of the article to receive the nonthermal plasma stream; treating the surface of the article with the non-thermal plasma stream to create an energized surface region; generating an arc-spray coating stream; directing the arc- spray coating stream at the energized surface region; wherein: the arc-spray coating stream forms an arc-spray coating surface associated with the energized surface region of the article.
  • the energized surface region comprises etched organic residues.
  • the non-thermal plasma stream provides a chemical etching and cleaning of the substrate.
  • the non-thermal plasma stream comprises monatomic oxygen species.
  • the article is metallic, and the surface is a metallic surface.
  • the energized surface region is a metal oxide region.
  • the metal oxide region comprises an outer oxide surface.
  • the arc-spray coating stream is directed at the outer oxide region.
  • the article is metallic, the surface comprises a metallic surface, and the arc-spray stream comprises a metal.
  • the method further comprises the step of forming chemical bonding sites
  • the article is metallic, and the surface is a metallic surface, and the method further comprises the step of heating the article. In one aspect, the method further comprises the step of applying an auxiliary gas onto the surface of the article.
  • the non-thermal plasma stream comprises monatomic nitrogen. In one aspect, the arc-
  • the 80 spray coating stream is a metallic arc-spray coating stream comprising a stream of projected molten metal surrounded by a sheath of air plasma.
  • the surface is a metallic surface
  • the non-thermal plasma stream comprises an energetic species chemically reactive with the metallic surface.
  • the method further comprises applying a gas curtain associated with the non-thermal plasma stream.
  • the arc-spray stream comprises
  • the method further comprises the step of forming chemical bonding sites on the energized surface region, the chemical bonding sites promoting chemical bonding with the energized surface region.
  • the article is metallic, and the surface is a metallic surface.
  • the method further comprises the step of applying an auxiliary gas onto the energized surface region.
  • the non-thermal plasma stream comprises monatomic nitrogen.
  • the arc-spray coating stream is a metallic arc-spray coating stream comprising a stream of projected molten metal surrounded by a sheath of air plasma.
  • the surface is a metallic surface, and the non-thermal plasma stream comprises an energetic species chemically reactive with the metallic surface.
  • the article is ceramic, the surface comprises a ceramic surface, and the arc-spray stream comprises a metal. In one aspect, the article is ceramic, the surface comprises a ceramic surface, and the arc-spray stream comprises a cermet. In one aspect, the article is ceramic, the surface comprises a ceramic surface, and the arc-spray stream comprises a ceramic.
  • the non-thermal plasma 100 stream comprises monatomic chemical species. In one aspect, the non-thermal plasma stream comprises a tailored gas that forms a tailored chemical species on the surface. In one aspect, the tailored gas is ammonia and the tailored chemical species comprise amine groups. In one aspect, the tailored gas is water and the tailored chemical species comprise hydroxyl groups. In another embodiment, a method to bond an arc-spray coating to a metal surface of an arc-spray stream comprises a metal. In one aspect, the article is ceramic, the surface comprises a ceramic surface, and the arc-spray stream comprises a metal. In one aspect, the article is ceramic, the surface comprises
  • the method comprising: generating a non-thermal plasma stream, the nonthermal plasma stream at atmospheric pressure and comprising monatomic oxygen (and/or other atomic and molecular species); positioning the metal surface of the article to receive the non-thermal plasma stream; treating the metal surface of the article with the non- thermal plasma stream to create a metal oxide region, the metal oxide region comprising an outer oxide
  • a metallic arc-spray coating stream comprising a stream of projected molten metal surrounded by a sheath of air plasma; and directing the metallic arc-spray coating stream at the metal oxide region; wherein: the molten metal bonds with the metal oxide region to bond the arc-spray coating to the metal surface of the article.
  • the system comprising: a plasma generating device configured to generate a non-thermal plasma stream at atmospheric pressure; and an arc-spray generating device configured to generate an arc-spray coating stream; wherein: the non-thermal plasma stream is directed at the surface of the article to create an energized surface region; the arc-spray coating stream is directed at the energized surface region; and the arc-spray coating is adhered to the non-thermal plasma stream is directed at the surface of the article to create an energized surface region; the arc-spray coating stream is directed at the energized surface region; and the arc-spray coating is adhered to the
  • the non-thermal plasma stream comprises monatomic oxygen
  • the article is metallic with a metallic surface
  • the arc-spray stream comprises a metal.
  • the non-thermal plasma generating device is configured to direct an auxiliary gas onto the metallic surface
  • the arc-spray coating stream is a metallic arc-spray coating stream
  • plasma generally refers to an ionized gas comprising a mixture of charged species (ions and electrons), metastable (electronically excited) species, and neutral species; the volume of matter in the plasma state additionally emits photons.
  • ions and electrons charged species
  • metastable species metastable species
  • neutral species neutral species
  • the word “plasma” encompasses not only
  • non-thermal plasma generally refers to a plasma exhibiting low temperature ions and neutral species (relative to a
  • thermo plasma 135 "thermal " plasma) and high electron temperatures relative to the temperature of the surrounding gas.
  • a non-thermal plasma is distinguished from a thermal plasma in that a thermal plasma exhibits a higher overall temperature and energy density with both high electron temperatures and high ion and neutral temperatures.
  • a plasma will be sustained as long as the conditions required for sustaining the plasma are maintained, such as an input of electrical (or electromagnetic) power with the appropriate operating parameters (e.g., voltage, frequency, etc.), a sufficient source of, plasma- precursor gas etc.
  • Atmospheric pressure such as used the context of "atmospheric pressure plasma,” is not limited to a precise value of pressure corresponding exactly to sea-level conditions. For instance, the value of “atmospheric pressure” is not limited to exactly 1 atm. Instead, “atmospheric pressure” generally encompasses ambient pressure at any geographic location and thus may encompass a range of values less than and/or greater than 1 atm as
  • an "atmospheric pressure plasma” is one that may be generated in an open or ambient environment, i.e., without needing to reside in a pressure- controlled chamber or evacuated chamber, although a chamber (at or around atmospheric pressure), may be utilized to confine the plasma to maintain a desired chemical environment, such as excluding oxygen to prevent oxidation.
  • substrate generically refers to any structure that includes a surface on which an adhesion-promoting oxide layer may be formed in accordance with the present disclosure.
  • the substrate may present a surface having a simple planar or curved geometry or may have a complex or multi-featured topography.
  • metal substrate refers to a substrate composed of a single metal or a
  • Such a substrate is not necessarily pure, in that a trace amount of impurities may exist in its lattice structure.
  • metal oxide or “metal nitride,” depending on the type of oxide or nitride, generally may refer a stoichiometric or non- stoichiometric formulation of the oxide or nitride.
  • titanium oxide may encompass stoichiometric titanium oxide
  • nanoscale 165 typically but not exclusively titanium dioxide (T102), and/or TiOfact where y ranges from 0.7- 2.
  • a mixture of stoichiometric metal oxide (or nitride) and non- stoichiometric metal oxide (or nitride) may be present in a layer of metal oxide (or nitride) formed in accordance with the present disclosure.
  • the word "nanoscale” refers to a dimension (e.g., thickness) on the order of nanometers 170 (nm).
  • a nanoscale dimension is typically one that is less than 1000 nm, i.e., less than 1 micrometer ( ⁇ ).
  • arc-spray as used in the phrase “arc-spray coating” or “arc-sprayed coating” means a sprayed molten metal propelled by a gas, such as propelled by compressed air via atomization, applied as a surface coating.
  • thermo spray means as used in the phrase “thermal spray coating” or
  • thermal -sprayed coating means a sprayed coating comprising a heat source and a coating in a molten form that is propelled toward a substrate to form a coating of the molten material.
  • energized surface region means an elevated surface energy from a nominal surface energy, as typically measured by dyne level (a dyne meaning 10 micronewtons 180 or 10 E-5 newtons).
  • etched organic residue means an organic remainder that has been embedded into a surface.
  • auxiliary gas means a gas that is complementary to a primary gas, such as ammonia, water, nitrogen, a combination of an inert gas with a reactive gas, a combination 185 of different gases that creates specific ionization state such as Penning ionization mixture, an inert gas.
  • the primary gas may be composed primarily of oxygen or air.
  • energetic species means any unstable compound, such as an ionized gas, a neutral gas that is unstable, or any chemical constituent not in an equilibrium state at given temperature and pressure.
  • gas curtain means a gas stream that surrounds, encircles, or exists adjacent another stream, such as a gas curtain of oxygen that surrounds a stream of molten metal.
  • sheath such as used in the phrase “sheath of air plasma” means a formation that surrounds, encircles, or exists adjacent a stream, such as a sheath of air surrounding a 195 stream of molten metal.
  • molten metal means metal that has been heated to a temperature above its melting point and is in the liquid state.
  • the phrase “monatomic” such as used in the phrase “monatomic oxygen” means consisting of one atom in a material.
  • organic coating means a typically carbonaceous coating that depends primarily on its chemical inertness and impermeabi lity to form a layer or coating onto a surface, to include primers, adhesive cements and topcoats such as enamel, varnish and paints.
  • each of the expressions “at least one of A, B and C”, “at least one of A, B, or C”, “one or more of A, B, and C", “one or more of A, B, or C" and "A, B, and/or C” means A alone, B alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
  • a process or operation can be automatic, even though performance of the process or operation uses material or immaterial human input, if the input is received before performance of the process or operation. Human input is deemed to be material if such input influences how the process or operation will be performed. Human input that consents to the performance of the process or operation is not deemed to be "material”.
  • computer-readable medium refers to any storage and/or transmission medium that participate in providing instructions to a processor for execution.
  • Such a computer-readable medium is commonly tangible, non-transitory, and non-transient and can take many forms, including but not limited to, non-volatile media, volatile media, and transmission media and includes without limitation random access memory (“RAM”), read
  • Non-volatile media includes, for example, NVRAM, or magnetic or optical disks.
  • Volatile media includes dynamic memory, such as main memory.
  • Common forms of computer-readable media include, for example, a floppy disk (including without limitation a Bernoulli cartridge, ZIP drive, and JAZ drive), a flexible disk, hard disk, magnetic tape or cassettes, or any other magnetic medium, magneto-optical medium, a digital
  • video disk such as CD-ROM
  • any other optical medium punch cards, paper tape, any other physical medium with patterns of holes
  • a RAM, a PROM, and EPROM a FLASH-EPROM
  • solid state medium like a memory card, any other memory chip or cartridge, a carrier wave as described hereinafter, or any other medium from which a computer can read.
  • a digital file attachment to e-mail or other self-contained information archive or set of archives is considered
  • the computer-readable media is configured as a database
  • the database may be any type of database, such as relational, hierarchical, object-oriented, and/or the like. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium and prior art- recognized equivalents and successor media, in which the software implementations of the
  • Computer-readable storage medium commonly excludes transient storage media, particularly electrical, magnetic, electromagnetic, optical, magneto- optical signals.
  • the disclosed methods may be readily implemented in software and/or firmware that can be stored on a storage medium to improve the performance of: a programmed
  • the systems and methods can be implemented as program embedded on personal computer such as an applet, JAVA.RTM. or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated communication system or system component, or the like.
  • the system can also be implemented as program embedded on personal computer such as an applet, JAVA.RTM. or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated communication system or system component, or the like.
  • the system can also be implemented as program embedded on personal computer such as an applet, JAVA.RTM. or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated communication system or system component, or the like.
  • the system can also be implemented as program embedded on personal computer such as an applet, JAVA.RTM. or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated communication
  • 260 be implemented by physically incorporating the system and/or method into a software and/or hardware system, such as the hardware and software systems of a communications transceiver.
  • Various embodiments may also or alternatively be implemented fully or partially in software and/or firmware.
  • This software and/or firmware may take the form of instructions contained in or on a non-transitory computer-readable storage medium. Those instructions may
  • the instructions may be in any suitable form, such as but not limited to source code, compiled code, interpreted code, executable code, static code, dynamic code, and the like.
  • a computer- readable medium may include any tangible non- transitory medium for storing information in a form readable by one or more computers, such as but not limited to 270 read only memory (ROM); random access memory (RAM); magnetic disk storage media; optical storage media; a flash memory, etc.
  • module refers to any known or later developed hardware, software, firmware, artificial intelligence, fuzzy logic, or combination of hardware and software that can perform the functionality associated with that element.
  • Fig. 1 is a flowchart depicting one embodiment of a method to promote adhesion of a surface coating to an article
  • Fig. 2A is a schematic elevation view of an article to receive a surface coating consistent with the method of Fig. 1 ;
  • FIG. 2B is a schematic elevation view of the article of Fig. 2A after application of a nonthermal plasma stream to a surface of the article;
  • Fig. 2C is a schematic elevation view of the article of Fig. 2B after application of an arc-spray coating to a surface of the article;
  • Fig. 3 is a block diagram of an embodiment of a system to promote adhesion of a surface 310 coating to an article.
  • the following disclosure generally relates to methods and systems to promote adhesion of coatings on surfaces, such as promoting adhesion of arc-spray or thermal-spray coatings onto surfaces such as metallic or ceramic surfaces with use of a non-thermal plasma stream at 335 atmospheric pressure.
  • FIG. 1 a flowchart depicting one embodiment of a method 100 to promote adhesion of a surface coating to an article is depicted.
  • the description of the method 100 of Fig. 1 will reference elements of Figs. 2A-C, which depicts three schematic elevation 340 views of an article 200 receiving a surface coating consistent with the method of Fig. 1, and to Fig. 3, which depicts a system 300 to promote adhesion of a surface coating to an article 200.
  • the method 100 applies a non-thermal plasma stream 410 at atmospheric pressure to an article surface 208, creating an energized surface region that promotes adhesion of an arc-spray coating.
  • the non-thermal plasma stream 410 at atmospheric pressure increases the surface energy of a metallic or ceramic surface which in turn increases the bonding of an arc sprayed metallic surface coating.
  • the non-thermal plasma stream 410 is used as a bonding adhesion promoter that enhances the adhesion of arc-sprayed coating layers, thereby enabling smooth surfaces with little roughness to be coated with an arc spray coating with improved adhesion.
  • both the article and the arc-spray are metallic.
  • the system 300 to promote adhesion of a surface coating to an article comprises a plasma generating device 400 and an arc-spray generating device 500 (or a thermal spray generating device).
  • a plasma generating device 400 and an arc-spray generating device 500 or a thermal spray generating device.
  • both the article and the arc-spray are metallic.
  • the arc-spray may be a ceramic, a mixture of a ceramic and a metal (termed a CERMET)
  • the arc-spray may be a semiconductor, or other material that can be liquefied and sprayed in its molten state to impact on a surface that is at a temperature that is below the melting point of
  • the material being sprayed such that when the molten/liquid spray impacts the surface it is cooled to a temperature that is lower than the melting point of the liquefied material and solidifies onto the surface forming a coating.
  • the method 100 starts at step 104 and ends at step 128. Any of the steps, functions, and operations discussed herein can be performed continuously and automatically. In some 365 embodiments, one or more of the steps of the method 100 may comprise computer control, use of computer processors, and/or some level of automation. The steps are notionally followed in increasing numerical sequence, although, in some embodiments, some steps may be omitted, some steps added, and the steps may follow other than increasing numerical order.
  • a non- thermal plasma stream 410 After starting at step 104, at step 108 a non- thermal plasma stream 410, at atmospheric
  • a plasma generating device 400 is generated by a plasma generating device 400. Any of several means may be used to generate the non-thermal plasma stream at atmospheric pressure, to include by use of the devices and methods described in the previously-identified patent documents: U.S. Pat. Nos. 8,981,251 to Yancey, 8,604,379 to Yancey, and WIPO 2017/087991 to Yancey (collectively, the "Yancey techniques.")
  • the non-thermal plasma stream 410 is provided by a plasma generating device 400 configured to discharge an atmospheric pressure plasma stream (or plasma "plume") 410 from a nozzle.
  • the plasma generating device 400 may be positioned at some specified distance between the nozzle and the surface of the article 200, and oriented to direct the atmospheric pressure non-thermal plasma stream 410 toward the surface 208 of the
  • the nozzle directing the atmospheric pressure non-thermal plasma stream 410 device may be moved across the surface 208 of the article 200.
  • the non-thermal plasma stream 410 and/or the plasma generating device 400 may be configured with any combination of the following parameters. Generally, the operating
  • 385 parameters associated with the plasma generating device 400 to generate the non-thermal plasma stream 410 are selected to produce a stable plasma discharge.
  • the operating parameters may vary depending on the composition of the metallic substrate 204 (i.e., the type of metal or metal alloy) on (from) which the energized surface region 212 is to be formed. Examples of operating parameters will now be provided with the understanding that the broad teachings
  • an air flow rate of between 20 and 200 standard liter per minute (SLM) is used. In a more preferred embodiment, an air flow rate of between 50 and 150 SLM is used. In a most preferred embodiment, an air flow rate of between 75 and 125 SLM is used. In one embodiment, an air flow rate of about 100 SLM is used.
  • SLM standard liter per minute
  • a plasma power of between 0.3kW and 5kW is used. In a more preferred embodiment, a plasma power of between 1.2 and 3.2 kW is used. In a most preferred embodiment, a plasma power of between 1.7 and 2.7 kW is used. In one embodiment, a plasma power of about 2.2 kW is used.
  • an electrode voltage of between 500V and 4000V is used. 405 In a more preferred embodiment, an electrode voltage of between 1000V and 3000V is used.
  • an electrode voltage of between 1000V and 1400V is used. In one embodiment, an electrode voltage of about 1200V is used.
  • a frequency of between direct current (DC) and 2540MHz i.e. 2.54 GHz
  • a frequency of between 50kHz and 410 200 kHz is used.
  • a frequency between 100kHz and 150kHz is used.
  • an article of manufacture (or product) 200 is positioned to receive the nonthermal plasma stream 410.
  • the (unworked or untreated) article 200 comprises a substrate 204, such as a metal substrate, with an untreated upper surface 208.
  • the 415 untreated upper surface 208 is the surface which will undergo treatment per the method 100.
  • the substrate 204 of the article 200 may be configured with any combination of the following parameters.
  • the substrate temperature is between -50 deg C and +80 deg C. In a more preferred embodiment, the substrate temperature is between -20 deg C and +50 420 deg C. In a most preferred embodiment, the substrate temperature is +10 deg C and +30 deg C. In one embodiment, the substrate temperature is about +20 deg C.
  • the substrate temperature may be as high as 0.95 times the melting point of the surface that is being treated.
  • tin melts at 232C.
  • the tin surface could be as hot as 220 C and still be in a solid state and accept a plasma 425 treatment.
  • the substrate temperature may be as low as absolute zero.
  • the air flow rate is between 5 SLM and 300 SLM. In a more preferred embodiment, the air flow rate is between 10 SLM and 250 SLM. In a most preferred 430 embodiment, the air flow rate is between 20 SLM and 200 SLM.
  • the substrate is descaled metal with a smooth surface roughness of less than 10 mil. In a more preferred embodiment, the substrate is descaled metal with a smooth surface roughness of less than 5 mil. In a most preferred embodiment, the substrate is descaled metal with a smooth surface roughness of less than 0.01 mil. In one 435 embodiment, the substrate is descaled metal with a smooth surface roughness of between 0.01 mil to 5 mil.
  • the method of the disclosure generally works to enhance bonding on either atomically flat surfaces or jagged and rough surfaces with, e.g. +/- 3cm roughness.
  • An advantage is that whatever surface roughness is presented may be useable such
  • the substrate 204 may be, in one embodiment, any metal or metal alloy. In one embodiment, the substrate 204 is a composite material, a ceramic, and/or a semiconductor.
  • step 112 the method 100 continues to step 116.
  • the untreated upper surface 208 of article 200 is treated with the nonthermal plasma stream 410.
  • the non-thermal plasma stream 410 energies the untreated upper surface 208 (of Fig. 2A) to increase the surface energy of the untreated upper surface 208, creating an energized surface region 212 with treated upper surface 220 (see Fig. 2B). Stated another way, the non-thermal plasma stream 410 creates an energized surface region 212 with
  • the energized surface region 212 acts as an adhesion layer and is disposed above or adjacent a bulk layer 216 of the substrate 204.
  • the article 200 After undergoing treatment by the non-thermal plasma stream, the article 200 comprises a treated upper surface 220.
  • the treated upper surface 220 in effect replaces the untreated upper surface 208 depicted in Fig. 2A.
  • the substrate 204 is a metal or metal alloy, the
  • bulk layer 216 is a bulk metallic layer
  • the energized surface region 212 is a metal oxide layer
  • the treated upper surface 220 is an outer oxide surface.
  • the non-thermal plasma stream 410 is provided by a plasma generating device 400 configured to discharge an atmospheric pressure plasma stream (or plasma "plume”) 410 from a nozzle.
  • the plasma or plasma "plume”
  • 460 generating device 400 may be positioned at some specified distance between the nozzle and the untreated upper surface 208 of the article 200, and oriented to direct the atmospheric pressure plasma stream 410 toward the surface 208 of the article 200. While the atmospheric pressure plasma stream 410 is active, the nozzle directing the atmospheric pressure plasma stream 410 device may be moved across the untreated upper surface 208 of the article 200.
  • the non-thermal plasma stream 410 promotes or enhances the bonding of the surface 208 of the article 200 to a coating, such as an arc-spray coating or a thermal-spray coating.
  • the non-thermal plasma stream 410 may be generated in close proximity to the substrate surface to ensure the surface is exposed to the non-thermal plasma stream 410 or at least the afterglow thereof.
  • the generated plasma may
  • the plasma 470 be transported toward the substrate surface by a flow of air, or additionally by an electric field, which may be the electric field utilized to generate the plasma.
  • the plasma is generated under conditions that, if desired, can produce a high concentration of monatomic oxygen in the plasma or other chemical ly reactive atomic or molecular species.
  • the plasma may also produce a high concentration of highly energetic and reactive singlet oxygen in the plasma or other
  • the plasma can be effectively directed to selectively oxidizing the substrate surface.
  • the non-thermal plasma can be utilized to only alter the first few atomic layers of a substrate, effectively just changing the chemical surface groups on the substrate's surface.
  • the plasma forms an oxide layer of nanoscale thickness on the metallic substrate to promote bonding.
  • the plasma-formed oxide layer may be grown from the base metal of the metallic substrate itself and may therefore be permanently and rigidly attached to the substrate. Stated another way, in some embodiments, the oxide layer may be characterized as being integral with the underlying bulk of the metallic substrate. The bulk of
  • the metallic substrate may be characterized as that part of the metallic substrate that is substantially free of the metal oxide formed as the overlvins oxide layer.
  • the plasma-formed oxide layer in some embodiments, is porous, may add a nanoscale surface texture and/or may increase the surface area that is available for bonding to the coating (see steps 120 and 124) as applied by the coating stream 510.
  • nanoscale roughness may be enhanced to increase (in particular, mechanical) bonding of the arc-spray or thermal-spray.
  • the post plasma treated surface promotes stronger chemical bonds to the surface.
  • the plasma works on atomically smooth surfaces because there is chemical bonding which can be many times higher bond 495 strength.
  • the plasma can promote adhesion on atomically smooth surfaces because there is chemical bonding which can impart higher bond strengths compared to strictly mechanical means.
  • Another effect of the application, or spraying, of the non-thermal plasma stream 410 to the untreated upper surface 208 of the article 200 is to increase the surface energy of the newly
  • 500 formed plasma-oxidized oxide layer (as compared to the surface energy of the original outer surface of the metallic substrate), which further enhances adhesion when a coating is applied to the surfaces within a certain period of time.
  • the non-thermal plasma stream 410 as generated by a plasma generating device 400, may be operated with enriched gas mixtures which may increase the flux of oxygen or other
  • a plasma pen may be operated with nitrogen to produce atomic nitrogen species which may be used to nitride surfaces or to from amine groups in the presence of hydrogen.
  • alternative gases may be used to terminate the surface such as: N, O, F,
  • a chemical species other than oxygen to activate a metallic surface, e.g. a nitride may be used to bond with certain nitride forming alloy systems.
  • a DBD plasma device may be used to activate the surface but at relatively lower plasma densities and slower treatment times.
  • any atmospheric plasma device that produces enough flux of energetic plasma species could be used to treat the untreated upper surface 208 of the article 200.
  • many atmospheric plasma sources that are used for surface treatment do not produce a significant flux of energetic species to
  • the composition of an air plasma is a mixture of different components, including various charged and electronically excited species of oxygen and nitrogen, and other trace gases found in air.
  • the plasma is generated tinder conditions that produce a high plasma densi ty, which, if desired, can produce a high density of monatomic oxygen ions (and/or other
  • the density of ionized species in the plasma is in a range from 1 x i(> 3 .ions/cm 3 to 1 x TO ions/cm 3 , one specific yet non-exclusive example being about 2.55 x TO ions/cm 3 .
  • singlet oxygen is a highly energetic and chemically reactive form of diatomic oxygen (O.j, as compared to the ground-state, or triplet, diatomic oxygen (02) [hat is a predominant constituent of naturally occurring air.
  • diatomic oxygen has a much higher diffusivity and chemical reactivity compared to molecular oxygen species such as diatomic oxygen (02) and ozone (03), which may also be produced in the air plasma.
  • molecular oxygen species such as diatomic oxygen (02) and ozone (03), which may also be produced in the air plasma.
  • a distinct energized surface region 212 is formed from a portion of the metallic substrate 204 and is rigidly attached to the metallic substrate 204.
  • the metal oxide layer 212 serves as a highly effective adhesion promoting layer to which a coating may be applied (see step 124 and arc-spray 510).
  • the treated upper surface 220 (which in this example is an outer oxide surface) is porous, or at least is superficially porous. Such nanoscale porosity may significantly increase the surface area of the outer oxide surface, thereby providing a significantly increased surface area for bonding and adherence to the arc-spray coating, as compared to a nonporous or less rough surface.
  • the treated upper surface 220 may not be generally porous and is a few atoms or molecules thick.
  • the bulk layer 216 is a bulk metallic layer
  • the energized surface region 212 is a metal oxide layer
  • the treated upper surface 220 is an outer oxide surface.
  • the plasma treatment may provide a surface treatment that changes the first few atomic or molecular layers on the surface.
  • the non-thermal plasma stream 410 is directed toward the surface of substrate at high velocities. In one embodiment, the non-thermal plasma stream 410 impacts the surface of the substrate at near or exceeding sonic velocities. Stated another way, in one embodiment the non- thermal plasma stream 410 impacts the surface of the substrate at a velocity faster than the
  • the treated upper surface 220 is more amenable to adhesion of an arc-spray (or thermal) coating.
  • One or more processes occur to enable the heightened adhesion. For example, surface monolayers may be added to change chemical groups which promote adhesion to a substrate' s
  • surface monolayers may slightly alter to change surface chemical groups, thereby promoting adhesion to a substrate's base metallic material.
  • plasma treatment may etch organic residues onto the surface and leave the surface nearly atomically clean.
  • energetic species from the plasma may increase the surface energy of the metal surface and reduce the surface tension, which promotes wetting of the surface by the
  • the plasma treatment may be performed manually or robotically with overlapping surface coverage to ensure complete treatment area coverage.
  • step 116 After completion of step 116, the method 100 continues to step 120.
  • an arc-spray coating stream is generated.
  • the arc-spray coating stream is directed at the energized surface region 212, to form or create an arc-spray coating 240.
  • the arc-spray coating stream is directed at the energized surface region 224 and adheres or bonds an arc-spray coating to an upper surface of the article 200.
  • the arc spray may also be a pure metal, a pure metal alloy, a cermet or a mixture of metal and inorganic particulates.
  • the arc-sprayed metal is sprayed in air and, in some embodiments, includes a sheath of
  • the arc-spray coating stream 510 (see step 124) is applied within 60 minutes after the completion of spraying of the article with the non-thermal plasma stream 410 (i.e. within 60 minutes after step 116.) In a more preferred embodiment, the arc-
  • step 124 595 spray coating stream 510 (see step 124) is applied within 40 minutes after the completion of spraying of the article with the non-thermal plasma stream 410.
  • the arc-spray coating stream 510 (see step 124) is applied within 30 minutes after the completion of spraying of the article with the non-thermal plasma stream 410.
  • the energized surface region 212 is much thinner in thickness than the arc-sprayed coating 240.
  • the energized surface region 212 is of thickness at the molecular level.
  • the thickness of the arc-sprayed coating 240 may vary from micron thickness to inches.
  • the arc-sprayed coating 240 is of thickness between 10
  • the arc-sprayed coating 240 is of thickness between 20 micron and 2000 micron. In a most preferred embodiment, the arc- sprayed coating 240 is of thickness between 25 micron and 1000 micron. In one embodiment, the arc-sprayed coating 240 is of thickness of about 200 micron.
  • the arc-sprayed coating 240 is of thickness of more than 12,700
  • the arc-sprayed coating 240 is of thickness of more than 19,050 micron (0.75 inch).
  • the benefits include: reduction in the steps required to prepare a surface for arc-spray bonding, vitiate the need to grit blast a surface to make a profile or surface roughness, increase chemical bonding at the
  • Fig. 3 depicts the system 300 to promote adhesion of a surface 625 coating to an article comprising both a plasma generating device 400 and an arc-spray generating device 500 (or a thermal spray generating device), these two components (400, 500) may be separated, in one or both of time and physical proximity.
  • the plasma generating device 400 may treat a surface of an article at a first location, and the arc-spray generating device 500 may coat the surface at a second location.
  • the time between treatment 630 of the surface by the plasma generating device 400 and the coating by the arc-spray (or thermal spray) generating device 500 may be several hours, e.g. from 2-5 hours in one embodiment.
  • the methods and devices of the disclosure may be applied to ceramic surfaces, and inorganic composites, such as metallic matrix composites with embedded ceramic fibers and the like.
  • the arc-spray may be used to deposit varied materials onto varied surfaces, e.g. deposit ceramic on metal, metal on ceramic, cermet on metal, metal on ceramic, etc.
  • Examples of the processors as described herein may include, but are not limited to, at least one of Qualcomm® Qualcomm® Qualcomm® Qualcomm® 800 and 801, Qualcomm® Qualcomm® Qualcomm® 610 and 615
  • components of the system can be combined in to one or more devices or collocated on a particular node of a distributed network, such as an analog and/or digital telecommunications network, a packet-switch network, or a circuit-switched network. It will be appreciated from the preceding description, and for reasons of computational efficiency, that the components of the system can be arranged at any location within a distributed network of components without
  • the various components can be in a switch such as a PBX and media server, gateway, in one or more communications devices, at one or more users' premises, or some combination thereof.
  • a switch such as a PBX and media server, gateway, in one or more communications devices, at one or more users' premises, or some combination thereof.
  • one or more functional portions of the system could be distributed between a telecommunications device(s) and an associated computing device.
  • the various links connecting the elements can be wired or wireless links, or any combination thereof, or any other known or later developed element(s) that is capable of supplying and/or communicating data to and from the connected elements.
  • These wired or wireless links can also be secure links and may be capable of communicating encrypted information.
  • Transmission media used as links, for example, can
  • 680 be any suitable carrier for electrical signals, including coaxial cables, copper wire and fiber optics, and may take the form of acoustic or light waves, such as those generated during radio- wave and infra-red data communications.
  • exemplary hardware that can be used for the disclosed embodiments, configurations and aspects includes computers, handheld devices, telephones (e.g., cellular, Internet enabled, digital, analog, hybrids, and others), and other hardware known in the art. Some of these devices include processors (e.g., a single or multiple
  • microprocessors 700 microprocessors), memory, nonvolatile storage, input devices, and output devices.
  • the disclosed methods may be partially implemented in software that can be stored on a storage medium, executed on programmed general-purpose computer with the cooperation of a controller and memory, a special purpose computer, a
  • the systems and methods of this disclosure can be implemented as program embedded on personal computer such as an applet, JAVA® or CGI script, as a resource residing on a server or computer workstation, as a routine embedded in a dedicated measurement system, system component, or the like.
  • the system can also be implemented by physically incorporating the system and/or method into a software and/or
  • present disclosure in various aspects, embodiments, and/or configurations, includes providing devices and processes in the absence of items not depicted and/or described herein or in various aspects, embodiments, and/or configurations hereof, including in the absence of such items as may have been used in previous devices or processes, e.g., for improving performance, achieving ease and ⁇ or reducing cost of implementation.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Plasma & Fusion (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Application Of Or Painting With Fluid Materials (AREA)

Abstract

L'invention concerne des procédés pour favoriser l'adhérence de revêtements sur des surfaces, par exemple la promotion de l'adhérence de revêtements par pulvérisation à l'arc ou de revêtements par pulvérisation thermique sur des surfaces telles que des surfaces métalliques ou céramiques. Le procédé consiste à appliquer un courant de plasma non thermique à pression atmosphérique sur une surface d'article pour créer une région de surface excitée qui favorise l'adhérence d'un revêtement par pulvérisation à l'arc. Selon un aspect, le revêtement par pulvérisation à l'arc est appliqué sur une surface métallique ou céramique.
PCT/US2018/049972 2017-09-14 2018-09-07 Procédé et système pour favoriser l'adhérence de revêtements par pulvérisation à l'arc Ceased WO2019055310A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201762558714P 2017-09-14 2017-09-14
US62/558,714 2017-09-14

Publications (1)

Publication Number Publication Date
WO2019055310A1 true WO2019055310A1 (fr) 2019-03-21

Family

ID=65630700

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2018/049972 Ceased WO2019055310A1 (fr) 2017-09-14 2018-09-07 Procédé et système pour favoriser l'adhérence de revêtements par pulvérisation à l'arc

Country Status (2)

Country Link
US (1) US20190078191A1 (fr)
WO (1) WO2019055310A1 (fr)

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU2019364543A1 (en) * 2018-10-24 2021-05-27 Atmospheric Plasma Solutions, Inc. Plasma source and method for preparing and coating surfaces using atmospheric plasma pressure waves
CN113088864B (zh) * 2021-04-13 2022-11-29 宁波大学 一种电场辅助电弧喷涂装置及方法
CN115785702B (zh) * 2022-11-28 2023-09-19 西安理工大学 用于再入飞行器缓解通信黑障的催化涂层及其制备方法

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5733662A (en) * 1994-09-26 1998-03-31 Plas Plasma, Ltd. Method for depositing a coating onto a substrate by means of thermal spraying and an apparatus for carrying out said method
US5770273A (en) * 1995-02-14 1998-06-23 General Electric Company Plasma coating process for improved bonding of coatings on substrates
US20140335282A1 (en) * 2011-12-09 2014-11-13 Georg Fischer Automotive (Suzhou) Co Ltd Method for coating a substrate
WO2017087991A1 (fr) * 2015-11-22 2017-05-26 Atmospheric Plasma Solutions, Inc. Procédé et dispositif favorisant l'adhérence de surfaces métalliques

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4262034A (en) * 1979-10-30 1981-04-14 Armotek Industries, Inc. Methods and apparatus for applying wear resistant coatings to roto-gravure cylinders
US5194501A (en) * 1990-10-30 1993-03-16 Minnesota Mining And Manufacturing Company Pressure-sensitive adhesive based on ethylenically-unsaturated α-olefin polymer cured with hydrosilane
US5958849A (en) * 1997-01-03 1999-09-28 Exxon Research And Engineering Co. High performance metal working oil
JP4430266B2 (ja) * 2001-05-25 2010-03-10 東京エレクトロン株式会社 プラズマ処理容器内部材及びプラズマ処理装置
CA2754458A1 (fr) * 2010-10-11 2012-04-11 Sulzer Metco Ag Methode de fabrication d'une structure d'enduction de barriere thermique

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US5733662A (en) * 1994-09-26 1998-03-31 Plas Plasma, Ltd. Method for depositing a coating onto a substrate by means of thermal spraying and an apparatus for carrying out said method
US5770273A (en) * 1995-02-14 1998-06-23 General Electric Company Plasma coating process for improved bonding of coatings on substrates
US20140335282A1 (en) * 2011-12-09 2014-11-13 Georg Fischer Automotive (Suzhou) Co Ltd Method for coating a substrate
WO2017087991A1 (fr) * 2015-11-22 2017-05-26 Atmospheric Plasma Solutions, Inc. Procédé et dispositif favorisant l'adhérence de surfaces métalliques

Also Published As

Publication number Publication date
US20190078191A1 (en) 2019-03-14

Similar Documents

Publication Publication Date Title
US11384420B2 (en) Method and device for promoting adhesion of metallic surfaces
Williams et al. Surface analysis of 316 stainless steel treated with cold atmospheric plasma
US20190078191A1 (en) Method and system for promoting adhesion of arc-spray coatings
CN101743785A (zh) 使用高强度和高功率超声波增强等离子体表面改性
Lee et al. Ar and O2 linear ion beam PET treatments using an anode layer ion source
CA3117338C (fr) Source de plasma et procede de preparation et de revetement de surfaces a l'aide d'ondes de pression de plasma atmospherique
JP2001516947A (ja) マイクロ波の入射によりプラズマを発生させる方法
Friedrich et al. Nonthermal Plasmas for Materials Processing
ATE447630T1 (de) Verfahren zur herstellung einer superharten beschichtung aus amorphem kohlenstoff im vakuum
KR101617984B1 (ko) 백색 불화물 용사 피막의 흑색화 방법 및 표면에 흑색층을 갖는 불화물 용사 피막 피복 부재
TW538130B (en) Process method of metal casing
CN104674159A (zh) 一种基于高能量叠加的合金钢表面处理方法
JPS6344965A (ja) 多層塗膜の形成法
TWI273026B (en) Method of low-temperature surface modification of plastic substrate
JP7075666B2 (ja) 線状の基材用の放電後プラズマ被覆装置
JP4420116B2 (ja) プラズマ処理装置及びプラズマ処理方法
Awazu et al. Films formed by hybrid pulse plasma coating (HPPC) system
CN1249266C (zh) 便携式电子装置外壳制造方法
Frey Plasma Treatment Methods
Okubo Hydrophobic Treatment for Polymer Surfaces
Kaplan et al. Plasma surface treatment
Okubo Hydrophobic Treatments for Plastic, Glass, and Metal Surfaces and Their Applications
KR101842126B1 (ko) 코팅 장치 및 코팅 방법
Kawara et al. Investigation of affecting factors on the hardness of fluorine-containing amorphous carbon film coated by pulsed-plasma ablation
JP2004311314A (ja) プラズマ処理用ガス

Legal Events

Date Code Title Description
121 Ep: the epo has been informed by wipo that ep was designated in this application

Ref document number: 18856301

Country of ref document: EP

Kind code of ref document: A1

NENP Non-entry into the national phase

Ref country code: DE

122 Ep: pct application non-entry in european phase

Ref document number: 18856301

Country of ref document: EP

Kind code of ref document: A1