CN108220865A - The thermal spray deposition of hollow microsphere - Google Patents
The thermal spray deposition of hollow microsphere Download PDFInfo
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- CN108220865A CN108220865A CN201711399206.6A CN201711399206A CN108220865A CN 108220865 A CN108220865 A CN 108220865A CN 201711399206 A CN201711399206 A CN 201711399206A CN 108220865 A CN108220865 A CN 108220865A
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- 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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/021—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material including at least one metal alloy layer
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- 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
- C23C28/00—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
- C23C28/02—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material
- C23C28/023—Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D only coatings only including layers of metallic material only coatings of metal elements only
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- 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
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- 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
- C23C4/08—Metallic material containing only metal elements
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- 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
- C23C4/129—Flame spraying
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- 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
- C23C4/18—After-treatment
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- Engineering & Computer Science (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Plasma & Fusion (AREA)
- Coating By Spraying Or Casting (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
Abstract
Provide the method that insulating coating is formed by thermal spraying.In a variant, this method includes having the injection stream of the maximum temperature greater than or equal to about 900 DEG C to be sprayed towards substrate, to form insulating coating in substrate.Thermal spraying can be Velocity Oxygen Fuel (HVOF) technique.Injection stream includes multiple hollow microspheres, may include the metal of such as nickel or iron.The insulating coating formed has the thermal conductivity (K) less than or equal to about 200mW/mK in standard temperature and pressure conditions, and can have greater than or equal to about 100kJ/m3Thermal capacity (the c of Kv)。
Description
Background technology
The part provides and the relevant background information of the disclosure, is not necessarily the prior art.
This disclosure relates to for hollow minute particle thermal spraying to be formed the method for insulation thermal barrier coating in substrate.
Insulation thermal barrier coating is applied to reduce hot transmission for various.It is expected that there is this coating low heat capacity and low-heat to lead
Rate.In certain aspects, thermal barrier coating may include insulating materials, including one or more hollow microspheres.Therefore, insulation or heat
Barrier coating can be used in various applications, including as non-limiting examples, for the surface of the component in internal combustion engine, to subtract
Few heat, which is transmitted, loses and improves performance and efficiency.The new method that firm thermal barrier coating is formed in various complex components is it is expected
's.
Invention content
The part provides the summary of the disclosure, and is not its four corner and the comprehensive disclosure of all features.
This disclosure relates to the thermal spray deposition of the hollow micro-structure of such as microballoon.In a variant, present disclose provides
A kind of method for forming insulating coating, this method include the injection stream spray for the maximum temperature that will have greater than or equal to about 900 DEG C
It is basad, to form insulating coating in substrate.Injection stream includes multiple hollow microspheres.In standard temperature and pressure conditions,
The insulating coating of formation has the thermal conductivity (K) less than or equal to about 200mW/mK.
In an aspect, after thermal spraying, insulating coating includes multiple hollow micro- knots with complete void area
Structure.
In another aspect, insulating coating has the net porosity greater than or equal to about 80 volume %.
In another aspect, insulating coating has the thickness less than or equal to about 200 microns (μm).
In certain aspects, injection stream has the maximum temperature less than or equal to about 1400 DEG C.
In another aspect, multiple microballoons include the metal in the group being made of nickel, iron, a combination thereof and its alloy.
In other aspects, multiple microballoons include first layer in metal, and further comprise be selected from by copper, zinc, tin,
The bimetallic second layer in the group of nickel and combinations thereof composition.
In another aspect, substrate is included in the group being made of nickel, iron, copper, zinc, aluminium, a combination thereof and its alloy
At least one metal.
In another aspect, in standard temperature and pressure conditions, the thermal conductivity (K) of insulating coating less than or equal to about
100mW/m·K。
In further, the thermal capacity (c of insulating coatingv) less than or equal to about 100kJ/m3·K。
In another modification, present disclose provides a kind of method for forming insulating coating, this method is included from high speed oxygen
Fuel (HVOF) device includes the stream of multiple hollow microspheres towards substrate injection.The stream includes multiple microballoons, and microballoon includes having
The first metal layer selected from the first metal being made of nickel, iron, a combination thereof and its alloy and be selected from by copper, zinc, tin, nickel,
The bimetallic second metal layer of a combination thereof and its alloy composition.Further, in injection period, which has than the first metal
Layer fusing point it is low at least about 50 DEG C but equal to or higher than second metal layer fusing point maximum temperature.This method is additionally included in mark
It is formed with less than in substrate under quasi- temperature and pressure or the insulating coating of thermal conductivity (K) equal to about 200mW/mK.
In an aspect, after thermal spraying, insulating coating includes multiple hollow micro- knots with complete void area
Structure.
In another aspect, insulating coating has the net porosity greater than or equal to about 80 volume %.
In another aspect, insulating coating has the thickness less than or equal to about 200 microns (μm).
In another aspect, insulating coating can have the thickness less than or equal to about 200 microns (μm).
In further, maximum temperature is to less than or equal to about 1400 DEG C greater than or equal to about 900 DEG C.
In another aspect, substrate includes being selected from what is be made of nickel, iron, copper, zinc, tin, nickel, aluminium, a combination thereof and its alloy
At least one of group metal.
In other aspects, substrate includes the first metal in the group being made of nickel, iron, a combination thereof and its alloy,
And further comprise selected from the second metallic surface coating being made of copper, zinc, tin, nickel, a combination thereof and its alloy.
In another aspect, multiple microballoons include the first metal layer with nickel and the second metal layer with copper.
In another further aspect, in standard temperature and pressure conditions, thermal conductivity (K) is less than or equal to about 100mW/mK.
In another aspect, insulating coating has less than or equal to about 100kJ/m3Thermal capacity (the c of Kv)。
In another aspect, this method further comprises sintering insulated layer after spraying.
In another modification, present disclose provides a kind of method for forming insulating coating, this method is included from high speed oxygen
Fuel (HVOF) device is basad to spray the stream for including multiple hollow microspheres, and hollow microstructured layers are deposited to be formed.In injection period
Between, stream is with the maximum temperature greater than or equal to about 900 DEG C extremely less than or equal to about 1400 DEG C.It is each in multiple hollow microspheres
It is a including the first metal layer and second metal layer.The first metal layer has selected from the group being made of nickel, iron, a combination thereof and its alloy
In the first metal, and second metal layer has selected from the second gold medal for being made of copper, zinc, tin, nickel, a combination thereof and its alloy
Belong to.This method further comprises the hollow microstructured layers of sintered deposit, to be formed in substrate in standard temperature and pressure conditions
With the thermal conductivity (K) less than or equal to about 200mW/mK and less than or equal to about 100kJ/m3Thermal capacity (the c of Kv) it is exhausted
Edge coating.
According to description provided herein, further areas of applicability will become obvious.Description and spy in this general introduction
Determine the purpose that example is merely to illustrate, and be not intended to limit the scope of the present disclosure.
Description of the drawings
Attached drawing described herein is only used for the illustration purpose of selected embodiment rather than all possible embodiment, and
It is not intended to limit the scope of the present disclosure.
Fig. 1 shows Velocity Oxygen Fuel (HVOF) hot spray apparatus, can be sunk according to some aspects of the disclosure
Hollow microsphere is accumulated to form insulating coating.
Fig. 2 shows the examples of the hollow microsphere with single metal coating.
Fig. 3 shows two different metal coats having for hot-spraying technique of some aspects according to the disclosure
Hollow microsphere another example.
Fig. 4 shows the hollow micro-structure included via thermal spray deposition in substrate of some aspects according to the disclosure
Insulating coating.
Fig. 5 shows composite thermal barrier coating, includes including some aspects according to the disclosure via thermal spray deposition
The insulating coating of hollow micro-structure in substrate.
Through multiple views of attached drawing, corresponding reference marker indicates corresponding part.
Specific embodiment
Example embodiment is provided, so that the disclosure is detailed thoroughly, and range can be fully conveyed to art technology
Personnel.Many specific details, such as the example of specific combination, component, device and method are elaborated, to provide the reality to the disclosure
Apply the thorough understanding of example.It will be apparent to those skilled in the art that it does not need to using specific detail, example embodiment
It can embody in many different forms, and shall not be interpreted to limit the scope of the present disclosure.Implement in some examples
In example, it is not described in known technique, known apparatus structure and known technology.
Terms used herein are only used for describing specific example embodiment rather than the limitation present invention.Such as this paper institutes
It uses, unless the context clearly indicates otherwise, otherwise singulative " one ", "one" and "the" can also be intended to include plural shape
Formula.Term " containing ", "comprising", " comprising " and " having " are inclusives, therefore specify the feature, element, composition, step
Suddenly, the presence of entirety, operation and/or component, but it is not excluded for one or more of the other feature, entirety, step, operation, element, portion
The presence or addition of part and/or its group.Although open-ended term "comprising" is interpreted as that this paper institutes are described and claimed as
The nonrestrictive term of the various embodiments illustrated, but in certain aspects, which alternatively understands to replace more limiting
System and restricted term, such as " consist of " or " substantially by ... form ".Therefore, for reference composition, material, portion
Part, element, feature, entirety, any given embodiment of operation and/or processing step, the disclosure also specifically include by this
The composition of reference, material, component, element, feature, entirety, operation and/or processing step composition or consisting essentially of
Embodiment.In the case of " consist of ", alternate embodiment eliminates any additional composition, material, component, element, spy
Sign, entirety, operation and/or processing step, and in the case of " substantially by ... form ", it substantially influences basic and novel
Any additional composition, material, component, element, feature, entirety, operation and/or the processing step of feature are excluded in this implementation
Except example, but the substantial any composition for not influencing basic and novel features, material, component, element, feature, entirety, operation
It can be included in the present embodiment with/processing step.
Any method and step described herein, process and operation be not necessarily to be construed as necessarily requiring they with discussion or show
The concrete order gone out performs, and is unless specified execution order.It will also be appreciated that it unless otherwise stated, can be used
Adjunctively or alternatively the step of.
When component, element or layer are referred to as " on another element or layer ", " being bonded to ", " being connected to " or " being coupled to " separately
When one element or layer, it can on directly other components, element or layer, be bonded to, be connected to or coupled to other components, element
Or layer or intermediary element or layer may be present.On the contrary, when element is referred to as " directly on another element or layer ", " directly engagement
To ", " being connected directly to " or " coupling directly to " another element or during layer, intermediary element or layer may be not present.It should be with class
As mode explain for describe the relationship between element other words (for example, " ... between " with " directly exist ... it
Between ", " adjacent " and " direct neighbor " etc..).As it is used herein, term "and/or" includes one or more associated institutes
Any and all combination of list of items.
Although term first, second, third, etc. originally can be used describe each step, element, component, region, layer and/or
Part, but these steps, element, component, region, layer and/or part should not be limited by these terms, unless otherwise
Explanation.These terms can be only used for distinguish a step, element, component, region, layer or part with another step, element,
Component, region, layer or part.Unless explicitly point out within a context, otherwise such as " first ", " second " and other numerical terms
Term as used herein not imply order or sequence.Therefore, in the case where not departing from the introduction of example embodiment,
First step discussed below, element, component, region, layer or part can be referred to as second step, element, component, region,
Layer or part.
For ease of description, such as " before ", " later ", " interior ", " outer ", " under ", " following ", " being less than ", " on ",
The space of " being higher than " etc. or time correlation term can be used herein, with describe an elements or features as depicted with it is another
The relationship of one elements or features.Other than the orientation described in attached drawing, spatially or time upper opposite term can be intended to
Cover use or device or the different direction of system in operation.
In the entire disclosure, numerical value represents the approximate measure or limitation to range, small inclined with set-point to cover
Difference and embodiment with about mentioned value and the embodiment with value mentioned by being exactly equal to.In addition to being described in detail
The working example that provides of end other than, before no matter whether " about " actually appear in numerical value, this specification is (including appended right
Claim) in all numerical value of parameter (for example, quantity or condition) be interpreted as all being repaiied by term " about " in all cases
Change." about " indicate that the numerical value allows some slight inaccurate (numerically close to exact value；Approximately or reasonably close to number
Value；It is approximate).If what is " about " provided is inaccurate in the art not with the understanding of this ordinary meaning, then used herein
" about " at least instruction may the modification as caused by measuring and use the commonsense method of these parameters.For example, " about " it may include small
In or equal to 5%, optionally less than or equal to 4%, optionally less than or equal to 3%, optionally less than or equal to 2%, optionally
Ground is less than or equal to 1%, optionally less than or equal to 0.5% and in certain aspects optionally less than or equal to 0.1%
Modification.
In addition, the disclosure of range includes all values in open four corner and the range further divided, including for model
Enclose given endpoint and subrange.
Example embodiment is described more fully with reference to the drawings.
In in all fields, the present disclosure describes the methods that insulating coating is formed in substrate.In certain aspects, the party
Method may include towards substrate thermal spraying injection stream.Thermal spraying refers to using a kind of technique, and wherein precursor material is heated and conduct
Individual particle promotes on the surface of the substrate, to form firm and bonding coating.Therefore, thermal spraying comes dependent on heat and momentum
Meet coating material and be bound to coating surface.
In certain aspects, hot-spraying technique has greater than or equal to about 900 DEG C, optionally greater than or equal to about 1000
DEG C, optionally greater than or equal to about the 1100 DEG C and in certain aspects highest temperature optionally greater than or equal to about 1200 DEG C
Degree.In certain aspects, hot-spraying technique has greater than or equal to about 900 DEG C to less than or equal to about 1400 DEG C and certain
Optionally greater than or equal to about 1100 DEG C to the temperature less than or equal to about 1200 DEG C in modification.As those skilled in the art will recognize
Know, as will be further described below, some coolings, therefore phase occur when sprayed on material leaves hot spray apparatus or spray gun
With hoping, the temperature in hot spray apparatus is sufficiently high to promote the softening or fusing of at least one of hollow precursor material, simultaneously
Avoid the overheat that can lead to structural collapse.
For all hot-spraying techniques, material is heated, is accelerated and is ejected into target surface.In different hot-spraying techniques
Middle particle speed is different, for example, the speed of injection stream is highest in Velocity Oxygen Fuel technique, and is fired in such as subsonic speed oxygen
Expect that the low speed spraying process medium velocity of powder technology is relatively low.Injection stream refers to that stream has relatively high speed and generates jet stream,
And still desirably avoid used during thermal spraying it is selected under the conditions of will promote (for example, selected temperature and pressure) it is hollow
The speed that precursor collapses.For example, according to the maximum speed of injection stream that some aspects of the disclosure use less than or equal to about
400m/s, about optionally less than or equal to 100m/s, and it is optionally less than or equal to about 10m/s in certain aspects.At certain
In a little modifications, injection stream can have greater than about 343m/s but the hypersonic velocity less than or equal to about 400m/s.
Using Velocity Oxygen Fuel spraying process, by mixing in a combustion chamber and lighting oxygen and fuel (gas or liquid)
And high pressure gas is made to accelerate to generate gas stream by nozzle.Particle is introduced into the stream, particle is by heating and court in stream
Accelerate to target surface.In a modification of some aspects according to the disclosure, the method for forming insulating coating is shown in Fig. 1
Go out, including from high-velocity oxy-fuel (HVOF) device 100 towards the injection of substrate 110 comprising multiple hollow minute particles or microballoon 102
Stream.Hollow minute particle limits the dead air space region that can be filled with insulating materials in the core.Therefore, as example, in core
Void area can be filled the gas of such as air or inert gas or can have vacuum condition.In certain aspects, particle
It is less than about 100 μm, optionally less than or equal to about 50 μm and in certain aspects less than or equal to about 10 μ at least one
The bulk of m.
Particle can be with substantially circular microballoon.As long as at least part at the center of particle defines dead air space area
Domain, " substantially circular " including have including spherical, spherical, oblate spheroid, disc, cylinder, dish type, cheese, egg type,
The particle of the shapes such as oval, spherical, avette.Therefore, the microballoon being mentioned herein can be covered any of these substantially circular
Shape.It is worth noting that, although precursor can be microballoon, after hot-spraying technique, microballoon may from spherical or
Substantially round deformation.
In certain aspects, the microballoon as precursor can have less than about 100 microns (μm), optionally during thermal spraying
Greater than or equal to about 10 μm extremely less than or equal to about 80 μm, optionally greater than or equal to about 20 μm to less than or equal to about 60 μm simultaneously
And in some variations optionally greater than or equal to about 30 μm to the average grain diameter less than or equal to about 40 μm.It should be understood that micro-
Ball has an average diameter in the range of these, but multiple microballoons are not necessarily all with identical diameter, because can be used
The mixture of microballoon with different-diameter can change to form insulation painting to provide desired porosity or packed density
Intensity in layer.It should be further noted that the diameter of the microballoon used is smaller, grain density is bigger, therefore by this
Particle shape into coating quality it is bigger.Therefore, compared with compared with minimicrosphere, relatively large microballoon is formed compared with light coating layer.
Multiple microballoons include at least one metal.In some variations, metal may be selected from by nickel, iron, a combination thereof and its conjunction
The group of gold composition.In a variant, metal is nickel or nickel alloy.In another modification, metal is iron, and microballoon may include
The ferroalloy of such as steel or stainless steel.As non-limiting examples, any alloy can contain understood by one of ordinary skill in the art
Additional elements, such as carbon, manganese, chromium and nickel, molybdenum etc..
In general, all hollow microspheres as shown in Figure 2 20 may include limiting the structural material 22 in dead air space region 24.Knot
The group of 22 optional free metal of structure material, glass, ceramics, polymer and combinations thereof composition, as long as the restriction of structural material 24 has
The hollow structure in dead air space region 24.Then the metals such as nickel, iron, nickel alloy compound, ferroalloy compound can be used
One or more conductive materials coat hollow microsphere 20.Therefore metal coating 26 is formed on structural material 22.In microballoon 20
Surface on applied metal can be carried out via the technique of plating, vapor deposition, electroless plating, flame-spraying, smearing etc..It is micro-
Ball 20 can be used for thermal spraying, but be used to form the precursor of multilayer hollow microballoon as shown in Figure 3 in certain aspects.
In figure 3, the hollow microsphere 30 that precursor is used as in the hot-spraying technique according to some aspects of the disclosure can have
There is multiple and different metal layers.In a variant, hollow microsphere 30 has limits void area 34 in central core area
Structural material 32.Structural material 32 can be formed by the material identical with more than structural material 22.Include the first of the first metal
Metal material can be applied to the surface of structural material 32 to form the first metal layer or coating 36.Second metal material may include can
It is applied on the first metal coating 36 to form the second different metal of second metal layer or coating 38.
First metal coating 36 may include nickel, iron, a combination thereof and its alloy.In certain aspects, the first metal coating 36
Include nickel or nickel alloy.Second metal coating 38 may include copper, zinc, tin, nickel, a combination thereof and its alloy.It is worth noting that, to the greatest extent
Pipe the first metal coating 36 and the second metal coating 38 are containing one or more identical metals, but each layer/coating has
It is made of and therefore with different fusing points different.In certain aspects, the second metal coating 38 includes copper or copper alloy.
Other aspects, the second metal coating 38 may include the combination of copper and zinc, such as brass alloys.In certain aspects, brass alloys
Zinc exist (to avoid undesirable phase is formed) with the amount less than or equal to about 32 weight %, and surplus may include copper and miscellaneous
Matter.In this way, the first metal coating 36 and the second different metal coating 38 have different melting temperatures, this is for following
The certain hot-spraying techniques further described can be advantageous.More specifically, the first metal layer or coating 36 can have than the
38 higher fusing point of two metal layers or coating.Therefore, in some variations, the second metal coating 38 may include copper and mickel, wherein
Nickel is present in being up to about 30 weight % in composition, and surplus is copper and impurity.In other aspects, the second metal coating 38 can wrap
Nickeliferous and tin, wherein tin are present in being up to about 30 weight % in composition, and surplus is nickel and impurity.This nickel-tin alloy tool
There is about 1130 DEG C of low melting point/eutectic point.In certain other aspects, the second metal coating 38 may include nickel and zinc, wherein zinc
It is present in composition with being up to about 40 weight %, surplus is nickel and impurity.
In certain aspects, the first metal coating 36 can have about 1 micron of thickness, and the second metal coating 38 can have
Thickness less than or equal to about 1 micron.Therefore, the thickness of second metal layer or coating 38 is less than the first metal layer or coating 36
Thickness.In the case where the first metal coating 36 includes nickel and the second metal coating 38 includes copper, copper can be spread in nickel.From
The copper that second metal coating 38 is diffused into the first metal coating 36 is more, and the maximum temperature that can be used in thermal spraying is got over
It is low, at the same still keep hollow structure (such as so that the complete hollow shape of 36 holding structure of the first metal coating is particularly worked as
When structural material 32 is removed from hollow microsphere 30).If however, carry out subsequent heat treatment (such as being sintered),
After hot-spraying technique, most of diffusion in copper to nickel occurs.Final alloy composition (Ni-Cu alloys) can be potentially
The maximum temperature (for example, as barrier material in engine) used in limitation final application.
Referring again to Fig. 1, HVOF techniques are generated heat and are assigned speed to injection stream using burning.HVOF devices 100
Two oxidants including being used for two fuel inlets 120 of The fuel stream and for introducing oxygen-containing stream (or other containing oxidant stream)
Entrance 122.It should be noted that fuel inlet 120 and oxidant inlet 122 are not limited to entrance shown in Fig. 3 or the number of arrangement
Amount.As non-limiting examples, fuel may include propane, propylene and/or hydrogen.Further, although it is not shown, can also carry
For the cooling entrance and channel for recycling cooling agent.Central inlet 130 receives carrier gas stream and the multiple hollow microspheres wherein injected
102.As non-limiting examples, carrier gas can be inert gas, for example, nitrogen and/or argon gas or carrier gas can have with it is oxygen-containing
Agent stream or the identical composition of The fuel stream.In unshowned certain alternate designs, central inlet 130 can be removed or repair
Change so that hollow microsphere is introduced directly into The fuel stream or oxidant stream.
In HVOF devices 100, oxygen-containing stream and fuel combine in Mixed Zone 132.Mixed flow introducing is wherein occurred
In the combustion chamber 134 of exothermic combustion reaction.Carrier gas and hollow microsphere 102 enter through combustion chamber 134, in wherein carrier gas in
Empty microballoon 102 is heated, subsequently into nozzle 136.High temperature and high speed injection stream 140 leaves nozzle 136.In some variations, it sprays
Jet stream 140 can be supersonic spray coating flame.The operating parameter of HVOF devices 100 is selected according to some aspects of the disclosure, with
Promote softening, adherency and combination of the microballoon in substrate, while minimize collapsing or rupturing for internal voids region.
For example, in certain aspects, the maximum temperature of injection stream 140 (and in HVOF devices 100) is selected as comparing
The fusing point for forming the selected metal of hollow microsphere 102 is at least about 50 DEG C low, for example, the first metal in the first metal layer/coating.
Therefore, in certain aspects, in the case where metal is nickel, maximum temperature is at least 50 DEG C lower than 1455 DEG C of the fusion temperature of nickel,
So that the maximum temperature of HVOF techniques and injection stream is less than about 1405 DEG C (or about 1400 DEG C).In some variations, in entire work
In skill, stream (and microballoon) injection period encounter greater than or equal to about 900 DEG C to less than or equal to about 1400 DEG C, be optionally more than
Or equal to about 1000 DEG C to less than or equal to about 1300 DEG C and in certain aspects optionally greater than or equal to about 1100 DEG C extremely
Maximum temperature less than or equal to about 1200 DEG C.The operation temperature used in HVOF and pressure can be adjusted with allow by such as this
Without melting at least one layer of microballoon on a little various depositing thems to surface comprising nickel or iron microballoon (such as steel or stainless steel).It is logical
Crossing can be with fast deposition on the surface using HVOF and other similar plasma spray technologies, hollow microsphere.Spray equipment and microballoon
In temperature can match so that microballoon does not collapse, but forms initial combination in the surface collision with target substrate.
In some variations, it is present in first layer and the second layer of second metal as hollow microsphere in the first metal
A part in the case of, maximum temperature in HVOF techniques can the first metal fusing point it is at least 50 DEG C low, but may be close to
Or more than the bimetallic fusing point on external coating.Therefore, the second metal and/or the second layer soften and melt partially or completely
Change, so as to the enhancing adherency when hollow microsphere is deposited in substrate 110 and combine.Therefore, in some variations, the first metal can
It is about 1455 DEG C of nickel for fusing point, the second metal can be the copper that fusing point is about 1084 DEG C, so that the maximum temperature of injection stream can
Fusing point less than nickel but the fusing point higher than copper.In this modification, maximum temperature is greater than or equal to about 1110 DEG C to being less than
Or equal to about 1400 DEG C.For example, when microballoon hits the mark, the temperature of injection stream can be greater than about the fusing point of 1084 DEG C of copper, but
Maximum temperature during being thermal spraying does not reach 1455 DEG C (fusing points of nickel).It is worth noting that, hollow minute particle is leaving spray
It is cooled down during rifle, therefore the higher maximum temperature in spray gun/hot spray apparatus can be higher than 1100 DEG C, and when hollow micro-
Grain is cooled down close to during simultaneously contact target.In the case where the second layer includes copper and zinc, melting temperature is relatively low.For example, include copper
The brass alloys of about 32 weight % zinc have about 903 DEG C of fusing point, therefore the thermal spraying temperature more than can be adjusted accordingly.When
When microballoon hits target, the temperature of injection stream may be close to or about 903 DEG C of the fusing point higher than brass alloys, but thermal spray process
The maximum temperature of middle injection stream is still below 1455 DEG C (fusing points of nickel).
Injection stream is directed toward the surface of substrate 110, and plurality of hollow micro-structure 142 is deposited on the high hole of bonding
In rate insulating coating 144.Substrate can be formed by a variety of materials that can bear high temperature, including metal, ceramics etc..In some aspects
In, substrate is included selected from least one of nickel, iron, copper, zinc, tin, aluminium, magnesium, a combination thereof and its alloy metal.As unrestricted
Property example, the substrate in certain modifications may include that steel, such as superalloy of inconel nickel superalloy, aluminium alloy and magnesium close
Gold.
Substrate 110 may include coating or by the material of the adherency of hollow micro-structure promoted to be formed.Surface may include selected from copper,
Zinc, tin, nickel, aluminium, a combination thereof and its alloy at least one metal.The surface can have coating for metal surfaces or by including copper
And/or the metal of zinc and/or its alloy is formed.Coating comprising copper and/or zinc can be via plating, electroless plating, vapor deposition, fire
Flame spraying, smearing etc. are applied in any heat resistant substrates.In a variant, substrate 110 can be formed by copper-bearing materials or can be wrapped
Containing containing copper coating.As non-limiting examples, in the case where substrate 110 is coated, substrate may include any kind of heat-resisting
Material, the superalloy including steel, such as inconel nickel superalloy.
Gained hot-spraying coating includes adjacent and/or overlapping hollow micro-structure.After thermal jet is coated onto in substrate 110,
Desirably most of hollow micro-structure 142 still has complete dead air space region, is greater than about 80%, is optionally more than
About 90%, the hollow micro-structure for be optionally greater than about 95%, being optionally greater than about 97% has complete gap, and in some sides
In face, the gap for being optionally greater than about 98% in hollow micro-structure after deposition keeps complete.In some variations, it deposits
Hollow micro-structure 142 can have the microballoon shape identical with the precursor being introduced into HVOF devices 100, but they may also
Deform or be twisted into other shapes.
Therefore, after thermal spraying, some distortions may occur for the shape of deposited particles, but it is desirable to inside ground holding
Dead air space region, so as to enhance and keep the insulating properties of depositing coating.As such, as shown in figure 4, via thermal spraying in substrate
The insulating coating 200 formed on 210 includes the hollow micro-structure (being formed by the deposition of microballoon) with complete void area.
Insulating coating with this hollow micro-structure desirably show in standard temperature and pressure conditions less than or equal to about
1000mW/mK, optionally less than or equal to about 500mW/mK, optionally less than or equal to about 250mW/mK, optionally
Less than or equal to about 200mW/mK, optionally less than or equal to about 100mW/mK, optionally less than or equal to about 50mW/
MK and the thermal conductivity (K) for being optionally less than or equal to about 20mW/mK in some variations.Standard temperature and pressure (STP) condition
It is the absolute pressure of about 32 °F or 0 DEG C and about 1atm or 100KPa.
Further, the insulating coating with this hollow micro-structure is desirably shown less than or equal to about 5000kJ/
m3K, it is optionally less than or equal to about 1000kJ/m3K, it is optionally less than or equal to about 500kJ/m3K, optionally less than
Or equal to about 100kJ/m3K, it and is optionally less than or equal to about 50kJ/m in some variations3Thermal capacity (the c of KvBody
Volumetric heat capacity).In a variant, insulating coating shows the thermal conductivity (K) less than or equal to about 100mW/mK and is less than
Or equal to about 100kJ/m3Thermal capacity (the c of Kv)。
There can be the hollow micro-structure 212 of intensive filling via the insulating coating 200 of thermal spraying (such as HVOF) deposition.
In some terms, the insulating coating 200 comprising multiple hollow micro-structures 212 via thermal spraying (such as HVOF is deposited) deposition has
High open porosity, such as the net porosity with the about 80 volume % more than or equal to coating total volume.Net porosity refers to
Overall porosity volume includes the volume of void space and the volume of the hole limited between nanostructured in nanostructured.
In certain modifications, this net porosity is greater than or equal to about 85 volume %, optionally greater than or equal to about 90 volume %, and
Optionally greater than or equal to about 95 volume % in certain modifications.
In some variations, the average thickness of insulating coating 200 may be less than or equal to about 4000 microns (4mm), optionally
Less than or equal to about 2000 microns of ground (2mm), optionally less than or equal to about 1000 microns (1mm), it is optionally less than or equal to
About 500 microns, optionally less than or equal to about 400 microns, optionally less than or equal to about 300 microns, optionally less than or wait
In about 200 microns, optionally less than or equal to about 100 microns, optionally less than or equal to about 75 microns and in certain modifications
In optionally less than or equal to about 50 microns.In certain aspects, the average thickness of insulating coating 200 be greater than or equal to about
100 microns to less than or equal to about 4000 microns, optionally greater than or equal to about 100 microns to less than or equal to about 500 microns,
Optionally greater than or equal to about 100 microns to less than or equal to about 300 microns.In a variant, insulating coating has and is less than
Or the thickness equal to about 200 microns (μm).It should be noted that the expectation thickness of coating, which may depend on, wherein uses insulating coating
Application so that relatively thick coating and/or the coating with larger quality are applicable to wherein slower thermal response and are acceptable
Using, and can be chosen compared with shallow layer or compared with light coating layer in the case where it is expected faster thermal response.
In certain aspects, insulating layer 200 can bear greater than or equal to about 8MPa, optionally greater than or equal to about
10MPa, optionally greater than or equal to about the 15MPa and in certain aspects pressure greater than or equal to about 20MPa, without losing
Effect.For high-temperature behavior, the insulating layer in certain modifications be configured to receive greater than or equal to about 200 DEG C, be optionally more than or
Equal to about 250 DEG C, optionally greater than or equal to about 300 DEG C, optionally greater than or equal to about 500 DEG C, be optionally greater than or equal to
About 700 DEG C, the surface temperature optionally greater than or equal to about 1000 DEG C and optionally greater than or equal to about 1300 DEG C, without losing
Effect.For example, thermal capacity can ensure that the surface for the substrate 210 for being provided with coating 200 does not rise to about 250 DEG C or more.
As understood by those skilled in the art, insulating layer 200 can actually have multiple micro-structures 212, multiple micro- knots
Structure 212 has different compositions, size or shape.This micro-structure can mix during thermal spraying or as not
Same layer (for example, different composition layers in insulating coating) is sequentially applied to over each other.
Referring again to Fig. 1, in certain aspects, thermal spraying optionally at ambient conditions or greater than or equal to about
It is carried out under the pressure of 0.5MPa.In this way, in the feelings around injection stream 140 and the region application positive pressure for closing on substrate 110
Under condition, with the increase of pressure, caused by the temperature change of hollow microsphere 102 and/or the hollow micro-structure 142 of deposition
Volume expansion and contraction can be suppressed and be minimized.
In certain alternative aspects, after thermal spraying, deposited particles can be cooled to environmental condition, then further added
Work.For example, the hollow micro-structure 212 in insulating coating 200 can be further heat-treated with promote additional combination and sintering with
Enhance the robustness of coating.It may include the sedimentary by the microballoon in substrate (first for the exemplary heating process of sintering
With the first metal and in the second layer with the second metal in layer) it is heated to the temperature for being less than bimetallic solidus temperature
Degree.For example, second metal layer may include Cu or Cu-Zn alloys.Therefore, pure Cu can be heated to being less than 1084 DEG C of (copper solid phases
Line temperature), while can will be heated to the Cu-Zn alloys less than 32 weight %Zn below about 900 DEG C.In an example
In, sintering can carry out in the inert atmosphere of such as argon gas at a temperature of about 800 DEG C.It can be into for the heat treatment of sintering
Row greater than or equal to about 1 hour, optionally greater than or equal to about 2 hours, optionally greater than or equal to about 4 hours, it is optionally big
In or equal to about 6 hours and in some variations greater than or equal to about 8 hours.In another modification, temperature can slowly rise
Up to it is higher than the fusion temperature of the second metal (such as Cu), condition is to diffuse into the second gold medal in the first metal layer (for example, Ni)
Belong to all diffusions, there is fusing temperature more higher than individual second metal including the first metal and bimetallic alloy
Degree.
Further, after deposition, can deposit additional layer on insulating coating 200, for example, ceramics, nickel, vanadium, molybdenum or its
Its high-temperature metal.
In some variations, substrate can not usually be added by that can have the substrate (such as aluminium) compared with low heat resistant to be formed
Heat is extremely higher than 800 DEG C of temperature.In this applications, face coat may be provided on the surface of aluminium, and deposited particles can be set
It puts on face coat.Deposited particles can heat, while aluminium substrate is kept to cool down in itself from outside.Alternatively, it can be used intermediate
Substrate, such as the graphite wafer with electronickelling.Hollow minute particle is deposited on nickel chip, is then sintered.These materials can add
It is added in mold, and aluminium or other low-temperature alloys can be cast around it.Another modification is to use intermediate base bottom, such as on
The nickel chip stated.Hollow minute particle is deposited on nickel chip, is then sintered.Low temperature substrates can have face coat as combination
Layer, for example, aluminium substrate can have for the copper of binder course and/or zinc surface coating.It then can be by the hollow minute particle with sintering
Chip be sintered on piston.The double sintering temperature is well below the initial sintering temperature of hollow minute particle (such as including nickel).
Therefore, substrate is optionally including nickeliferous or iron content sealant, and the sealant can also have fine copper coating or copper
Nickel coating is to promote to combine.
In a variant, insulating coating can be integrated into thermal boundary composite component 250 as shown in Figure 1.Thermal barrier coating 260
It is arranged in substrate 262 to limit thermal boundary composite component 250.In one non-limiting embodiment, as non-limiting examples,
Substrate 262 may include any kind of heat proof material, including steel, such as superalloy of inconel nickel superalloy, aluminium alloy
And magnesium alloy.
Thermal barrier coating 260 includes multiple layers (and can have 3 layers more than layer shown in fig. 5).Optional first layer 264 is (such as
If fruit use) it is provided in the binder course on the surface of substrate 262.The second layer 270 is comprising certain sides according to the disclosure
The insulating layer for multiple hollow micro-structures that face is formed.First layer 264 promotes the combination of substrate 262 and the second layer 270.It is arranged on
Third layer 272 on two layer 270 is used as the sealant being arranged on the second layer 270.Third layer can be to be configured to resist high temperature
Film, and it is impermeable and show the sealant of smooth surface as gas.
Optional first layer 264 as binder course can be formed by the metal comprising copper or zinc, which can be via aforementioned
Any technological diffusion is simultaneously combined with the surface of substrate 262 and the second layer being deposited thereon 270.In a variant, first layer
264 may include brass, be copper zinc (Cu-Zn) alloy material.It is the feelings that aluminium and microballoon include nickel and/or iron in substrate 262
Under condition, in a variant, copper and zinc can be selected to be included in first layer 264.Copper and zinc are respectively provided in aluminium, nickel and iron
Good solid solubility, and iron and nickel have extremely low solid solubility in aluminium.First layer comprising ormolu can be used for aluminium base
Bottom, such as containing aluminum piston.The substrate (such as valve) formed by steel or inconel (Inconel) can have be used to combining with
Enhance the optional first layer 264 of the combination of the second layer 270, although this binder course may not be required for these substrates
's.Therefore, the first layer 264 for having copper and/or zinc provides intermediate structure layer between substrate 262 and the second layer 270, to promote
Diffusion bond between aluminium substrate and nickel or iron micro-structure.It should be appreciated, however, that substrate 262, first layer 264 and the second layer
270 are not limited to aluminium, nickel, iron and brass, but may include other materials.
Third layer 272 is used as the sealant being arranged on insulating second layer 270.It can be high temperature film to seal third layer 272,
It can be configured to bear at least 1100 DEG C of temperature.Third layer 272 can have less than or equal to about 20 microns, optionally less than or
Thickness equal to about 5 microns, optionally less than or equal to about 1 micron.Third layer 272 is for the gas of such as burning gases
Impermeable.In this way, third layer 272 is used as the sealing on the second layer 270.This sealing prevents such as unburned
The clast of the burning gases of hydrocarbon, cigarette ash, the fuel of partial reaction, liquid fuel etc. enters in the second layer 270
In the opening and hole that are limited between hollow micro-structure.Minimizing this clast prevents intrapore gas from may be caused to insulate
Property reduce or eliminate clast movement.Third layer 272 can have smooth outer surface, and turbulent flow is generated when can prevent air from flowing
Air stream.Further, the third layer 272 with smooth surface can prevent the increase of heat transfer coefficient.In a nonrestrictive reality
In example, third layer can be applied to the second layer 270 (in thermal spraying and cooling via plating, vapor deposition or other application technology
Afterwards).In a variant, third layer 272 includes heat-resisting or resistant material.In a variant, third layer 272 may include molybdenum
Or vanadium.Third layer 272 is configured to have enough elasticity, to be resisted during burning gases, heat fatigue or clast is exposed to
Fracture or cracking.Further, third layer 272 is configured to have enough elasticity, to bear following insulating second layer 270
Any expansion and/or contraction.Third layer 272 may include multiple layers.
Thermal boundary composite component 250 can be used in various applications, such as the thermal boundary on the component in internal combustion engine.As non-limit
Property example processed, thermal boundary composite component 250 may be provided on the face or surface of one or more components of engine, such as in work
On plug, intake valve, air bleeding valve, the inner wall of exhaust manifold and burning dome.Thermal boundary composite component 250 ideally has lower thermal conductivity
Loss and low heat capacity are transmitted to reduce heat so that the surface temperature of thermal boundary composite component 250 follows the gas temperature in combustion chamber
Degree.Therefore, thermal boundary composite component 250 allows the surface temperature of component to be swung with gas temperature.Which reduce heat to transmit damage
It loses, the ventilation ability without influencing engine will not cause pinking.Further, into the cold air of cylinder
Heating is reduced.In addition, delivery temperature increases, lead to faster catalyst light off time and improved catalyst activity.
While characterized as method and material especially suitable for manufacture automobile or other vehicles component, but they
Available for various other industries and application, as non-limiting examples, including aerospace parts, the consumer goods, office equipment and furniture,
Building, industrial equipment and machinery, farm equipment or heavy-duty machinery.The component prepared according to some aspects of the disclosure can be forgiven
Vehicle non-limiting examples include automobile, train, heavy mobile service, tractor, bus, motorcycle, ship, shifting
Dynamic house, house trailer, aircraft (someone and nobody) and tank.
Method described herein and insulating coating provide low conductivity, low heat capacity thermal barrier coating.This thermal boundary applies
Layer can improve fuel consumption and the discharge of internal combustion engine, increase operation temperature, while reduce post processing preheating time, and improve
Waste Heat Recovery.Deposition method provides the ability on the profile and various surfaces of complex parts by depositing them, and otherwise this is
It is impossible.Compared with the insulating coating that the microballoon or the microballoon of sintering that are provided in by cured bonding agent matrix are formed, pass through
The insulating coating that this heat spraying method is formed only shows relatively low shrinkage.Further, with applying the other of microballoon
Method is compared, and the insulating coating formed by heat spraying method is considered to have increased and lower substrate adhesion level.
The purpose for example and description provides the foregoing description to embodiment.Its purpose be not limit or
Limit the disclosure.Each elements or features of specific embodiment are typically not limited to the specific embodiment, but in applicable situation
Under be interchangeable and can be used in selected embodiment, even if being specifically not shown or describing.Same situation also may be used
It is varied in many ways.This modification is not to be regarded as a departure from the disclosure, and all this modifications are intended to be included in this public affairs
In the range of opening.
Claims (10)
1. a kind of method for forming insulating coating, comprising：
The stream of multiple hollow microspheres is included from high-velocity oxy-fuel (HVOF) device towards substrate injection, wherein, it is the multiple hollow
Comprising the first metal layer and second metal layer, the first metal layer includes to be selected from by nickel, iron, its group each in microballoon
Close and its alloy composition group in the first metal, the second metal layer include be selected from by copper, zinc, tin, nickel, a combination thereof and its
The second metal in the group of alloy composition, wherein, it is described to flow the maximum temperature in the injection period at least below described first
About 50 DEG C of the fusing point of metal, but more than or equal to the fusing point of the second layer；And
It is formed with less than on the substrate in standard temperature and pressure conditions or the thermal conductivity equal to about 200mW/mK
(K) the insulating coating.
2. the method for claim 1, wherein after the thermal spraying, the insulating coating, which includes, has complete sky
Multiple hollow micro-structures in gap region.
3. the method for claim 1, wherein the insulating coating has the clear opening gap greater than or equal to about 80 volume %
Rate, and the insulating coating has the thickness less than or equal to about 200 microns (μm).
4. the method for claim 1, wherein the maximum temperature is to being less than or equal to greater than or equal to about 900 DEG C
About 1400 DEG C.
5. the method for claim 1, wherein the substrate include be selected from by iron, copper, zinc, tin, nickel, aluminium, a combination thereof and
At least one of the group of its alloy composition metal.
6. the method for claim 1, wherein the first metal layer includes nickel and the second metal layer includes
Copper.
7. the method for claim 1, wherein the thermal conductivity (K) is less than or equal to about 100mW/mK.
8. the method for claim 1, wherein the insulating coating has less than or equal to about 100kJ/m3The thermal capacitance of K
Measure (cv)。
9. the method as described in claim 1 is further contained in the injection and is sintered the insulating coating later.
10. a kind of method for forming insulating coating, comprising：
From basad stream of the injection comprising multiple hollow microspheres of high-velocity oxy-fuel (HVOF) device hollow micro-structure is deposited to be formed
Layer, the hollow microsphere include nickel, wherein, the stream have greater than or equal to about 900 DEG C to being less than in the injection period or
Maximum temperature equal to about 1400 DEG C, wherein, each in the multiple hollow microsphere includes the first metal layer and second
Metal layer, the first metal layer includes the first metal in the group being made of nickel, iron, a combination thereof and its alloy, described
Second metal layer includes the second metal in the group being made of copper, zinc, tin, nickel, a combination thereof and its alloy；And
The hollow microstructured layers of deposition are sintered, to be formed with less than on the substrate in standard temperature and pressure conditions
Or thermal conductivity (K) equal to about 200mW/mK and less than or equal to about 100kJ/m3Thermal capacity (the c of Kv) the insulation apply
Layer.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US15/388,284 US20180179623A1 (en) | 2016-12-22 | 2016-12-22 | Thermal spray deposition of hollow microspheres |
| US15/388284 | 2016-12-22 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CN108220865A true CN108220865A (en) | 2018-06-29 |
Family
ID=62510433
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201711399206.6A Pending CN108220865A (en) | 2016-12-22 | 2017-12-21 | The thermal spray deposition of hollow microsphere |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US20180179623A1 (en) |
| CN (1) | CN108220865A (en) |
| DE (1) | DE102017130806A1 (en) |
Families Citing this family (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US10214825B2 (en) | 2016-12-29 | 2019-02-26 | GM Global Technology Operations LLC | Method of depositing one or more layers of microspheres to form a thermal barrier coating |
| US10851711B2 (en) | 2017-12-22 | 2020-12-01 | GM Global Technology Operations LLC | Thermal barrier coating with temperature-following layer |
| DE102020103164A1 (en) | 2020-02-07 | 2021-08-12 | Bayerische Motoren Werke Aktiengesellschaft | Partially coated coolant-cooled exhaust manifold for a multi-cylinder internal combustion engine |
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| CN102471860A (en) * | 2009-07-02 | 2012-05-23 | 斯奈克玛 | Heat-protective coating for a turbine engine part, and method for producing same |
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| WO2015042491A1 (en) * | 2013-09-20 | 2015-03-26 | Hrl Laboratories, Llc | Thermal barrier materials and coatings with low heat capacity and low thermal conductivity |
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|---|---|---|---|---|
| US3047938A (en) * | 1958-03-31 | 1962-08-07 | Gen Motors Corp | High temperature bond and method of forming same |
| FR2507729B1 (en) * | 1981-06-12 | 1986-08-22 | Snecma | SEAL LIKELY TO BE USED BY ABRASION AND ITS MANUFACTURING METHOD |
-
2016
- 2016-12-22 US US15/388,284 patent/US20180179623A1/en not_active Abandoned
-
2017
- 2017-12-20 DE DE102017130806.7A patent/DE102017130806A1/en not_active Withdrawn
- 2017-12-21 CN CN201711399206.6A patent/CN108220865A/en active Pending
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|---|---|---|---|---|
| US4303737A (en) * | 1979-08-21 | 1981-12-01 | Rolls-Royce Limited | Coating material |
| US6245390B1 (en) * | 1999-09-10 | 2001-06-12 | Viatcheslav Baranovski | High-velocity thermal spray apparatus and method of forming materials |
| US20040137259A1 (en) * | 2003-01-09 | 2004-07-15 | Pabla Surinder Singh | High temperature, oxidation-resistant abradable coatings containing microballoons and method for applying same |
| US20050196545A1 (en) * | 2004-03-03 | 2005-09-08 | Konica Minolta Holdings, Inc. | Method for producing a composite layer |
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| CN102471860A (en) * | 2009-07-02 | 2012-05-23 | 斯奈克玛 | Heat-protective coating for a turbine engine part, and method for producing same |
| WO2015042491A1 (en) * | 2013-09-20 | 2015-03-26 | Hrl Laboratories, Llc | Thermal barrier materials and coatings with low heat capacity and low thermal conductivity |
| CN104018139A (en) * | 2014-06-20 | 2014-09-03 | 哈尔滨工业大学 | Hollow microsphere/Ni-Fe-P/Cu composite coating and preparation method thereof |
Also Published As
| Publication number | Publication date |
|---|---|
| DE102017130806A1 (en) | 2018-06-28 |
| US20180179623A1 (en) | 2018-06-28 |
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