JP2004175662A - 高温で耐性を維持する断熱層を製造するための噴霧粉末 - Google Patents
高温で耐性を維持する断熱層を製造するための噴霧粉末 Download PDFInfo
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Abstract
【解決手段】溶射方法によって基体上に形成する。基体は単層又は多層の部分的コーティングで、特に下塗りを有していてもよい。一方、基体よりも低い熱伝導性を有し、他方、高温で化学的及び熱的に安定な相を形成する少なくとも一種の断熱機能性材料が使用される。噴霧粉末はそれぞれ、互いに接着されている複数の顆粒3からなり、ミクロ構造2を有する凝集体状粒子を含む。該顆粒は、一の機能性材料又は複数の機能性材料からなる。一つの添加剤4、又は複数の添加剤からなる少なくとも一種のさらなる成分も存在する。更なる成分は、機能性材料顆粒3の表面30上に、すなわち、主に境界帯に、微細分散され分布される。さらなる成分は、そのままの形態で、又は転換された形態で、機能性材料顆粒の間に高温において形成され得る焼結化合物に対し阻害又は排除効果を示す。
【選択図】図1
Description
本発明による噴霧粉末は、粒子1のみからなるか、又はこれらを含む。図1に示すように、粒子1はそれぞれ、凝集体のようなミクロ構造2を有する。図2は、粒子1全体の断面の略図であり、これは点線で示された二つの領域11及び12の間の境界帯を有する。この配置において、領域11は粒子1の表面である。ミクロ構造2は、粒子1の内部において、矢印で指し示す。粒子1は、互いに接着した複数の顆粒3からなる。顆粒3の表面30において、顆粒は隣り合う顆粒と接触しており、ミクロ細孔が終結の少ない境界帯5を形成する。格子欠陥、不純物イオン類及び/又はさらなるミクロ細孔(図示せず)は、顆粒3内の熱伝導性の低下に寄与し、これらもまた多結晶質である。
A1)添加剤4の少なくとも一種を、含浸方法によって機能性材料3の多孔性凝集体に導入する。
A2)凝集体は、機能性材料顆粒3及び微視に分散された添加剤4の混合物から製造され、ここで、凝集体は、好ましくは、スラリー(スラリーの形成)の噴霧乾燥及びそれに次ぐか焼によって製造される。添加剤4は、例えば、硝酸塩、塩化物又は酢酸塩であり、溶液中のスラリーに導入することができる。溶液の代わりに、懸濁液を使用することもでき、この場合、添加剤4はコロイド状に分散される。
Claims (10)
- 高温に耐性であり続ける断熱層、すなわちTBC型のコーティングであって、溶射法によって基体上に製造され、ここで、該基体はあらかじめ単層又は多層の部分コーティング、特に下塗り剤を有していてもよく、また、一方で基体よりも低い熱伝導性を有し、他方で高温で化学的及び熱的に安定な相を形成する少なくとも一種の断熱機能性材料が用いられる、上記断熱層の製造のための噴霧粉末であって、
当該噴霧粉末が互いに接着している複数の顆粒(3)により形成される凝集体のようなミクロ構造(2)をそれぞれ有する粒子(1)を含むこと;
これらの顆粒は一の機能性材料又は複数の機能性材料からなること;
一の添加剤又は複数の添加剤(4)からなるさらなる成分が少なくとも一種存在すること;
当該さらなる成分が機能性材料顆粒(3)の表面(30)上に、すなわち、主に顆粒の境界帯(5)に、微細に分散され分布していること;及び
当該さらなる成分が、そのままの形態で又は転換された形態で、機能性材料顆粒の間に高温で形成され得る焼結化合物に対し、抑制又は排除効果を示すこと、
を特徴とする、上記噴霧粉末。 - すべての成分(3,4)に対し、一又は複数の添加剤(4)から形成される成分が5モル%以下、好ましくは最大3モル%までの割合を有すること、
機能性材料顆粒(3)が1nmより大きく、10μmより小さい平均直径d50を有し、噴霧粉末の粒子(1)が1μmから100μmの範囲の平均直径d50を有すること、
を特徴とする、請求項1に記載の噴霧粉末。 - 一又は複数の添加剤(4)が粒子(1)の機能性材料顆粒(3)の間、金属塩を含む相中に堆積され、ここで金属塩は金属酸化物へ熱的に転換され、添加剤が熱処理工程による塩の転換後、焼結化合物に影響を与える有効な形態のみをとることを特徴とする、請求項1又は2に記載の噴霧粉末。
- 粒子(1)を形成する凝集体が、粒子の外表面(11)に対し開放されている、互いに通じている細孔空間を含み、一又は複数の添加剤(4)が当該細孔空間中、及び該表面上に堆積されることを特徴とする、請求項1又は2に記載の噴霧粉末。
- 機能性材料顆粒(3)が、以下の材料の一種又は複数種を含み:
−酸化ジルコニウム、特に、安定化酸化ジルコニウムYSZ;
−パイロクロア状構造A2B2O7[式中、A及びBはカチオン形態An+及びBm+で存在する元素であり、ここで、それらの電荷n+及びm+にあたる(n,m)の値の組は、(3,4)又は(2,5)である]、ここでパイロクロア構造のための一般的な式はA2-xB2+xO7-yであり、A及びBは、以下の化学元素が選択し得る:A=La,Ce,Pr,Nd,Sm,Eu,Gd,Tb,Dy,Ho,Er,Tm,Yb又はこれらの化学元素の混合、及びB=Zr,Hf,Ti、を有するセラミック材料、例えば、ジルコン酸ランタン;
マグネトプランバイト相MMeAl11O19、ここで、M=La,Nd及びMe=Mg,Zn,Co,Mn,Fe,Ni,Cr、である、
他方、一又は複数の添加剤(4)は、例えば、Al−,Mg−又はLa−酸化物、酸化イットリウムアルミニウム又はスピネル、特に酸化マグネシウムアルミニウムであることを特徴とする、請求項1から4のいずれか一項に記載の噴霧粉末。 - 各添加剤(4)又は焼結過程に影響を及ぼすその転換形態が機能性材料と混和性でなく、機能性材料中への拡散がほとんど回避されることを特徴とする、請求項1から5のいずれか一項に記載の噴霧粉末。
- A1)複数の添加剤(4)の少なくとも一種が、含浸方法により機能性材料顆粒(3)の多孔性凝集体中に導入されること、又は
A2)凝集体が、機能性材料顆粒及び微細に分散された添加剤又は添加剤の均質な若しくはコロイド状の溶液の混合物から製造され、ここで該凝集体はスラリーの噴霧乾燥及びそれに次ぐか焼によって製造されることを特徴とする、
請求項1から6のいずれか一項に記載の噴霧粉末の製造方法。 - 第一の工程において、添加剤が金属塩溶液の形態で多孔性凝集体に添加されるか、又は機能性材料顆粒(3)と混合され、ここで、これらの金属塩は熱的に金属酸化物へと転換できるものである、
第二の工程において、該混合物は乾燥され、
第三の工程において、該塩が熱処理によって焼結過程に有効に影響を及ぼすことができる形態へと転換される、
ことを特徴とする、請求項7に記載の方法。 - 最終工程において、凝集体状の粒子(1)がプラズマ炎中で短時間溶融されることを特徴とする、請求項7又は8に記載の方法。
- 請求項1から9のいずれかに記載の噴霧粉末から製造される、断熱層を有するコーティングされた基体。
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JP2010241609A (ja) * | 2007-05-07 | 2010-10-28 | Siemens Ag | 2つのパイロクロア相と酸化物とを有するセラミック粉末、セラミック層及び層組織 |
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