CA2482287A1 - An apparatus and process for solid-state deposition and consolidation of high velocity powder particles using thermal plastic deformation - Google Patents

An apparatus and process for solid-state deposition and consolidation of high velocity powder particles using thermal plastic deformation Download PDF

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Publication number
CA2482287A1
CA2482287A1 CA002482287A CA2482287A CA2482287A1 CA 2482287 A1 CA2482287 A1 CA 2482287A1 CA 002482287 A CA002482287 A CA 002482287A CA 2482287 A CA2482287 A CA 2482287A CA 2482287 A1 CA2482287 A1 CA 2482287A1
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CA
Canada
Prior art keywords
powder particles
gas
nozzle
powder
deposition device
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.)
Granted
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CA002482287A
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French (fr)
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CA2482287C (en
Inventor
Howard Gabel
Ralph Tapphorn
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Innovative Technology Inc
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Individual
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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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/14—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas designed for spraying particulate materials
    • B05B7/1404—Arrangements for supplying particulate material
    • B05B7/144—Arrangements for supplying particulate material the means for supplying particulate material comprising moving mechanical means
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B12/00—Arrangements for controlling delivery; Arrangements for controlling the spray area
    • B05B12/16—Arrangements for controlling delivery; Arrangements for controlling the spray area for controlling the spray area
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B05—SPRAYING OR ATOMISING IN GENERAL; APPLYING FLUENT MATERIALS TO SURFACES, IN GENERAL
    • B05B—SPRAYING APPARATUS; ATOMISING APPARATUS; NOZZLES
    • B05B7/00—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas
    • B05B7/16—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed
    • B05B7/22—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc
    • B05B7/222—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc
    • B05B7/226—Spraying apparatus for discharge of liquids or other fluent materials from two or more sources, e.g. of liquid and air, of powder and gas incorporating means for heating or cooling the material to be sprayed electrically, magnetically or electromagnetically, e.g. by arc using an arc the material being originally a particulate material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
    • B22F3/001—Starting from powder comprising reducible metal compounds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/02—Coating starting from inorganic powder by application of pressure only
    • C23C24/04—Impact or kinetic deposition of particles
    • H—ELECTRICITY
    • H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05H—PLASMA TECHNIQUE; PRODUCTION OF ACCELERATED ELECTRICALLY-CHARGED PARTICLES OR OF NEUTRONS; PRODUCTION OR ACCELERATION OF NEUTRAL MOLECULAR OR ATOMIC BEAMS
    • H05H1/00—Generating plasma; Handling plasma
    • H05H1/24—Generating plasma
    • H05H1/26—Plasma torches
    • H05H1/30—Plasma torches using applied electromagnetic fields, e.g. high frequency or microwave energy

Abstract

Apparatus and process for solid-state deposition and consolidation of powder particles entrained in a subsonic or sonic gas jet onto the surface of an object. Under high velocity impact and thermal plastic deformation, the powder particles adhesively bond to the substrate and cohesively bond together to form consolidated materials with metallurgical bonds.

Claims (43)

1. A particulate deposition device adapted for accelerating powder particles entrained in a gas to speeds sufficiently high to deposit and consolidate said powder particles on a surface of an object, comprising a friction-compensated nozzle comprising a nozzle body defining a gas channel, wherein said gas channel comprises:
a converging section configured to receive the powder particles and gas mixture;
a diverging tapered outlet section; and a throat section of constant cross-sectional area connecting said converging section;
wherein the powder particles and gas mixture is received in the converging section of the gas channel at a first velocity and the gas is accelerated as it passes through the converging section to a second velocity which is at or below the sonic velocity; and and wherein the divergence of said diverging tapered outlet section of said gas channel maintains the gas at a substantially constant velocity equal to said second velocity as it flows through the outlet section.
2. The particulate deposition device according to claim 1, further comprising a heating unit which heats the powder particles to a temperature below the melting point of the particles, but which is high enough to reduce the yield strength of the particles so as to permit plastic deformation during impact at low flow stress levels.
3. The particulate deposition device according to claim 2, wherein the nozzle is configured to accelerate the carrier gas to a sonic or subsonic speed, which in combination with substantially maintaining the carrier gas at a density level that maximizes the drag force on the powder particles entrained in the carrier gas and accelerates the particles to a speed sufficiently high to deposit and consolidate the particles to a substantially maximum extent possible upon impingement with the surface of the object.
4. The particulate deposition device according to claim 3, wherein the speed of the powder particles at the point of impact with the surface of the object is controlled such that in conjunction with the reduced yield strength induced by heating the particles, the structure, as well as the physical and chemical properties of the deposited material, are tailored.
5. The particulate deposition device according to claim 4, wherein the action of controlling the impact speed of the powder particles comprises selecting the inlet pressure of the carrier gas, gas type, and gas mixture.
6. The particulate deposition device according to claim 1, wherein the carrier gas is an inert gas which reduces oxidation and chemical combustion of the powder particles while entrained in the carrier gas.
7. The particulate deposition device according to claim 2, wherein the heating unit comprises a plasma generator which generates a thermal-transfer plasma between the nozzle and the surface of the object through which the powder particles entrained in the carrier gas traverse prior to being deposited on the surface of the object.
8. The particulate deposition device according to claim 7, wherein:
the nozzle comprises a sacrificial nozzle piece disposed adjacent an end of the nozzle facing the surface of the object; and the plasma generator comprises, a RF generator and an impedance matching network, wherein the RF generator is coupled through the impedance matching network and the impedance matching network is connected to the object and the nozzle so as to place the surface of the object at the RF cathode potential and the nozzle at the RF anode potential; and wherein, the sacrificial nozzle piece is made of a material that atomizes in the presence of the thermal-transfer plasma existing between the nozzle and the surface of the object, said atomized sacrificial nozzle piece material becoming incorporated into the powder particles and carrier gas effluent.
9. The particulate deposition device according to Claim 8, wherein the atomized sacrificial nozzle piece material reacts with the powder particles in the presence of the thermal-transfer plasma, thereby altering the physical or chemical properties, or both, of the solid-state deposition in comparison to a deposition formed without the addition of the atomized material in the thermal-transfer plasma.
10. The particulate deposition device according to claim 2, wherein the heating unit comprises a plasma generator which generates a thermal-transfer plasma between the nozzle and the surface of the object through which the powder particles entrained in the carrier gas traverse prior to being deposited on the surface of the object.
11. The particulate deposition device according to claim 2, wherein the heating unit comprises a plasma generator which generates a thermal plasma in a chamber through which said carrier gas passes through thereby heating the gas which then heats said powder particles which are injected into the heated carrier gas downstream of the chamber.
12. The particulate deposition device according to claim 1, wherein the gas channel has a circular axisymmetric cross-section along its length.
13. The particulate deposition device according to claim 1, wherein the tapered outlet section has circular axisymmetric cross section along its length.
14. The particulate deposition device according to claim 1, wherein the tapered outlet section has a cross-sectional shape which is unequal in two orthogonal directions.
15. The particulate deposition device according to claim 1, wherein the powder particles and gas mixture that flows out of the tapered outlet section of the nozzle is confined to a narrow cross sectional area jet at slightly less than sonic velocity to prevent unwanted supersonic expansion of the jet for a large range of nozzle to surface of object standoff distances and to reduce influx of unwanted gas into the nozzle gas stream and deposition region.
16. The particulate deposition device according to claim 1, wherein the nozzle body is further configured to provide an inert gas shield to reduce influx of unwanted gas into the nozzle gas stream and deposition region.
17. The particulate deposition device according to claim 1, wherein the converging section of the gas channel has a length to diameter ratio of at least 10:1.
18. The particulate deposition device according to claim 1, further comprising an outer evacuator chamber surrounding the friction-compensated nozzle, wherein the outer evacuator chamber entrains and retrieve excess powder particles and gas out through said outer evacuator chamber.
19. The particulate deposition device according to claim 1, further comprising a powder fluidizing unit attached to the converging section of the nozzle which delivers said powder particles entrained in said gas.
20. A process of depositing powder particles upon a surface of an object to form a coating or spray-formed structure thereon, said process comprising:
introducing said powder particles into a carrier gas;
accelerating the carrier gas to a constant speed less than or equal to the sonic speed so as to maintain the carrier gas at a density level that substantially maximizes the drag force on the powder particles; and directing said gas to said surface of the object.
21. The process of claim 20 wherein the powder particles have a particle size distribution that is selected to produce a close packed structure between the matrix of deposited powder particles, thereby creating a dense coating or spray-formed structure.
22. The process of claim 20 wherein the powder particles have a particle size distribution that is selected to induce a void structure between the matrix of deposited powder particles, thereby creating a porous coating or spray-formed structure.
23. The process of claim 22 further comprising an action of backfilling the voids in the matrix of deposited powder particles with a metallic or nonmetallic material different from the powder particles.
24. The process of claim 22 wherein the powder particles comprise a reactive material comprising one of a catalytic, pyrophoric, or explosive material, and wherein the porosity of the matrix of deposited powder particles provides a larger surface area than a solid deposition of such material.
25. The process of claim 20, further comprising the action of heating the powder particles to a temperature below the melting point of the particles, but which is high enough to reduce the yield strength of the particles so as to permit plastic deformation during impact at low flow stress levels.
26. The process of claim 25, wherein the speed of the powder particles at the point of impact with the surface of the object is controlled such that in conjunction with the reduced yield strength induced by heating the particles, the structure, as well as the physical and chemical properties, of the deposited material are tailored.
27. The process of claim 25, further comprising the action of heating the object to alter the physical or chemical properties, or both, of the surface of the object and/or any material previously deposited on the surface of the object.
28. The process of claims 20 or 25, further comprising an action of introducing a second gas into the powder particle and carrier gas mixture which reacts with the powder particles, thereby altering the physical or chemical properties, or both, of the deposition in comparison to a deposition formed without the addition of the second gas.
29. The process of claims 20 or 25, further comprising an action of introducing a second gas into the powder particle and carrier gas mixture which reacts with the surface of the object, thereby altering the physical or chemical properties, or both, of the surface of the object.
30. The process of claim 25 wherein the powder particles are heated using a plasma.
31. The process of claim 30, wherein the plasma is generated within a chamber used to heat said gas which then heats said powder particles which are injected into the heated carrier gas downstream of the chamber.
32. The process of claim 30 wherein the plasma is generated as a direct-transfer plasma between the friction compensated nozzle and said surface of an object.
33. The process of claims 31 or 32, wherein the powder particles and the surface are heated and wherein the powder particles have sufficient speed to effect plastic deformation of the powder particles and the surface upon impact of the powder particles upon the surface.
34. The process of claim 20 wherein the powder particles comprise at least two different types of powder particles.
35. The process of claim 34 wherein a first powder particle material comprises a first metallic material and a second powder particle material comprises a second metallic material.
36. The process of claim 34 wherein the coating or spray-formed structure is a multilayer coating or spray formed structure.
37. The process of claim 36, wherein each layer comprises a different powder particle material.
38. The process of claim 36, wherein each layer comprises of a different combination of powder particle materials.
39. The process of claim 36, wherein each layer comprises of a powder particle material or a combination of powder particle materials.
40. The process of claims 37, 38 or 39, wherein a first layer comprises an undercoat of a diffusion-barrier metallic powder, a second layer comprises an aluminum braze-alloy filler powder and a third layer comprises a flux powder.
41. The process of claim 34 wherein the coating or spray-formed structure is a graded coating or spray formed structure wherein the concentration of at feast one of the types of powder particles is varied in proportion to the other types as a function of thickness.
42. The process of claim 41 wherein the grading is continuous.
43. The process of claim 41 wherein the grading is performed in a stepwise manner.
CA2482287A 2001-04-24 2002-04-20 An apparatus and process for solid-state deposition and consolidation of high velocity powder particles using thermal plastic deformation Expired - Lifetime CA2482287C (en)

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US28625601P 2001-04-24 2001-04-24
US60/286,256 2001-04-24
PCT/US2002/012693 WO2002085532A1 (en) 2001-04-24 2002-04-20 A apparatus and process for solid-state deposition and consolidation of high velocity powder particles using thermal plastic deformation

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CA2482287A1 true CA2482287A1 (en) 2002-10-31
CA2482287C CA2482287C (en) 2010-11-09

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EP (1) EP1383610B1 (en)
KR (1) KR100830245B1 (en)
AT (1) ATE321612T1 (en)
CA (1) CA2482287C (en)
DE (1) DE60210267T2 (en)
MX (1) MXPA03009813A (en)
WO (1) WO2002085532A1 (en)

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ATE321612T1 (en) 2006-04-15
EP1383610B1 (en) 2006-03-29
KR100830245B1 (en) 2008-05-16
DE60210267T2 (en) 2006-08-24
MXPA03009813A (en) 2005-03-07
US7178744B2 (en) 2007-02-20
WO2002085532A1 (en) 2002-10-31
US20020168466A1 (en) 2002-11-14
US6915964B2 (en) 2005-07-12
EP1383610A1 (en) 2004-01-28
KR20040031700A (en) 2004-04-13
CA2482287C (en) 2010-11-09
US20050153069A1 (en) 2005-07-14
DE60210267D1 (en) 2006-05-18

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