Diffusion heat treated thermally sprayed coatings

Details Diffusion heat treated thermally sprayed coatings Diffusion heat treated thermally sprayed coatings

1999-05-05

2000-12-26

Wyszomierski, George

Metal treatment

Process of modifying or maintaining internal physical...

Carburizing or nitriding using externally supplied carbon or...

148285, 148531, 148535, C22F 104

Patent

active

061652865

ABSTRACT:
A method of aluminum diffusion coating the surface of an iron-, nickel-, cobalt-, or titanium-base alloy product begins with cleaning and providing an anchor profile on the surface of the product, followed by depositing with an appropriate thermal spray method at least 4 mils (0.1016 millimeters) thickness of a minimum 85 wt. % aluminum alloy, which can also contain up to 12 wt. % silicon. A MCrAlX-type coating layer is also thermally sprayed on the substrate surface before the aluminum alloy is sprayed. The thermal sprayed products are heat treated in a sealed retort at a temperature of between 900.degree. F. and 1200.degree. F. (482.degree. C. and 649.degree. C.) and then maintained at that temperature for a period of at least one hour to ensure the formation of a strong metallurgical bond between the aluminum alloy layer and the product. The retort temperature is then elevated to between 1400.degree. F. and 2000.degree. F. (760.degree. C. and 1093.degree. C.) and held at that temperature for between 0.17 hour (10 minutes) and 7 hours to cause the diffusion of the aluminum alloy surface layer and subsequent formation of an aluminum diffusion coating. A further treatment step after diffusion heat treatment can be conducted to form a surface oxide, nitride, or combination surface layer. Abrasive blasting of the finished aluminum diffusion coated product may be done to remove any residual aluminum alloy overlay remaining on the coating surface and to provide an improved surface finish and appearance.

REFERENCES:
patent: 2988807 (1961-06-01), Boggs
patent: 3400010 (1968-09-01), Keating
patent: 4031274 (1977-06-01), Bessen
patent: 4364780 (1982-12-01), Blanken
ASM Handbook, vol. 4, "Heat Treating", pp 542-544, ASM, 1991.
ASM Handbook, vol. 5, "Surface Engineering", pp. 55-66, ASM, 1994.
"Guide for the Protection of Steel with Thermal Sprayed Coatings of Aluminum and Their Alloys and Composites," American Welding Society, 1993.
"Corrosion Tests Of Flame-Sprayed Coated Steel--19-Year Report." American Welding Society, 1973.

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