Method of making powder for thermal spray application

Details Method of making powder for thermal spray application Method of making powder for thermal spray application

1991-06-06

1992-06-30

Lechert, Jr., Stephen J.

Powder metallurgy processes

Powder metallurgy processes with heating or sintering

Metal and nonmetal in final product

419 14, 419 23, 419 26, 419 29, 419 33, 419 36, 419 57, 419 65, 419 66, B22F 100

Patent

active

051261049

ABSTRACT:
A method is disclosed for preparing an intimate mixture of powders of nickel-chromium-boron-silicon alloy, molybdenum metal powder, and Cr.sub.3 C.sub.2 /NiCr alloy suitable for thermal spray coatings which comprises milling a starting mixture of the above two alloys with molybdenum powder to produce a milled mixture wherein the average particle size is less than about 10 micrometers in diameter, forming an aqueous slurry of the resulting milled mixture and a binder which can be an ammoniacal molybdate compound or polyvinyl alcohol, and agglomerating the milled mixture and binder. The intimate mixture and binder may be sintered in a reducing atmosphere at a temperature of about 800.degree. C. to 950.degree. C. for a sufficient time to form a sintered partially alloyed mixture wherein the bulk density is greater than about 1.2 g/cc. The resulting sintered mixture may be entrained in an inert carrier gas, passed into a plasma flame wherein the plasma gas can be argon or a mixture of argon and hydrogen, and maintained in the plasma flame for a sufficient time to melt essentially all of the powder particles of the sintered mixture to form spherical particles of the melted portion, and to further alloy the sintered mixture, and cooled.

REFERENCES:
patent: 4453976 (1984-06-01), Smythe
patent: 4519840 (1985-05-01), Jackson et al.
patent: 4725508 (1988-02-01), Rangaswamy et al.

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