Plasma spray powders and process for producing same

Details Plasma spray powders and process for producing same Plasma spray powders and process for producing same

1987-08-03

1988-09-27

Stallard, Wayland

Specialized metallurgical processes, compositions for use therei

Processes

Electrothermic processes

75 05A, 75 05AA, 75 05B, 75 05BA, 75 05C, 75 1019, 427 39, B22F 904

Patent

active

047739282

ABSTRACT:
A process is disclosed for producing plasma type spray powders. The process involves forming, an admixture of a base metal, chromium, aluminum, and yttrium or master alloy powders containing these elements, and dry milling the admixture by high shearing to produce a homogeneous mixture. A slurry of this mixture and an aqueous solution of a binder is then spray dried to produce agglomerates, the major portion of which has a particle size of from about 20 to about 53 microns. This major portion is then separated from the remainder of the agglomerates and sintered in a reducing atmosphere to remove the binder and form a sintered powder. The sintered powder is then passed through a high temperature plasma reactor to melt the powder and produce a homogeneous plasma spray powder.
A plasma spray powder is disclosed which consists essentially of substantially spherical, melt solidified particles of from about 15 to about 44 microns in size, and having a weight composition of from about 14% to about 19% chromium, from about 10% to about 14% aluminum, from about 0.5% to about 1.0% yttrium and the balance a base metal selected from the group consisting of nickel, cobalt, iron and mixtures thereof.

REFERENCES:
patent: 3639151 (1972-02-01), Krutenat
patent: 3865722 (1975-02-01), Fisher et al.
patent: 3877930 (1975-04-01), Volin
patent: 4025334 (1977-05-01), Cheney et al.
patent: 4070184 (1978-01-01), Scheithauer, Jr. et al.
patent: 4156053 (1979-05-01), Baranow
patent: 4390368 (1983-06-01), Houck
patent: 4507189 (1985-03-01), Doi et al.
"Low-Pressure-Plasma-Deposited Coatings Formed from Mechanically Alloyed Powders" by J. R. Rairden and E. M. Habesch of General Electric Corporate Research and Development, published in Thin Solid Films accepted Apr. 10, 1981.

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