CN1042951A

CN1042951A - Improved abradable coating and manufacture method thereof

Info

Publication number: CN1042951A
Application number: CN89107176A
Authority: CN
Inventors: 萨布兰马尼亚·朗杰斯维密; 罗伯特·阿尔文·米勒; 丹尼尔·R·马兰兹
Original assignee: Sulzer Plasma Technik Inc
Current assignee: Sulzer Plasma Technik Inc
Priority date: 1988-09-20
Filing date: 1989-09-19
Publication date: 1990-06-13
Also published as: NO893748D0; BR8904694A; FI894380A0; PT91754B; FI894380A; DE68910072T2; KR950014071B1; PT91754A; EP0361709B1; DE68910072D1; AU4133689A; JPH02225598A; EP0361709A1; ES2045458T3; DK462089D0; DK462089A; NO893748L; KR910006512A

Abstract

The material that a kind of manufacturing can be worn and torn the method for matrix material and be made by this method.Charges inject high-temperature combustion gas stream vertically, and it is entrained in this air-flow.Send into the end of having melted wiry of air-flow then continuously with the airflow atomizing that contains charges.The two the last air-flow of deposite metal that will comprise charges and atomizing is guided the surface of a target into.Charges and molten metal impact target, and with it in conjunction with forming successive metal matrix basically, and charges in filling in the gap of matrix.Matrix material is wearing and tearing when contacting easily with the moving parts friction.

Description

Improved abradable coating and manufacture method thereof

The application is that sequence number is the part continuation application of the U.S. Patent application of NO247024 This patent proposed on September 20th, 1988, was entitled as " method that high-speed flame spraying plating equipment and material form ", and the whole disclosed part of this patent is listed the application as a reference in.

But the present invention relates generally to lost material and coating, as be used for forming the coating of closure of to wear and tear in the steam turbine engine.But the present invention specifically provides the making method of a kind of improved lost material and this material.

Be used in the many aspects that comprise as the closure that can wear and tear with the controllable mode lost material easily.The personnel that are familiar with this technology know, but in the contact that the parts that rotate and fixed can wear and tear between the closure lost material are worn away according to the shape that is meshed with moving parts at contact area.Thereby make closure present the accurately geometrical shape of routing motion parts.This has formed the closure with utmost point close tolerance effectively.

The special applications of closure of can wearing and tearing is to be used in the steam turbine engine.Usually, but on the internal surface of steam turbine cover cap, plate one deck lost material with spray gun

Be plated to preset thickness and be in operation when turbine blade rotates, blade is because expansion slightly just takes place in the influence of the heat that is produced.Rotating paddle most advanced and sophisticated thereby contact with abradable material

Thereby on coating, carve certain groove exactly, and blade itself does not contact with cover cap.Should be understood that these grooves provide accurate permission blades turning essential clearance, thereby to provide be the closure of cooperation customized basically.

In order to make turbine blade carve groove in the coating that can wear and tear, the material that constitutes coating must wear and tear and the tip of not loss blade easily, and this requires the material in the coating to reach meticulous equilibrium.Under this special environment, the coating that can wear and tear also must have good anti-particle erosion and the resistance performance that can degenerate at high temperature.Yet the personnel that are familiar with this technology know, adopt the method for conventional formation abradable coating, and it is very difficult obtaining these characteristics that need.

More precisely, a lot of conventional layers easy to wear are to adopt the attal of pulverized powder and the plasma body of metal component to form, and this formation method requires the many parameters of monitoring.These parameters comprise the component characteristic of feed powder

The various operational conditions of powder size and spray gun.Yet,, adopt conventional equipment and technology also can't successfully produce high-quality abradable coating consistently even when these factors are subjected to tight monitoring.

More particularly Be to adopt the method for the raw material that thermojet selects from the material of two kinds of general classes to make conventional matrix material abradable coating.The simplest in the raw material is the mixture of metal-powder and charges, and charges are non-metal powder normally.Promptly

At first mix the dispersed particles of every kind of component, and then use the plasma torch spray mixture.Yet these powdered mixture often have segregation, and segregation is not only arranged in storage tank, and in particle spraying stream self segregation are arranged also These two kinds of segregations all produce injurious effects to the microtexture of last coating.As everyone knows

Particle segregation will produce the regional area that mainly is made of single powdery components in coating.This just causes producing component and the inferior coating of the uneven functions of use of hardness.A kind of preferential evaporation of powder component or other thermal transition also can cause lacking this homogeneity, particularly in the occasion of making a kind of component with plastics.In addition, use blended or the powder admixed also causes the ratio that is difficult to adjust component to produce stratified coating, this stratified coating requires different raw material blendings to each layer coating.

In the another kind of general fashion of pulverized powder, two kinds of components are bonded in together, form composite material granular.Many bonding technologies are well-known, for example use first kind of material of second kind of material coated composite powder powder, or adopt a kind of suitable binding agent with two kinds of powder bondeds together simply.Yet binding agent may be effectively not enough aspect the segregation that prevents two kinds of differing materials.In addition, coating technology not only spends greatly, and the also possible preferential evaporation of coating layer, and this has just reduced the component equilibrium of coating, and single powder component can not be used for forming the coating that has different qualities along the degree of depth of coating.

For many materials, produce satisfied abradable coating and require to use high speed

This is inaccessiable to adopt conventional combustion flame spray gun.Though plasma gun provides high speed

But they operate in so high temperature, so that cause evaporation and heat to degenerate, and for example oxidation of the evaporation of plastic fraction and powdery components is because the eddy current of injection stream has quickened oxidation.

Therefore be desirable to provide a kind of method of forming abradable material, adopt this method can reduce or eliminate the problem of particle segregation.It would also be desirable to provide a kind of like this method, this method has the additional advantage of producing the high quality abradable coating and any significant degeneration that does not produce raw material.It would also be desirable to provide a kind of like this method.In the method, can control independently is material component and do not use complicated powder measurement system, thereby can obtain the gradient of component in coating, and this method also can be avoided undue temperature of plasma jet and velocity slope.The invention provides a kind of method of forming abradable material, this method has reached these purposes and a kind of abradable material with the method for the invention composition of novelty is provided.

In a kind of situation, the invention provides a kind of method of making abradable material

In the method, with charges, preferably powder nonmetal (for example plastics) is incorporated in the high-temperature fuel gas stream, thereby charges are sent in the air-flow.Charges are preferably in axial introducing gas-flow, thereby can avoid uncontrollable side direction to disperse when particle enters in the high velocity air.Heating and edge that charges are subjected to combustion gas advance with high speed with the axis that the deposite metal intersects.The high-temperature fuel gas stream that carries charges makes the deposite metal atomizing, so the deposite metal enters air-flow with charges.Thereby formed the mixed airflow that comprises charges and atomization metal.Make mixed airflow or injection stream facing to a target then, charges that are heated and deposite metal thereby at full speed the surface of ballistic target form the coating of one deck abradable material.When impacting, the deposite metal forms successive metal matrix basically, and charges are embedded in the space in the matrix.Last coating is easily wearing and tearing, and is well suited for and is used for forming the closure that can wear and tear.

In a kind of best situation

Adopt the disclosed high-speed flame spraying plating equipment of aforesaid United States Patent (USP) NO.247024 to realize method of the present invention.Disclose flame plating equipment in this patent, this equipment comprises a pedestal part, and this pedestal partly has the raw material supply hole of tape entry and outlet, and inlet is used to accept raw material Outlet communicates with the convergence spout.Assemble spout preferably and the raw material supply hole axially collimate.Pedestal partly comprises the fuel channel of tape entry and outlet

Inlet enters fuel, and discharge ring communicates around the raw material hole and with the convergence spout.The pedestal part of spray gun also is provided with the oxidant channel with entrance and exit in addition

Inlet is used to enter oxidant gas, and outlet communicates with the convergence spout.Therefore, assemble spout and before fuel and the mixing of raw material charges, just accept fuel and oxygenant from channel outlet individually.Assemble spout and comprise a conical wall

This wall and fuel and oxidant outlet separate sufficient spacing Thereby make fuel and oxygenant mixed and carry out partial combustion in assembling spout.Form flame front, the fuel that heating enters once lighting when fuel and oxygenant assembling in the spout

Fuel is owing to the chemical reaction that generates releases energy

Thereby provide the motivating force of keeping the continuous high speed diffusion reaction.In this mode, raw material is accelerated by the outlet on the conical wall summit.The summit of conical wall and raw material supply hole collimation, therefore the raw material that quickens passes the end perforate of the cylindrical shell of spray gun towards the straight hole jet pipe.In one embodiment, its temperature of the combustion gases that are heated of carrying raw material is enough to the end of deposite metal silk, and the molten metal silk is then by high-speed gas atomization.In another embodiment Best spraying plating equipment is furnished with the composite wire arcing device, makes the electric-arc heating wire

The end of deposite metal silk

Molten metal is atomized and enters in the air-flow that sprays from the convergence spout of spray gun then

Thereby form the blended injection stream.

Under another situation The invention provides a kind of fabulous inhomogeneity abradable material that has, the metal oxide content of this abradable material is lower than the material of a lot of spraying platings routinely.Abradable material comprises metal matrix, and charges are evenly dispersed in the matrix, and charges are soft frangible nonmetal preferably.In one embodiment, abradable material of the present invention comprises for the such matrix material that uses of some purposes closure that can wear and tear of the worn and torn closure that resembles steam turbine engine.Abradable material of the present invention and victory fitting adopt method of the present invention to form.In a best embodiment Abradable material of the present invention comprises metal matrix Plastics are evenly distributed in the gap of matrix.

Fig. 1 is the sectional view for the best flame plating equipment of implementing the method for the invention.For simplicity's sake

Wire and transport sector wiry are not shown among this figure;

Fig. 2 is the best flame plating equipment of using for the present invention, wherein shows the composite wire arcing device;

Fig. 3 is a synoptic diagram

It is illustrated in the formation of flame front in the convergence spout of spray gun and constitutes the generation of the mixing collimated particle stream of lost material of the present invention.

Fig. 4 is the photomicrography at cross section of the abradable material made by the present invention.

The invention provides a kind of method of abradable material and this abradable material of manufacturing of novelty.In most preferred embodiment

Material of the present invention is shaped as the abradable coating of one deck on parts surface.Abradable coating of the present invention comprises the sealing-in that can wear and tear in its great majority are implemented.

According to the method described in the present invention, adopt the combustion flame spraying plating equipment to form the high temperature and high speed combustion gas flowing.The optimum structure of this coating apparatus draws among as a reference the U.S. Patent application NO.247024 in the above to be narrated.Yet the personnel that are familiar with this technology should be understood that, other preferably high speed spraying plating system also can be used for quickening the charges particle.

Referring now to accompanying drawing 1, the equipment of flame plating shown in the figure 10, it generally has burner seat cover 12 This seat cover forms whole with cylindrical shell 14.The conical wall 16 of burner seat cover 12 forms a convergence spout 18 of realizing continuous detonation reaction therein.Raw material supply tube 22 forms raw material supply hole 20, and this pipe is installed in the raw material cover seat 24 hermetically.Raw material cover seat 24 in disclosed embodiment has the thread head 26 that the burner seat of packing into covers 12 threaded portions.It is 24 in place so that help the raw material seat to cover that flange 28 can be set.Raw material seat cover 24 and raw material supply tube 22 are configured in the supply of fuel nozzle 30, make it form annular fuel passage 32.The end 34 of fuel burner 30 preferably taper and be force-fitted on the fuel seat cover 12.

Raw material seat cover 24 comprises second flange or the flange section 36 that meshes fuel burner 30 Be provided with the longitudinal holes that is parallel to raw material supply hole 20 in the flange 36.During operation, flow through the fuel of circular channel 32 so can not be subjected to obviously stopping of flange 36 along direction shown in the arrow.Therefore that is, flange 36 has the outside surface that has the duct, and it works to do support with respect to fuel burner 30, and fuel can be filled basically without restriction flow through annular fuel passage 32.Fuel burner 30 is provided with a series of substantially parallel longitudinal holes in a similar fashion.And This channel architecture also makes the end parts 38 of fuel burner 30 may be engaged on the conical wall 16, assembles spout 18 and oxygenant is entered by annular oxidation passage 40.Annular oxidant channel 40 is that the part 42 and 44 by burner hood seat 12 forms.Should be noted that part 44 also has conical wall 16.For part 44 is fixed firmly on the part 42, attacked screw thread in the part 42

Threaded part in order to the part 44 of packing into.

For making fuel feed annular fuel passage 32, fuel feed passage 48 is provided, this passage run through burner seat cover 12 end parts 50 and with annular fuel passage 32 fluid communication.This successive passage plays a part the duct, and fuel is sent to flame front in assembling spout 18 by this duct.Equally, annular oxidant channel 40 and oxidant inlet passage 52 fluid communication.End parts 50 comprises junctor 54

Attacked screw thread on it, in order to connect the raw material supply flexible pipe, this will explain in method of the present invention in more detail.The weighting material raw material is incorporated into raw material supply hole 20 by junctor 54.

The cross-sectional area in raw material supply hole 20 makes powder stock sufficiently high speed to send into convergence spout 18 preferably significantly less than the cross-sectional area of annular fuel passage 32 and annular oxidant channel 40, is high enough to run through convergence spout 18.Raw material supply hole 20 is generally than annular fuel passage 32, or littler by about 15% on cross-sectional area than annular oxidant channel 40.In addition, the diameter in raw material supply hole 20 generally is about 1 to 5 with the ratio of the internal diameter of injection channel 56.Therefore the ratio of its cross-sectional area generally is about 1 to 25.

Cylindrical shell 14 as tubulose straight hole jet pipe comprises the hollow cylinder part 46 that is formed by injection channel 56.As being described in detail

High-velocity particles is pushed through passage 56 as the air-flow of collimation.For preventing that barrel wall 46 is overheated and realizing that ((a kind of phenomenon that keeps and strengthen the particle flux collimation) is provided with the annular heat exchange jacket 58 that forms annular heat switch room 60 to this paper said " hot constriction ".Heat exchange chamber 60 is only limited on cylindrical shell 14, makes directly not remove heat from assembling spout.In use

Heat exchange medium (for example water)

passing hole channel

62 and 64 flows through heat exchange chamber 60.One end of flexible pipe (not shown) is received junctor 66 and 68 respectively, and heat exchange medium is circulated by heat exchange chamber 60.

With reference now to accompanying drawing 2,, flame plating equipment 10 comprises the deposite metal feeding mechanism of the illustrational composite wire arcing device of this paper (not shown among Fig. 1 for simplicity's sake).Arcing device 70 comprises the carriage 72 that

wire guide bracket

74 and 76 are housed.Wire guide bracket 774 and 76 is provided to by predetermined speed transferring

metal silk

78 and 80 to arc zone 82.In great majority are used

Angle between the

wire

78 and 80 is general best less than about 60 ° of angles.In the best approach of the present invention, the electric arc starting the arc of predetermined strength is also maintained between the end of wire electrode continuously.In another embodiment, with the fuse metal silk 78 of the combustion gas flowing that has collimated and 80 end.May be suitable with a single wire 78 in some applications, wherein use the hot melt wire of burning gas.In disclosed embodiment, when when

wire

78 and 80 fusings and as the deposite metal that atomizes, consuming.Wire 78 and 80 is transported to the point of crossing in the arc zone 82 continuously.Though the distance between arc zone 82 and the cylindrical shell 18 is not important.And in order to be controlled at the coating that spraying plating operating period forms or the various characteristics of finished product

This distance can also be adjusted

But in great majority were used,

wire

78 and 80 was preferably disposed on the place about 4 to 10 centimetres apart from cylindrical shell 14.Electric arc and molten metal silk end should be arranged in from the particle flux that has collimated of cylindrical shell 14 ejections; Promptly

Should be along the longitudinal center line configuration of cylindrical shell 14.

Can use many kinds of fuel and many kinds of oxygenants in the present invention.U.S. Patent application is described as described above, and gaseous state, aqueous or granulous fuel or oxygenant all share.Be to use for oxygenant, most oxygen-containing gas.The present invention preferably adopts purified basically oxygen.The propulsive suitable fuel gas of spraying plating particle high speed that reaches in the present invention is a hydrocarbon gas

Preferably high-purity propane or propylene, these fuel produce high inert oxidizing reaction in some applications, and hydrogen and other liquid, solid fuel also are suitable.In the present invention, can adopt the method for suitable selection fuel, and adopt pilot-gas pressure and the particle residence of control raw material or be trapped in the temperature that the time method of assembling in spout 18 and the passage 56 is controlled flame

Thereby the temperature of control charges raw material.

In addition

The component of control fuel and the velocity of particle that gaseous tension can also obtain wide range.Best fuel gas pressure is from 20 to 100 pounds/square inch (gauge pressure) approximately, preferably from about 40 to about 70 pounds/square inch (gauge pressures).Oxidant gas pressure typically about 20 to the scope of about 100 pounds/square inch (gauge pressures)

For most application

Preferably from about 40 to about 80 pounds/square inch (gauge pressures) in operating in these pressure ranges the time

From the speed of the products of combustion of cylindrical shell 14 ejection will be ultrasonic, significantly greater than the speed of other conventional commodity flame spray gun under the similar operations condition.It is also recognized that

The characteristic of fuel gas and its mass flow characteristic are being arranged speed nearly.

With reference now to accompanying drawing 3,, this figure illustrates flame plating equipment 10

Wherein, charges raw material 110 is injected into by raw material supply hole 20.In this embodiment, raw material 110 is particulate state or pulverous, and is entrained in a kind of with respect to by depositing materials preferably in the torpescence carrier gas.Show flame front 112 and impact zone 114 in flame jet 18.After the atomizing of the end, deposite metal of

wire

78 and 80, just form the mixed airflow 115 of impact target 116, thereby form one deck according to abradable material of the present invention.

Many charges are suitable for being used for forming abradable material of the present invention.The best charges that can use for the present invention are plastics.Said herein " charges " speech generally is defined as follows: a kind of material This material before spraying plating, according to of the present invention carry out spraying plating during and in the environment for use of last abradable material, physically chemically be heat-staple basically.In addition, the hardness value of best weighting material should be less than the hardness value of the material of the abradable material that is used for wearing and tearing

Promptly Should be than the material softer that constitutes the moving parts that contacts with abradable material.At last, during carrying out spraying plating according to the present invention and between the usage period at abradable coating, best weighting material and substrate material should be chemically stable.When weighting material provided as powder, it also must be flowable.In addition, best weighting material used in this invention not thermolysis significantly during making abradable material.Though weighting material preferably provides with particle form

For example powder is bar-shaped but it also can form.

Therefore generally speaking, in the present invention, the frangible charges that hardness is low are best

They can be organism, also can be inorganicss.Good especially charges are as plastics The such synthetic polymer of fiber or synthetic rubber.Natural polymer with desired characteristic also is suitable.Best synthetic polymer or multipolymer comprise acrylic resin, for example the polymkeric substance or the multipolymer of vinylformic acid, methylacrylic acid, these sour ester classes and vinyl cyanide.It also is good that following material uses for the present invention: the method for using diamine and maleic anhydride condensation For example use that the method for methylenedianiline (methylene dianiline) and maleic anhydride condensation produces than Si Maer imide (bismaleimide); Fluoroplastics

For example tetrafluoroethylene and polyethylene; Whole Aromatic copolyesters As liquid crystalline polymers (for example by Amoco Chemicals company with trade mark Xydar ^TMWith by Hochest Celanese company with trade mark Vectra ^TMThe product of selling) Polyimide-imide (polyamide-imide) (for example by Amoco Chemicals company with trade mark Torlon ^TMThe product of selling); Thermoplastic two kinds of polyimide that add thermoset; The polymkeric substance of sulfone (Sulfone polymers)

Comprise polysulfones, polyaryl sulfone and polyethersulfone; Plastics polyester (plastic polysters) Aromatic polyester is for example preferably used the equal polyester of bis-phenol aromatics (bisphenol aromatic homopolyster), polybutylene terephthalate (polybutylene terephthalate), polyethylene terephthalate (polythylene terephthalate) and whole polyarylates of making from different terephthalate (iso-tere-phthalate) and terephthalate of Aromatic copolyesters; Silicone resin; Resins, epoxy; Polyether etherketone (polyether-etherketone) and polyphenylene sulfides (polyphenylene sulfide).Thermoplastics and thermosetting resin that great majority have described characteristic are suitable in the present invention as the charges composition.Used thermoplastics and thermosetting resin comprise the molecular weight of wide range among the present invention, for example from about 2,000 to about 1,500,000.Value beyond this scope Monomer and performed polymer also share.

As previously mentioned

Be used for synthetic be worn the charges of material should be soft with frangible So that produce abradable material with desired characteristic.Except polymkeric substance

Preferably be used as other nonmetal solid lubricant that comprises of charges component of the present invention, for example boron nitride, Calcium Fluoride (Fluorspan), moly-sulfide, fluorizated (agraphitic) carbon, fluorizated graphite, agraphitic carbon and graphite and their mixture.

The stupalith that some hardness are low also is suitable as for example lime carbonate of charges; Clay

As kaolin and wilkinite; Calcium phosphate; Wollastonite; Pyrophyllite; Perlite; Gypsum; Barite; Hydrated aluminum oxide; Quartzy; Diatomite

The diatomite that comprises calcination; And their mixture.Usually

Great majority non-grinding mineral of hardening within reason in the flame plating process is an acceptable.In addition, it also is suitable utilizing the low metal of some hardness to make the charges component in the present invention.

The charges of most preferred embodiment of the present invention are powder The granularity of powder is preferably in about 5 microns to about 100 microns, and still, the diameter beyond this scope also is suitable in some applications.The particle dia of best charges powder is between about 5 to 70 microns.Requirement according to spraying plating equipment

The charges powder should be flowable, and very narrow size-grade distribution is arranged, and makes it not have meticulous or excessive particle.The personnel that are familiar with this technology know the method for these powder of processing.

As previously mentioned, the metal that is used for the metal matrix of abradable material of the present invention preferably makes to become wire

As shown in Figure 3, an end wiry is set on the path of the combustion gases stream that is entrained with weighting material.When utilizing the hot melt metal end of combustion gases

Can only use an one metal wire.Perhaps as shown in Figure 3, also can be with two metals Between the head of two one metal wires, can play electric arc or not play electric arc.The electrically heated that mariages electric arc produces when playing electric arc makes the wire ends fusing Form the source, deposite metal

Deposite metal and then by airflow atomizing.In the occasion with two one metal wires, wire can be identical metal or different metals.Therefore, during a kind of device in adopting these devices, wire must be fusible.

The metal that is fit to be applied to form among the present invention the metal matrix component of abradable material of the present invention preferably has shape wiry.Best metal comprises aluminium and alloy thereof, for example aluminum 1100,1350 and other 1xxx series; The Al-zn-mg-cu alloy of 2xxx series; Aluminum-silicon alloy.For example 4043,4047 and other 4xxx series; Aluminium-magnesium alloy, for example 5356 and other 5xxx series; The al-mg-si alloy of 6xxx series; And aluminum-titanium alloy.Copper and copper alloy also are suitable, comprise copper UNS C101000-C15735; Copper-aluminium alloy

Example UNS C60600-C64400(xantal); Copper-nickel alloy

UNS C70100-C72500 for example.Nickel and nickelalloy also are suitable Comprise nickel UNS N02200, UNS N02201 and UNS N0 2205; Nickel-copper alloy comprises UNS N04400, UNS N04404 and UNS N04405; And nickel-chromium alloy, for example UNS N06003.Be suitable for as the present invention can wear and tear other metal of metal matrix of plating be Ni-based and (or) cobalt-based super heat-resistant alloy and superalloy or corrosion resisting alloy.Best is the MCrAlX alloy, wherein M is Fe, Ni, Co and composition thereof; X is a rare earth metal, comprises La, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, T _m, y _b, Lu, H _fAnd their mixture or X are Z _r, Si and their mixture; Also the best metal of Shi Yonging is an intermetallic compound, comprises the aluminide of nickel, titanium etc.Steel comprises that soft steel, steel alloy and stainless steel also share.Pure metal also is an acceptable

This comprises that nickel, cobalt, iron, copper, aluminium and other can make any metal wiry.

Size wiry is inessential, but the scope of its diameter is generally at about 0.03 inch to about 0.25 inch.The value that surpasses this scope also is feasible.When the end of fusing wiry is atomized, the direction that one or more wire can constantly provide the speed of the deposite metal of atomizing to enter air-flow.

An advantage in the lot of advantages that is provided by flame plating equipment 10 is to adjust the speed that the grain packing thing is injected into flame front.Unlike many equipment, flame plating equipment 10 can independently be adjusted the injection speed of particle

Gas flow rate and oxidant gas flow velocity.The raw material particle is injected into flame front with the individual air stream of inert carrier gas.Because can adjust flow velocity independently,, so just reduced the eddy current in assembling spout 18 significantly so nebulizer gas pressure is remained on than on the high numerical value of fuel gas pressure (this has increased velocity of particle).The nebulizer gas pressure scope about 40 to about 40 between about 70 pounds/square inch (gauge pressures) for well, be more preferably from about 50 to about 60 pounds/square inch (gauge pressures), best is to keep greater than fuel gas pressure.As previously mentioned, though that the relative dimension of outlet 33 shown in Figure 3 and 41 can change is very big, the general remarkable transversal part of the internal diameter of raw material supply tube 22 less than annular fuel passage 32 or annular oxidant channel 40.Raw material supply hole 20 generally is about 1 to 25 with the ratio of the cross-sectional area of the injection channel 56 of cylindrical shell 14, thereby reduces contact during the spraying plating of charges particle and be attached to possibility on the internal surface of cylindrical shell 14.Make nebulizer gas pressure remain on 50 pounds/square inch (gauge pressures) when above, in about 45 to 50 pounds/square inch (gauge pressures) and oxidant gas pressure occasion, can prevent the phenomenon of splashing that is referred to as that under low nebulizer gas pressure, takes place at fuel gas in about 70 to 90 pounds/square inch (gauge pressures).Splash phenomena is that particle may be attached on the conical wall 16 because the radial motion of particle causes, and this phenomenon is considered to be under the lower nebulizer gas pressure that eddy current produces owing to having increased.Therefore, nebulizer gas pressure is remained on high value and reduced eddy current.

When the charges particle enters convergence spout 18

Because thermopositive reaction, the heat of particle and kinetic energy just significantly increase.High energy charges particle passes assembles the high-energy particle flow that spout 18 forms collimation This particle flux passes the passage 56 of cylindrical shell 14 basically along linear advancement.As previously mentioned

This has also reduced the eddy current radial motion of spraying plating particle.Assemble spout 18 and in being limited to convergence spout 18, keep successive high speed diffusion reaction because the gas stream of non-eddy current is entered, so combustion gases and charges particle flux have reached the axial flow that does not have eddy current basically, this has just formed the particle flux of collimation at a high speed.In addition, when particle flux passes cylindrical shell 14, owing to removed the heat of barrel wall 46 with heat exchange jacket 58, so reduced the diffusion of air-flow

This has further reduced any radial motion of high energy particle to cylindrical shell 14 sidewalls again.

When the particle flux of collimation passed cylindrical shell 14, it just passed arc zone 82.During passing

Wire

78 and 80 electricity are excited, thereby between end wiry, produce the electric arc that continues.The voltage that is enough to pilot arc between

wire ends

78 and 80 is provided with suitable power supply.Generally just enough about 15 to about 30 volts voltage.When forming the deposite metal in end wiry, the particle flux molten metal that just atomizes.For pilot arc and foregoing in order to keep the deposite metal to send into continuously in the jet-stream wind,

wire

78 and 80 is sent to predetermined speed.When molten metal is atomized, just form the two compound or the blended particle flux 115 of deposite metal comprise charges and atomizing.Though because

wire

78 and 80 existence have produced some eddy current but the blended particle flux still keeps good collimation.The blended air-flow sprays to target 116 then, and it forms abradable material 118 of the present invention on target.

The metal matrix of selling the last coating on the closure that can wear and tear general best merchant preferably account for the abradable coating volume about 40% to about 95%, the charges component then accounts for about 5% to about 60% of abradable material volume.In special application, the present invention is used to form the coating that can wear and tear on the surface of parts.In most of most preferred embodiments, the present invention includes moving parts is formed the sealing-in that can wear and tear, for example to the worn and torn sealing-in of steam turbine engine at this on the one hand, method of the present invention is utilized to form the coating that can wear and tear on the internal surface of the cover cap of steam turbine engine.One when coating curing Turbine engine blade is rotated In abradable coating, carve groove

Thereby form the worn and torn sealing-in that accurately cooperates.

In order to narrate the present invention in more detail, provide following Example, the scope that this example is not meant to limit the present invention in any manner.

Adopt the spray gun be shown in accompanying drawing 1 to 3 substantially, abradable material is formed as follows: diameter is that the wire of two aluminum 1100s of 1/16 inch is transported in the jet-stream wind with the speed of 34.5 Grams Per Minutes.The charges component is thermoplastic polyimide, it with above-mentioned mode with the speed of about 15 Grams Per Minutes from axially be transported to combustion gases stream.The size of thermoplastic powder is about every square of inch 140～325 eyelets.Oxidant gas is purified basically oxygen

Flow velocity is 225 liters/minute.Do combustion gas with propylene Flow velocity is 46 liters/minute.Tested two kinds of powder carriers, nitrogen and carbonic acid gas, its speed is respectively 85 liters/minute and 67 liters/minute.Distance between target and the spray gun begins calculation from arc zone and is about 11.5 inches.Combustion gas velocity is about the velocity of sound.In the photomicrography of Fig. 4, show the synthetic situation of material grass of can wearing and tearing at cross section.

Although this paper has illustrated and has narrated special embodiment of the present invention, should be clear in the nature of things, the present invention is not limited thereto, because according to content of the present disclosure

People, the personnel that particularly are familiar with this technology can carry out many remodeling.Therefore can expect Appended claims comprises any remodeling of a class as belonging to true spirit of the present invention and scope.

Claims

1, a kind of method of making abradable material, this method comprises the steps:

Weighting material is transported in the high-temp combustion air-flow, above-mentioned charges are entrained in the above-mentioned combustion gases;

With the above-mentioned high-temp combustion airflow atomizing that is entrained with above-mentioned charges molten metal, the deposite metal of above-mentioned atomizing is entrained in the said flow together in company with above-mentioned powder filling thing,

Guide the above-mentioned high-temperature combustion gas stream that is entrained with above-mentioned charges and is entrained with the deposite metal of above-mentioned atomizing into a target;

The above-mentioned above-mentioned charges of carrying secretly in high-temperature combustion gas stream and the metal of above-mentioned atomizing form one deck settled layer on above-mentioned target, above-mentioned settled layer comprises the abradable material that has metal matrix and embed above-mentioned charges in matrix.

2, by the method described in the claim 1, wherein, above-mentioned combustion gases stream forms in burning spray gun, and speed is in supersonic speed.

3, by the method described in the claim 1, wherein, above-mentioned powder filling thing becomes particulate state

4, by the method described in the claim 1, wherein, the end of at least one one metal wire is placed in the above-mentioned high-temperature combustion gas stream that is entrained with above-mentioned charges, above-mentioned end wiry is melted by above-mentioned combustion gases, thereby supply with above-mentioned molten metal.

5,, wherein, two one metal wires are set and electric current is added to mechanism on the above-mentioned wire by the method described in the claim 1.And between above-mentioned wire, forming electric arc, above-mentioned electric arc is enough to melt above-mentioned above-mentioned end wiry, thereby supplies with above-mentioned molten metal.

6, by the method described in the claim 1, wherein, above-mentioned powder filling thing is to comprise the powder synthetic polymer of selecting the material of thermosetting polymer, thermoplastic polymer and their mixture from a group.

7, by the method described in the claim 1, wherein, above-mentioned powder filling thing is a kind of solid lubricant powder.This solid lubricant is to select from a group comprises the material of boron nitride, Calcium Fluoride (Fluorspan), moly-sulfide, fluorizated agraphitic carbon, fluorizated graphite, agraphitic carbon, graphite and their mixture.

8, by the method described in the claim 1, wherein, above-mentioned charges are ceramic powders of selecting from a group material

This group material comprises the diatomite of lime carbonate, kaolin, wilkinite, calcium phosphate, wollastonite, pyrophyllite, perlite, gypsum, barite, hydrated aluminum oxide, quartz, diatomite, calcination and their mixture.

9, by the method described in the claim 1, wherein, above-mentioned charges can make rod.

10, by the method described in the claim 1, wherein, above-mentioned molten metal is selected from a group metal.This group metal comprises aluminium, aluminum-silicon alloy, al-mg-si alloy and aluminum-titanium alloy, copper, copper-aluminium alloy, copper-nickel alloy, nickel, nickel-copper alloy, nickel-chromium alloy, cobalt-based super heat-resistant alloy and their mixture.

11, by the method described in the claim 1, wherein, above-mentioned deposite metal is the MCrAlX alloy.Wherein X selects from a group comprises the material of rare earth metal, yttrium, hafnium, zirconium and silicon, and M is iron, nickel, cobalt and their mixture.

12, by the method described in the claim 1, wherein, above-mentioned molten metal is to select from the material of a group nickel aluminide and titanium aluminide.

13, by the method described in the claim 1, wherein

Above-mentioned molten metal comprises soft steel, steel alloy and the stainless steel from a group to be selected.

14, by the method described in the claim 1

Wherein, above-mentioned molten metal is selected from a group pure metal, and this group pure metal comprises nickel, cobalt, iron, copper, aluminium and their mixture.

15, a kind of method that forms abradable coating, this method comprises the steps:

The grain packing raw material is injected the high-temp combustion air flow stream that flows through spray gun basically vertically, above-mentioned rice charges raw material is entrained in the above-mentioned high-temperature combustion gas stream;

With the end of having melted of at least one one metal wire place above-mentioned high-temperature combustion gas stream path, make an end atomizing of having melted of an above-mentioned one metal wire, thereby make above-mentioned deposite metal together be entrained in the said flow in company with above-mentioned grain packing raw material;

Make the above-mentioned air-flow that is entrained with the deposite metal of above-mentioned grain packing raw material and above-mentioned atomizing face toward a surface for the treatment of spraying plating,

With above-mentioned grain packing raw material in the said flow and the above-mentioned surface of above-mentioned molten metal spraying plating

Thereby form the coating that can wear and tear on above-mentioned surface, the above-mentioned coating that weares and teares comprises successive metal matrix basically, is filled with above-mentioned grain packing raw material in the gap of above-mentioned metal matrix.

16, the method for metal-matrix composite coating that can wear and tear of a kind of formation as the sealing-in of can wearing and tearing.This method comprises the steps:

Adopt the method for introducing the powder filling raw material basically vertically, above-mentioned powder filling raw material is injected in the high temperature and high speed combustion gases stream of the rapid expansion in the spray gun;

Guide the above-mentioned high-temperature combustion gas stream that carries above-mentioned powder filling raw material the end of at least one one metal wire into

The molten metal that atomizes makes formation wherein be entrained with the compound high temperature and high speed combustion gases stream of above-mentioned powder filling raw material and above-mentioned deposite metal;

Make above-mentioned compound air-flow facing to a surface

Make above-mentioned charges and above-mentioned deposite metal at full speed impact on above-mentioned surface, thereby above-mentioned charges and above-mentioned deposite metal are deposited on the above-mentioned surface, thereby on above-mentioned surface, form the composite deposit that weares and teares as the sealing-in of can wearing and tearing.

17, a kind of method of manufactured materials, this method comprises the steps:

Charges are injected in the high-temperature combustion gas stream, thereby above-mentioned charges are entrained in the above-mentioned combustion gases;

With the above-mentioned high-temperature combustion gas stream that the is entrained with above-mentioned charges molten metal that atomizes

Make the molten metal of above-mentioned atomizing be entrained in the said flow together in company with above-mentioned powder filling thing;

Guide the above-mentioned high-temperature combustion gas stream that is entrained with the molten metal of above-mentioned charges and above-mentioned atomizing into a target;

Be entrained in the above-mentioned charges in the above-mentioned high-temperature combustion gas stream and the metal of above-mentioned atomizing and form one deck settled layer on above-mentioned target, above-mentioned settled layer comprises the material that has metal matrix and be embedded with above-mentioned charges in metal matrix.

18, a kind of material of producing according to the described method of claim 17.

19, a kind of method of making as material as described in the claim 17, wherein, above-mentioned charges are plastics, above-mentioned metal is to select from a group metal that comprises steel, Steel Alloy.