# US 11,441,228 B2 · Thermal spray powder

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- Number: US 11,441,228 B2
- Document ID: US11441228B2
- Status: Granted
- Kind: B2
- Application number: 16/697,978
- Filed: 2019-11-27
- Published: 2020-06-25
- Granted: 2022-09-13
- Earliest claimed: 2018-12-20
- Assignees: Toyota Jidosha Kabushiki Kaisha
- Applicants: Toyota Jidosha Kabushiki Kaisha
- Inventors: Noritaka Miyamoto
- Web page: https://patentgrep.com/patent/US11441228B2

## CPC

- C23C 4/06: Metallic material
- B22F 1/102: Metallic powder coated with organic material
- B22F 1/105: containing inorganic lubricating or binding agents, e.g. metal salts
- B22F 1/17: Metallic particles coated with metal
- C22C 19/058: {without Mo and W}
- C23C 4/067: containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
- C23C 4/134: Plasma spraying
- C23C 4/18: After-treatment
- C23C 24/087: {Coating with metal alloys or metal elements only}
- B22F 3/115: by spraying molten metal, i.e. spray sintering, spray casting
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- 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 (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- C22C: ALLOYS (treatment of alloys C21D, C22F)

## Abstract

A thermal spray powder according to the present disclosure is a thermal spray powder which is used to form a thermal spray film having a characteristic of abradability, the thermal spray powder includes Ni alloy particles, solid lubricant particles, and aluminum flakes, the content of oxygen in the aluminum flakes is within a range of 0.29 mass % to 4.1 mass %, and the coverage of aluminum flakes on the surfaces of the Ni alloy particles is within a range of 60% to 100%.

## Claims

### Claim 1

A thermal spray powder which is used to form a thermal spray film having a characteristic of abradability,
wherein the thermal spray powder includes Ni alloy particles, solid lubricant particles, and aluminum flakes,
the content of oxygen in the aluminum flakes is within a range of 0.29 mass % to 4.1 mass %, and
the coverage of aluminum flakes on the surfaces of the Ni alloy particles is within a range of 60% to 100%.

### Claim 2 (depends on 1)

The thermal spray powder according to claim 1, wherein the content of oxygen in aluminum flakes is within a range of 0.29 mass % to 1 mass %.