Nanostructured feeds for thermal spray systems, method of manufacture, and coatings formed therefrom
AssigneesUniversity of Connecticut, Rutgers, The State University of New Jersey
InventorsPeter R. Strutt, Bernard H. Kear, Ross F. Boland
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Abstract
This invention relates to methods whereby nanoparticle liquid suspensions are used in conventional thermal spray deposition for the fabrication of high-quality nanostructured coatings. Ultrasound is used for disintegration of the as-synthesized particle agglomerates, nanoparticle dispersion in liquid media, and liquid precursor atomization.
Claims10
A method for forming a nanostructured coating, comprising
- dispersing a nanostructured material in a liquid medium by ultrasound to form a solution having dispersed therein nanostructured particles having particle sizes in the range from 3 to 30 nanometers;
- injecting the solution directly into the feed of a thermal spray apparatus;
- and
- spray coating the solution onto an article to form a nanostructured coating on the article.
A method for forming nanostructured coating having at least a first and a second layer, comprising
- dispersing a first nanostructured material in a liquid medium by ultrasound to form a first solution having dispersed therein nanostructured particles with particle sizes in the range from 3 to 30 nanometers;
- injecting the first solution directly into the feed of a thermal spray apparatus;
- spray coating the solution onto an article to form the first nanostructured coating layer;
- and
- dispersing a second nanostructured material in a liquid medium by ultrasound to form a second solution having dispersed therein nanostructured particles with particle sizes in the range from 3 to 30 nanometers;
- injecting the second solution directly into the feed of a thermal spray apparatus;
- and spray coating the second solution onto the first layer to form the second nanostructured coating layer.
The method of claim wherein the first and second nanostructured materials are the same or different, and are selected from the group consisting of WC/Co, Cr3C2/Ni, Fe3Mo3C/Fe, ZrO2, Al2O3, yttria-stabilized zirconia, hydroxyapatite, vitellium, SiC, SiCxNy, Si3N4, Cr3C2/NiCr, and MnO2.
Dependencies are inferred from the claim text.