Warm spray coating method and particles used therefor

A warm spray coating method, comprising:

• providing a mixture of standard aggregates and additive aggregates, wherein
• each standard aggregate and additive aggregate comprises a binder comprising an organic compound, and particles having an identical composition;
• and having a particle diameter smaller than a diameter of the standard aggregate and additive aggregate,
• each standard aggregate has a diameter of 45 μm or less, and each additive aggregate has a diameter larger than the standard aggregate,
• each standard aggregate and additive aggregate does not comprise other particles, and
• the mixture has a K value, determined by the following formula, of greater than or equal to 1 and less than or equal to 2:
• K=A×(B/C)×D
• A:
• mass % of the content of additive aggregate
• B:
• center diameter of standard aggregate (μm)
• C:
• center diameter of additive aggregate (μm)
• D:
• (maximum diameter−minimum diameter) of additive aggregate/10 (μm);
• heating and blowing the mixture in a warm spray having a temperature of 4×102° C. to 25×102° C. at a supersonic velocity on an object to be treated, wherein
• the mixture is heated to a temperature equal to or higher than a sublimation or vaporization temperature of the binder and equal to or lower than a phase transition temperature of the particle;
• and
• depositing the particles on the object.

A mixture of standard aggregates and additive particle aggregates, wherein

• each standard aggregate and additive aggregate comprises particles having an identical composition, and having a particle diameter smaller than a diameter of the standard aggregate and additive aggregate,
• each standard aggregate has a diameter of 45 μm or less, and each additive aggregate has a diameter larger than the standard aggregate,
• each standard aggregate and additive aggregate does not comprise other particles, and
• the mixture has a K value, determined by the following formula, of greater than or equal to 1 and less than or equal to 2:
• K=A×(B/C)×D
• A:
• mass % of the content of additive aggregate
• B:
• center diameter of standard aggregate (μm)
• C:
• center diameter of additive aggregate (μm)
• D:
• (maximum diameter−minimum diameter) of additive aggregate/10 (μm).