# US 9,752,632 B2 · Spray powder with a superferritic iron-based compound as well as a substrate, in particular a brake disk with a thermal spray layer

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- Number: US 9,752,632 B2
- Document ID: US9752632B2
- Status: Granted
- Kind: B2
- Application number: 13/859,216
- Filed: 2013-04-09
- Published: 2013-11-07
- Granted: 2017-09-05
- Earliest claimed: 2012-04-11
- Assignees: Oerlikon Metco AG, Wohlen
- Applicants: Oerlikon Metco AG, Wohlen
- Inventors: Peter Ernst; Alexander Barth
- Web page: https://patentgrep.com/patent/US9752632B2

## CPC

- F16D 65/125: {characterised by the material used for the disc body}
- B32B 15/012: {one layer being formed of an iron alloy or steel, another layer being formed of aluminium or an aluminium alloy}
- B32B 15/015: {the said other metal being copper or nickel or an alloy thereof}
- C22C 21/02: with silicon as the next major constituent
- C22C 33/0285: {with Cr, Co, or Ni having a minimum content higher than 5%}
- C22C 38/02: containing silicon
- C22C 38/04: containing manganese
- C22C 38/22: with molybdenum or tungsten
- C22C 38/44: with molybdenum or tungsten
- C22C 38/48: with niobium or tantalum
- C23C 4/06: Metallic material
- C23C 4/067: containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
- C23C 28/321: {with at least one metal alloy layer}
- C23C 28/324: {with at least one metal matrix material layer comprising a mixture of at least two metals or metal phases or a metal-matrix material with hard embedded particles, e.g. WC-Me}
- B22F 3/115: by spraying molten metal, i.e. spray sintering, spray casting
- Y02T 50/60: Efficient propulsion technologies, e.g. for aircraft
- Y10T 428/26: Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
- F16D: COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- 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
- Y02T: CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The invention relates to a spray powder with a superferritic iron-based compound for the thermal coating of a substrate, wherein the spray powder includes, apart from impurities, a chemical list from the list of chemical elements consisting of C, Mn, Cr, Mo, Ni, Nb, P, S, Si, Fe, Al, O, and Zr. In accordance with the invention, the spray powder has the following chemical composition: C at a maximum up to 0.7% by weight, Mn at a maximum up to 0.7% by weight; Ni at a maximum up to 0.5% by weight, Nb at a maximum up to 1.2% by weight, Pat a maximum up to 0.1% by weight, S at a maximum up to 0.1% by weight, Si at a maximum up to 0.2% by weight, Cr in the range from 20% to 40% by weight, Mo in the range 2.0% to 6% by weight, and a ceramic component Al2O3/ZrO2 up to a maximum of 50% by weight, with the remainder being Fe, and otherwise a total of a maximum of 0.4% by weight of further chemical components being contained as impurities. The invention furthermore relates to a substrate, in particular to a brake disk, having a superferritic thermal spray layer.

## Claims

### Claim 1

A spray powder for thermal spray coating comprising a superferritic iron-based compound and a ceramic component comprising Al2O3 and ZrO2;
said superferritic iron-based compound having C, Mn, Cr, Mo, Ni, Nb, P, S, Si, Fe, Al, O, and Zr, wherein amounts are:
C at a maximum up to 0.7% by weight;
Mn at a maximum up to 0.7% by weight;
Ni at a maximum up to 0.5% by weight;
Nb at a maximum up to 1.2% by weight;
P at a maximum up to 0.1% by weight;
S at a maximum up to 0.1% by weight;
Si at a maximum up to 0.2% by weight;
Cr in the range from 20% to 40% by weight;
Mo in the range 2.0% to 6% by weight;
a remainder of Fe; and
a total of a maximum of 0.4% by weight of impurities; and
said ceramic component comprising Al2O3 and ZrO2 being in an amount of up to a maximum of 50% by weight of said spray powder,
wherein the ceramic component comprising Al2O3 and ZrO2 contains between 60% and 90% by weight Al2O3 and between 10% and 40% by weight ZrO2.

### Claim 2

The spray powder of clam 1, wherein said amounts are:
C at a maximum up to 0.5%;
Mn at a maximum up to 0.5%;
Ni at a maximum up to 0.3%;
Nb at a maximum up to 0.8%;
P at a maximum up to 0.05%;
S at a maximum up to 0.05%;
Si at a maximum up to 0.15%;
Cr in the range from 25% to 35% by weight;
Mo in the range 3.5% to 4.5% by weight; and
a remainder of Fe;
a total of a maximum of 0.3% by weight of impurities; and
said ceramic component comprising Al2O3 and ZrO2 is from 10% up to a maximum of 40% by weight.

### Claim 3 (depends on 1)

The spray powder of claim 1, wherein said amounts are:
C at a maximum up to 0.017% by weight;
Cr in the range from 27.5% to 29.5% by weight;
Mo in the range 3.8% to 4.2% by weight; and
a remainder of Fe; and
the ceramic component comprising Al2O3 and Zr02 is in range 34% to 36%.

### Claim 4 (depends on 1)

The spray powder of claim 1, wherein the ceramic component comprising Al2O3 and ZrO2 contains between 75% and 85%, by weight Al2O3 and between 15% and 25%, by weight ZrO2.

### Claim 5

A substrate with a thermal spray layer that comprises a superferritic iron-based compound and a ceramic component comprising Al2O3 and ZrO2;
said superferritic iron-based compound having C, Mn, Cr, Mo, Ni, Nb, P, S, Si, Fe, Al, O and Zr, wherein amounts are:
C at a maximum up to 0.7% by weight;
Mn at a maximum up to 0.7% by weight;
Ni at a maximum up to 0.5% by weight;
Nb at a maximum up to 1.2% by weight;
P at a maximum up to 0.1% by weight;
S at a maximum up to 0.1% by weight;
Si at a maximum up to 0.2% by weight;
Cr in the range from 20% to 40% by weight;
Mo in the range 2.0% to 6% by weight;
a remainder of Fe; and
a total of a maximum of 0.4% by weight of impurities; and
said ceramic component comprising Al2O3 and ZrO2 being in an amount of up to a maximum of 50% by weight of said thermal spray layer,
wherein the ceramic component comprising Al2O3 and ZrO2 contains between 60% and 90% by weight Al2O3 and between 10% and 40% by weight ZrO2.

### Claim 6 (depends on 5)

The substrate of claim 5, wherein said amounts are:
C at a maximum up to 0.5%;
Mn at a maximum up to 0.5%;
Ni at a maximum up to 0.3%;
Nb at a maximum up to 0.8%;
P at a maximum up to 0.05%;
S at a maximum up to 0.05%;
Si at a maximum up to 0.15%;
Cr in the range from 25% to 35% by weight;
Mo in the range 3.5% to 4.5% by weight; and
a remainder of Fe;
a total of a maximum of 0.3% by weight of impurities; and
said ceramic component comprising Al2O3 and ZrO2 is from 10% up to a maximum of 40% by weight.

### Claim 7 (depends on 5)

The substrate of claim 5, wherein said amounts are:
C at a maximum up to 0.017% by weight;
Cr in the range from 27.5% to 29.5% by weight;
Mo in the range 3.8% to 4.2% by weight; and
a remainder of Fe; and
the ceramic component comprising Al2 O3 and ZrO2 is in the range 34% to 36%.

### Claim 8 (depends on 7)

The substrate of claim 7, wherein the ceramic component comprising Al2O3 and ZrO2 contains between 75% and 85%, by weight Al2O3 and between 15% and 25%, by weight ZrO2.

### Claim 9 (depends on 5)

The substrate of claim 5, wherein the thermal spray layer is a compound layer of a matrix containing metal and having inclusions including the ceramic component comprising Al2O3 and ZrO2.

### Claim 10 (depends on 5)

The substrate of claim 5, wherein a porosity of the thermal spray layer is less than 5%.

### Claim 11 (depends on 5)

The substrate of claim 5, wherein a microhardness of the thermal spray layer is between 300 HV.03 and 1000 HV.03.

### Claim 12 (depends on 5)

The substrate of claim 5, wherein a thickness of the thermal spray layer is between 50 μm and 500 μm.

### Claim 13 (depends on 5)

The substrate of claim 5, wherein the substrate includes aluminum or an aluminum alloy.

### Claim 14 (depends on 5)

The substrate of claim 5, wherein the substrate is a brake disk.

### Claim 15 (depends on 14)

The substrate of claim 14, wherein the brake disk is a vehicle or motor vehicle brake disk.

### Claim 16 (depends on 5)

The substrate of claim 5, further comprising an adhesive layer arranged between the thermal spray layer and the substrate, wherein the adhesive layer comprises at least one of:
Ni and Al; and/or
Ni and Cr.

### Claim 17 (depends on 5)

The substrate of claim 5, wherein the thermal spray layer is one of:
a thermal spray layer applied by a powder flame spraying process;
a thermal spray layer applied by a high-velocity powder flame spraying process; or
a thermal spray layer applied by a plasma spraying process.

### Claim 18

A thermal spray coating layer arranged on a substrate and comprising a superferritic iron-based metal matrix and inclusions of ceramic component comprising Al2 O3 and ZrO2;
said superferritic iron-based metal matrix that includes only elements from the following; C, Mn, Cr, Mo, Ni, Nb, P, S, Si, Fe, Al, O and Zr,
wherein amounts of the elements are:
C at a maximum up to 0.7% by weight;
Mn at a maximum up to 0.7% by weight;
Ni at a maximum up to 0.5% by weight;
Nb at a maximum up to 1.2% by weight;
P at a maximum up to 0.1% by weight;
S at a maximum up to 0.1% by weight;
Si at a maximum up to 0.2% by weight;
Cr in the range from 20% to 40% by weight;
Mo in the range 2.0% to 6% by weight;
a remainder of Fe; and
a total of a maximum of 0.4% by weight of impurities that include elements Al, O and Zr; and
said inclusions of ceramic component comprising Al2O3 and ZrO2 being in an amount of up to a maximum of 50% by weight of said thermal spray coating layer,
wherein the ceramic component comprising Al2O3 and ZrO2 contains between 60% and 90% by weight Al2O3 and between 10% and 40% by weight ZrO2.