Spray bonding of nickel aluminum and nickel titanium alloys

• US 4,027,367 A
• Filed: 07/24/1975
• Issued: 06/07/1977
• Est. Priority Date: 07/24/1975
• Status: Expired due to Term

• Current Assignee: Virginia C. Rondeau
• Original Assignee: Henry S. Rondeau
• Inventors: Rondeau, Henry S.
• Primary Examiner(s): Hoffman, James R.
• Application Number:
  US05/598,822
• Time in Patent Office: 684 Days
• Field of Search: 427/37, 427/34, 427/423, 29/196.2, 29/196.6, 29/197, 29/197.5, 29/198
• US Class Current: 428/652
• CPC Class Codes: B05D 1/10 Applying particulate materials
• CPC Class Codes: B05D 7/26 synthetic lacquers or varnishes B05D7/08, B05D7/16 take precedence
• CPC Class Codes: C23C 4/08 containing only metal elements C23C4/073 takes precedence
• CPC Class Codes: C23C 4/18 After-treatment
• CPC Class Codes: Y10T 428/1275 Next to Group VIII or IB metal-base component
• CPC Class Codes: Y10T 428/12757 Fe
• CPC Class Codes: Y10T 428/12764 Next to Al-base component
• CPC Class Codes: Y10T 428/12806 Refractory [Group IVB, VB, or VIB] metal-base component

Abstract

An alloy of nickel and aluminum, which also may contain varying percentages of intermetallics, in the form of a wire or rod is sprayed in an electric arc spray gun to form a self-bonding coating on a smooth, clean substrate. Alternatively an alloy of nickel and titanium, which also may contain varying percentages of intermetallics, in the form of a wire may be similarly electric arc sprayed to effect a self-bonding coating on a substrate. The nickel aluminum alloy and possibly intermetallics or the nickel titanium alloy and possibly intermetallics are supplied as a wire feed to the electric arc spray gun, and when heated in the electric arc of the spray gun and sprayed onto a substrate will form a coating that has a high degree of tenacity to many metal substrates and also has a moderate degree of hardness, low R_c, high R_b. The self-bonding is attributed to the formation of superheated liquid in the arc process and the affinity of that superheated liquid to iron, nickel, aluminum, etc.

Claims

1. A method of thermal spraying a substrate to deposit a self-bonding coating on such substrate, comprising supplying an electric arc thermal spray gun with a wire feed comprising an alloy of nickel and aluminum or titanium, and using such electric arc thermal spray gun, spraying said wire feed onto such substrate to coat the same thereby to establish a diffusion bond between such coating and such substrate to provide a self-bonding coating on such substrate.

2. A method as set forth in claim 1, wherein said step of supplying comprises supplying a wire feed comprising an alloy of nickel and aluminum.

3. A method as set forth in claim 1, wherein said step of supplying comprises supplying a wire feed comprising an alloy of approximately from 80 to 98 percent by weight nickel and approximately from two to twenty percent by weight aluminum.

4. A method as set forth in claim 1, wherein said step of supplying comprises supplying a wire feed comprising an alloy of approximately from 90 to 95 percent by weight nickel and approximately from four to six percent by weight aluminum.

5. A method as set forth in claim 1, wherein said step of supplying comprises supplying a wire feed comprising an alloy of nickel and titanium.

6. A method as set forth in claim 1, wherein said step of supplying comprises supplying a wire feed comprising an alloy of approximately from forty to seventy percent by weight nickel and approximately from thirty to sixty percent by weight titanium.

7. A method as set forth in claim 1, wherein said step of supplying comprises supplying a wire feed comprising an alloy of approximately from fifty-four to fifty-six percent by weight nickel and approximately from forty-four to forty-six percent by weight titanium.

8. A method as set forth in claim 1, wherein said step of spraying comprises spraying said wire feed onto a smooth, clean substrate of metallic material.

9. A method as set forth in claim 1, further comprising the step of heat treating such coated substrate.

10. An article of manufacture, comprising a metallic substrate and a coating of an alloy of nickel and aluminum or titanium applied to said substrate by supplying to an electric arc thermal spray gun a wire feed comprising an alloy of nickel and aluminum or titanium, and using such electric arc thermal spray gun, spraying said wire feed onto said substrate to coat the same, thereby to establish a diffusion bond between said coating and said substrate, whereby said coating is self-bonding to said substrate.

11. An article as set forth in claim 10, wherein said coating comprises an alloy of nickel and aluminum.

12. An article as set forth in claim 10, wherein said coating comprises an alloy of approximately from eightly to ninety-eight percent by weight nickel and approximately from two to twenty percent by weight aluminum.

13. An article as set forth in claim 10, wherein said coating comprises an alloy of approximately from ninety to ninety-five percent by weight nickel and approximately from four to six percent by weight aluminum.

14. An article as set forth in claim 10, wherein said coating comprises an alloy of nickel and titanium.

15. An article as set forth in claim 10, wherein said coating comprises an alloy of approximately from forty to seventy percent by weight nickel and approximately from thirty to sixty percent by weight titanium.

16. An article as set forth in claim 10, wherein said coating comprises an alloy of approximately from fifty-four to fifty-six percent by weight nickel and approximately from forty-four to forty-six percent by weight titanium.

17. An article as set forth in claim 10, wherein said coated substrate is heat treated.