Thermal spray powder of dicalcium silicate and coating thereof and manufacture thereof

Abstract: A powder of dicalcium silicate is made by spray drying calcia and silica with incorporation of sodium and phosphorus or stabilized zirconia. The spray dried powder is sintered to form a thermal spray powder. Sprayed coatings have a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. The coatings are stable in thermal cycling and a hot corrosive environment.

Description: This invention relates to thermal spray powders of dicalcium silicate, thermal spray coatings thereof, and a process for manufacturing such powders. BACKGROUND Thermal spraying involves the melting or at least heat softening of a heat fusible material such as a metal or ceramic, and propelling the softened material in particulate form against a surface which is to be coated. The heated particles strike the surface where they are quenched and bonded thereto. In a plasma type of thermal spray gun, a high temperature stream of plasma gas heated by an arc is used to melt and propel powder particles. Other types of thermal spray guns include a combustion spray gun in which powder is entrained and heated in a combustion flame, such as a high velocity, oxygen-fuel (HVOF) gun. Thermal spray coatings of oxide ceramics are well distinguished from other forms such as sintered or melt casted by a characteristic microstructure of flattened spray particles visible in metallographically prepared cross sections of coatings. In one group of thermal spray materials, powders are formed of oxides for spraying coatings that are used for thermal insulation at high temperature such as on burner can surfaces in gas turbine engines. Coatings are also needed for erosion and wear protection at high temperatures, and require resistance against thermal cycle fatigue and hot corrosion in a combustion environment. Zirconium dioxide (zirconia) typically is used in such applications. Because of phase transitions, the zirconia is partially or fully stabilized with about 5% (by weight) 15% calcium oxide (calcia) or 6% to 20% yttrium oxide (yttria) However, these coatings have limitations particularly in resistance to hot corrosion as they allow attack of the substrate or a bond coating Dicalcium silicate (Ca 2 SiO 4 ) is a ceramic conventionally used for cement and refractory applications. Excellent hot corrosion and heat resistance of dicalcium silicate based coatings also has been demonstrated in a high temperature combustion environment. However, it is polymorphic with at least five phases including three high temperature α modifications, an intermediate temperature monoclinic β phase (larnite) and an ambient temperature γ phase. The transformation from the β phase to the γ phase exhibits a volume increase of 12% leading to degradation in both the thermal spray process and the coatings in thermal cycling. The β phase may be retained by quenching or the use of a stabilizer such as sodium or phosphorous. Other suggested stabilizers include oxides (or ions) of sulphur, boron, chromium, arsenic, vanadium, manganese, aluminum, iron, strontium, barium and potassium. At least some of these have also been reported as unsuccessful, and therefore still questionable in stabilizing, including chromium, aluminum, iron, strontium and barium. U.S. patent No. 4,255,495 (Levine et al.) discloses plasma sprayed coatings of thermal barrier oxides containing at least one alkaline earth silicate such as calcium silicate. U.S. patent No. 5,082,741 (Tiara et al.) and an article "Advanced Thermal Barrier Coatings Involving Efficient Vertical MicroCracks" by N.Nakahira, Y.Harada, N.Mifune, T.Yogoro and H.Yamane, Proceedings of International Thermal Spray Conference, Orlando FL, 28 May - 5 June 1992, disclose thermal spray coatings of dicalcium silicate combined with calcium zirconate (CaZrO 3 ) in a range of proportions. A commercial powder of β phase dicalcium silicate for thermal spraying is sold by Montreal Carbide Co. Ltd., Boucherville CQ, Canada, indicated in their "Technical Bulletin MC-C 2 S" (undated). In a chemical analysis the present inventors measured less than 1% by weight of potential stabilizers such as phosphorous in Montreal Carbide powder. A commercial powder of dicalcium silicate for thermal spraying also is sold by Cerac Inc., Milwaukee, Wisconsin. In a Certificate of Analysis for calcium silicate (October 20, 1997), Cerac reports major β phase and low levels of aluminum (0.12%), iron (0.1%) and magnesium (0.25%), and 0.02% or less of other elements. An object of the present invention is to provide an improved powder of dicalcium silicate for thermal sprayed coatings for thermal barriers having resistance to hot corrosion and sulfidation in a combustion environment. A further object is to provide a novel process of manufacturing such a powder. Another object is to provide an improved thermal sprayed coating of dicalcium silicate for thermal barriers having resistance to hot corrosion and sulfidation in a combustion environment. SUMMARY The foregoing and other objects are achieved by a thermal spray powder comprising a substantially uniform powder composition consisting of dicalcium silicate, sodium, a further ingredient selected from the group consisting of phosphorous and zirconium, and incidental ingredients, such that the dicalcium silicate is stabilized in a larnite phase that is majority by volume. Acording to the invention the further ingredient comprises phosphorous, in which case, preferably, the sodium recited as disodium monoxide is present in an amount of 0.2% to 0.8%, and the phosphorous recited as phosphorous pentoxide is present in an amount of 2.5% to 4%. In a prefered embodiment the further ingredient comprises zirconium, in which case, preferably, the sodium recited as disodium monoxide is present in an amount of about 0.2% to 0.8%, and the zirconium recited as zirconium dioxide is present in an amount of 10% to 50%. These percentages are by weight of oxide based on the total composition. The zirconium, if present, should be at least partially in the form of zirconium dioxide containing calcium oxide as stabilizer of the zirconium dioxide, or yttrium oxide its stabilizer. Objectives also are achieved by a process of manufacturing a thermal spray powder of dicalcium silicate having a stabilized crystal structure. An aqueous mixture is formed of calcium carbonate powder, silicon dioxide powder, and an organic binder containing as an integral constituent a stabilizing element in an amount sufficient to stabilize the dicalcium silicate in a larnite phase that is majority by volume. The aqueous mixture is spray dried to form a powder. The spray dried powder is heated, such as by sintering or plasma melting, such that the dicalcium silicate is formed with larnite phase that is majority by volume. Preferably the stabilizing element is sodium, advantageously contained in an organic binder sodium carboxymethylcellulose. Further advantageously, the aqueous mixture further comprises a compound of phosphorous, preferably as hydrous aluminum phosphate in aqueous solution. Alternatively or in addition to phosphorous, the aqueous mixture further comprises stabilized zirconium dioxide powder with calcia or yttria stabilizer. Objectives are further achieved by a thermal spray coating of a composition as described above for the powder. The coating has a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. The coating may include a bonding layer of a thermal sprayed nickel or cobalt alloy on a metallic substrate, and an intermediate layer of a thermal sprayed partially or fully stabilized zirconium oxide. The layer of dicalcium silicate composition is thermal sprayed onto the intermediate layer. The intermediate layer blocks reaction between the bonding layer and the layer of dicalcium silicate composition. DETAILED DESCRIPTION Dicalcium silicate compositions can be manufactured by agglomeration procedures such as spray drying as taught in U.S. patent No. 3,617,358 (Dittrich), incorporated herein in its entirety by reference, followed by sintering (calcination) or melting. Sodium is added as a stabilizing ingredient. A second added ingredient is phosphorous as a stabilizer. Alternatively to the phosphorous, the second additive is stabilized zirconia or, as another alternative, both phosphorous and zirconia may be added. In spray drying a water soluble organic or inorganic binder is used in an aqueous mixture or slurry containing the other ingredients. In a preferred embodiment, the sodium is added by way of containment in the binder formulation, advantageously sodium carboxymethylcellulose (sodium CMC) containing about 2% by weight sodium. Other ingredients and calculated formulae are listed in Table 1 for seven formulations. Table 1 Spray Dry Menu (Quantities in units of weight) Run # CaCO 3 SiO 2 AP CZ YZ 1 154 46 2 150 50 25 3 150 50 10 4 154 46 25 5 154 46 10 6 154 46 33 7 154 46 33 AP- Al(H 2 PO 4 ) 3 , 50% solution. CZ - ZrO 2 -5CaO-0.5Al 2 O 3 -0.4SiO 2 , in weight percents. YZ - ZrO 2 -7Y 2 O 3 , in weight percent. Raw materials were precipitated calcium carbonate (CaCO 3 , purity 98%, size 1-10 µm), ground silica (SiO 2 , purity 99%, 2-15 µm), hydrous aluminum phosphate (AP), calcia stabilized zirconia (CZ, 98% purity, 0.4-20 µm) and yttria stabilized zirconia (YZ, 99% purity, 0.4-15 µm). The amounts of each ingredient are in units of weight, each formulation being in 60 liters of distilled water per unit of weight of the raw materials. The binder is present in an amount of 4% by weight of the raw materials. The Na 2 O content was nearly constant around 0.45% as the binder remained constant. A surfactant such as sodium polyacrylate is added in an amount of 2% by weight. The mixture is atomized conventionally with compressed air upwardly through a nozzle into a heated oven region, as described in the aforementioned Dittrich patent, and the resulting agglomerated powder is collected. Table 2 lists powders by lot numbers formulated (some in two sizes) from these compositions. All were subsequently sintered at 1200°C for 3 hours, except Lot 709 which was treated by feeding through a plasma gun as described in U.S. patent Nos. 4,450,184 (Longo et al.), the portions describing such process being incorporated herein by reference. Table 3 gives chemical compositions (from chemical analyses) and phases (from x-ray diffraction) for eight of the lots. Table 2 Powders Lot # Run # Size Additives Heat Treat 307 1 Std Na Sinter 309 1 Fine Na Sinter 403 2 Std Na, P Sinter 414 3 Std Na, P Sinter 429 4 Std Na, P Sinter 506 5 Std Na, P Sinter 513 6 Std Na, CZ Sinter 515 6 Fine Na, CZ Sinter 520 7 Std Na, YZ Sinter 709 1 Std Na Plasma 821 Blend of Run 1 & CZ 75/25 Wt% Std = Standard - predominantly 30 to 125 µm Fine - predominantly 22 to 88 µm. Na - sodium; P - phosphorous Table 3 Powder compositions (Volume Percents) Lot# CaO SiO 2 MgO Al 2 O 3 P 2 O 5 Na 2 O Y 2 O 3 ZrO 2 Phases 307 62.23 36.28 0.42 0.29 0.03 0.49 100% β 309 64.48 43.03 0.40 0.29 0.09 0.41 100% β 403 56.92 33.62 0.35 1.80 6.67 0.39 75% β, CA 414 58.83 36.66 0.37 0.89 2.73 0.42 75% β, CA 429 57.67 33.30 0.38 1.72 6.17 0.45 75% β, CA 506 61.96 32.58 0.40 0.95 3.09 0.49 75% β, CA 513 49.19 29.09 0.33 0.47 0.01 0.40 0.04 19.71 75% β, CZ 515 51.04 27.63 0.33 0.47 0.01 0.41 0.03 19.25 75% β, CZ 520 47.37 28.84 0.28 0.42 0.02 0.40 1.53 20.62 75% β, YZ CA is calcium aluminate, Ca 3 Al 2 O 6 . β - larnite The powders were thermal sprayed with a Sulzer Metco model F4 plasma gun with a model Twin 10 (TM) powder feeder, using an 8 mm nozzle, argon primary gas at 30 standard liters/minute (slpm) flow, hydrogen secondary gas at 12 slpm, argon powder carrier gas at 3 slpm, 550 amperes, 63 volts, 12 cm spray distance and 3 kg/hr powder feed rate. Several types of substrates included cold rolled steel, Fe-13Cr-44Mo alloy and a Ni alloy of 1.5Co-18Fe-22Cr-9Mo-0.6W-0.1C-max1Mn-max1Si. The substrates were prepared conventionally by grit blasting. Coatings having a thickness of 650 to 730 µm were effected. The finer powders were sprayed with the same gun and parameters except at a spray rate 1.2 kg/hr. Table 4 shows detected phases in the coatings. Table 4 Plasma Sprayed Coating Phases Lot/Coating # Detected Phases 307 β 309 β 403 α ortho 414 β (+), α ortho 429 α ortho 506 β (+) 513 α ortho, cubic zirconia 515 α hex, cubic zirconia 520 α hex, cubic zirconia 709 β 821 β, cubic zirconia (+) after β designates disordered lattice. A more important feature of the preferred coatings is a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. Such cracks relieve stresses in thermal cycling. These microcracks were observed particularly in a coating from lot 506 which is stabilized at 75% β phase (larnite) with disodium monoxide and phosphorous pentoxide, and contains aluminum oxide bound with the calcia as Ca 3 Al 2 O 6 . However, the x-ray diffraction pattern indicated a disordered lattice. Similar microcracking was observed in a coating from lot 515 containing sodium and calcia stabilized zirconia (CZ). Compositional inhomogeneity was visible in coatings with high amounts of silica or phosphorous (lots 403, 429), and inhomogeneity for lot 414. Lot 429, low in phosphorous, was most uniform. The microcracking is considered to be important for stress relief in thermal cycling. In the coatings, there should be between about 1 and 5 microcracks per cm 2 of coating surface. After a heat treatment at 1200°C for 48 hours, only three coatings appeared stable against dusting, 506 (low phosphorous) and 515 (CZ), and 414 which completely detached. The only coating to retain the β phase was 506. Coating 515 exhibited a mechanical stable appearance. It is concluded that the coatings that dusted would not be stable in hot environments. Coating 414 was "superstabilized" in a high temperature α phase formed in the heat treatment. A significant amount of calcium zirconate (CaZrO 3 ) was formed in the heat treated coating 515. After a second heat treatment of coatings 506 and 515 at 1300°C for 48 hours, only the β phase was detected in the coatings. These coatings remained stable. Further long term cyclic corrosion testing was performed with coatings 414, 506 (both low phosphorous) and 515 up to 900°C, with V 2 O 5 , (85 wt%) / Na 2 SO 4 (15 wt%) ash as a corrosive agent. These coatings efficiently protected the underlying bond coat and substrate from attack from the agent which did not penetrate the coatings. Reference yttria stabilized zirconia coatings were damaged and partly spalled, and the corrosive agent penetrated the coating. More broadly, the disodium monoxide should be present in an amount of 0.2% to 0.8%. If phosphorous pentoxide is the second stabilizer, it should be present in an amount of 2.5% to 4%. Alternatively, if zirconium dioxide (zirconia) is the second additive, it should be present in an amount of 10% to 50% by weight. The powder should have a size distribution generally within a range between about 10 and 100 µm. Alternatives to the aluminum phosphate as a raw material are sodium phosphate and zirconium phosphate. As indicated above for, a preferred aspect of the invention, the organic binder for the spray dry process contains the stabilizing element sodium as an integral constituent of the binder compound. More broadly, other stabilizing elements such as potassium or any of the other stabilizing elements set forth above for dicalcium silicate may be used. The stabilizing element is in an amount sufficient to stabilize the dicalcium silicate in a larnite phase that is at least majority or, preferably, substantially fully stabilized larnite. The powder size distribution generally should be in a range of 10 µm to 200 µm, for example predominantly 30 to 125 µm for thicker coatings or 22 to 88 µm for thinner coatings. The zirconia, when used, should be partially or fully stabilized with 5% to 15% by weight of calcia or 6% to 20% by weight of yttria. At least some stabilization of the zirconia is desired because some zirconia phase is in the powder particles. Stabilized zirconia is distinguished from calcium zirconate which contains substantially more calcia. Other known or desired stabilizers for the zirconia such as magnesium oxide may be used. In an alternative embodiment, phosphorous is used along with the sodium in powder and coatings containing the stabilized zirconia. Proportions should be the same as for the individual cases. Plasma gun melting of spray dried powder in place of sintering, is an alternative. Also, lot 821 tested a blend of lot 307 dicalcium silicate with a partially stabilized zirconia powder. Although lot 307 was stabilized only with sodium which was less effective, the testing suggested that powders of the present invention may be blended with other compatible high temperature powders for tailored results. Advantageously, the zirconium oxide is blended in an amount of 10% to 50% by weight of the total powder, preferably 15% to 25%, for example 20%. Preferably the dicalcium silicate is applied over a conventional bonding layer of alloy, such as Ni-22Cr-10Al-1.0Y (by weight)., or Ni-20Cr or Ni-50Cr, thermal sprayed on an alloy substrate. However, at high temperature the dicalcium silicate may react with the bonding alloy. Zirconia is less prone to such a reaction. Therefore, an advantageous coating is formed of a bonding layer of a thermal sprayed nickel or cobalt alloy on a metallic substrate, and an intermediate layer of a thermal sprayed partially or fully stabilized zirconium oxide. The layer of dicalcium silicate composition is thermal sprayed onto the intermediate layer, the bonding layer being between about 100 µm and 200 µm thick, and the intermediate layer preferably being between about 50 and 200 µm thick. The intermediate layer thereby blocks reaction between the bonding layer and the layer of dicalcium silicate composition. Applications for the coatings include burner cans, heat shields, blades, vanes and seals in gas turbine engines, rocket nozzles, piston crowns and valve faces in diesel engines, and contast rolls and tundish outlets in steel mills. While the invention has been described above in detail with reference to specific embodiments, various changes and modifications which fall within the spirit of the invention and scope of the appended claims will become apparent to those skilled in this art. Therefore, the invention is intended only to be limited by the appended claims or their equivalents.

Claims: A thermal spray powder comprising a substantially uniform powder composition consisting of dicalcium silicate, sodium, a further ingredient selected from the group consisting of phosphorous and zirconium, wherein the further ingredient comprises phosphorous, and incidental ingredients, such that the dicalcium silicate is stabilized in a larnite phase that is majority by volume, wherein the sodium recited as disodium monoxid is present in an amount of about 0.2% to 0.8%, and the phosphorous recited as phosphorous pentoxide is present in an amount of about 2.5% to 4%, the percentage being by weight of oxide based on the total composition. The powder of claim 1 wherein the incidental ingredients comprise aluminum recited as aluminum oxide up to 2%. The powder of claim 1 wherein the incidental ingredients comprise magnesium recited as magnesium oxide up to 0.5%. The powder of claim 1 wherein the further ingredient comprises zirconium. The powder of claim 4 wherein the sodium recited as disodium monoxide is present in an amount of about 0.2% to 0.8%, and the zirconium recited as zirconium dioxide is present in an amount of 10% to 50%, the percentages being by weight of oxide based on the total composition. The powder of claim 4 wherein the zirconium is at least partially in the form of zirconium dioxide containing calcium oxide as stabilizer of the zirconium dioxide. The powder of claim 4 wherein the zirconium is at least partially in the form of zirconium dioxide containing yttrium oxide as stabilizer of the zirconium dioxide. The powder of claim 1 having a size distribution within a range between 10 and 100 µm. The powder of claim 1 further comprising a powder of stabilized zirconium oxide in an amount of 10% to 50% blended with the powder composition of dicalcium silicate, based on the total weight of the powder. A process of manufacturing a thermal spray powder of dicalcium silicate having a stabilized crystal structure, comprising steps of: forming an aqueous mixture comprising calcium carbonate powder, silicon dioxide powder, and an organic binder containing as an integral constituent a stabilizing ingredient in an amount sufficient to stabilize the dicalcium silicate in a larnite phase that is majority by volume; wherein the stabilizing ingredients comprises sodium and a further ingredient selected from the group consisting of phosphorous and zirconium, wherein the further ingredient comprises phosphorous and incidental ingredients, wherein the sodium recited as disodium monoxid is present in a amount of 0.2% to 0.8%, and the phosporous recited as phosphorous pentoxide is present in an amount of 2.5% to 4%, the percentage being by weight of dried oxide, spray drying the aqueous mixture to form a spray dried powder; and heating the spray dried powder such that the dicalcium silicate is formed with larnite phase that is majority by volume. The process of claim 10 wherein the organic binder is sodium carboxymethylcellulose. The process of claim 11 wherein the compound of phosphorous is hydrous aluminum phosphate in aqueous solution. The process of claim 11 wherein the compound of phosphorous is hydrous aluminum phosphate in aqueous solution. The process of claim 10 wherein the aqueous mixture further comprises stabilized zirconium dioxide. The process of claim 14 wherein the zirconium dioxide contains calcium oxide as stabilizer. The process of claim 14 wherein the zirconium dioxide contains yttrium oxide as stabilizer. The process of claim 10 wherein each powder in the aqueous mixture has a size less than 20 µm. The process of claim 10 wherein the step of heating comprises sintering the powder. The process of claim 10 wherein the step of heating comprises feeding the powder through a plasma gun. A thermal spray coating comprising a layer of a substantially uniform coating composition consisting of dicalcium silicate, sodium, a further ingredient selected from the group consisting of phosphorous and zirconium, and incidental ingredients, the coating having a coating surface and a web of interconnected, randomly oriented microcracks substantially perpendicular to the coating surface. The coating of claim 20 wherein the further ingredient comprises phosphorous, and the dicalcium silicate is stabilized in a larnite phase that is majority by volume. The coating of claim 21 wherein the sodium recited as disodium monoxide is present in an amount of about 0.2% to 0.8%, and the phosphorous recited as phosphorous pentoxide is present in an amount of about 2.5% to 4%, the percentages being by weight of oxide based on the total composition. The coating of claim 21 wherein the incidental ingredients comprise aluminum recited as aluminum oxide up to 2%. The coating of claim 20 wherein the incidental ingredients comprise magnesium recited as magnesium oxide up to 0.5%. The coating of claim 20 wherein the further ingredient comprises zirconium. The coating of claim 25 wherein the sodium recited as disodium monoxide is present in an amount of 2% to 0.8%, and the zirconium recited as zirconium dioxide is present in an amount of about 10% to 50%, the percentages being by weight of oxide based on the total composition. The coating of claim 25 wherein the zirconium is at least partially in the form of zirconium dioxide containing calcium oxide as stabilizer of the zirconium dioxide. The coating of claim 25 wherein the zirconium is at least partially in the form of zirconium dioxide containing yttrium oxide as stabilizer of the zirconium dioxide. The coating of claim 20 wherein the coating contains between one and five microcracks per cm of coating surface. The coating of claim 20 wherein the layer of dicalcium silicate composition is between 50 µm and 200 µm thick. The coating of claim 20 further comprising a bonding layer of a thermal sprayed nickel or cobalt alloy on a metallic substrate, and an intermediate layer of a thermal sprayed partially or fully stabilized zirconium oxide, the layer of dicalcium silicate composition being thermal sprayed onto the intermediate layer, the bonding layer being between about 100 µm and 200 µm thick, and the intermediate layer being between about 50 µm and 200 µm thick, whereby the intermediate layer blocks reaction between the bonding layer and the layer of dicalcium silicate composition.

Inventors: CORREA LOUIS F, DORFMAN MITCHELL R, JANSEN FRANZ, PETERS JOHN, WEI XIAOHAN, CORREA, LOUIS F., DORFMAN, MITCHELL R., JANSEN, FRANZ, PETERS, JOHN, WEI, XIAOHAN
Applicants: SULZER METCO US INC, SULZER METCO (US) INC.
Application year: 2000
Main classification: C23C4
IPC codes: C23C4