Method of producing thermal spray powder, manufacture apparatus of thermal spray powder, and thermal spray powder produced by the producing method
View Patent ↗A method for producing a thermal spray powder includes: a preparing step of preparing a powder mixture containing a first particle made from zirconia-based ceramic containing a first additive agent and a second particle made from zirconia-based ceramic containing a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm; and a secondary-particle producing step of producing a plurality of secondary particles each of which includes the first particle and the second particle sintered with each other.
1. A method for producing a thermal spray powder, comprising:
a preparing step of preparing a powder mixture comprising a first particle made from a zirconia-based ceramic comprising a first additive agent of yttrium oxide and a second particle made from a zirconia-based ceramic comprising a second additive agent of ytterbium oxide, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm; and
a secondary-particle producing step of producing a plurality of secondary particles each of which comprises the first particle and the second particle sintered with each other.
2. A method for producing a thermal spray powder, comprising:
a preparing step of preparing a powder mixture comprising a first particle made from a zirconia-based ceramic comprising a first additive agent and a second particle made from a zirconia-based ceramic comprising a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm;
a secondary-particle producing step of producing a plurality of secondary particles each of which comprises the first particle and the second particle sintered with each other; and
a secondary-particle classifying step of obtaining a powder having a 10% cumulative particle diameter of not less than 20 μm and not more than 150 μm from the secondary particles obtained in the secondary-particle producing step.
3. The method for producing a thermal spray powder according to claim 1 ,
wherein the powder mixture has a 10% cumulative particle diameter of not more than 5 μm.
4. The method for producing a thermal spray powder according to claim 1 ,
wherein the secondary-particle producing step comprises:
a powder agglomeration step of producing a plurality of intermediate particles each comprising the first particle and the second particle by a spray dry method, and
a heat treatment step of performing heat treatment on the intermediate particles to obtain the secondary particles.
5. The method for producing a thermal spray powder according to claim 1 , further comprising a secondary-particle classifying step of obtaining a powder having a 10% cumulative particle diameter of not less than 20 μm and not more than 150 μm from the secondary particles obtained in the secondary-particle producing step.
6. The method for producing a thermal spray powder according to claim 1 , wherein the preparing step further comprises:
a non-adhering particle recovery step of recovering a plurality of first non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the first additive agent, and a plurality of second non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the second additive agent; and
a powder crushing step of crushing the plurality of first non-adhering particles and the plurality of second non-adhering particles collectively.
7. The method for producing a thermal spray powder according to claim 2 ,
wherein the first additive agent is yttrium oxide, and
wherein the second additive agent is ytterbium oxide.
8. The method for producing a thermal spray powder according to claim 2 ,
wherein the powder mixture has a 10% cumulative particle diameter of not more than 5 μm.
9. The method for producing a thermal spray powder according to claim 2 ,
wherein the secondary-particle producing step comprises:
a powder agglomeration step of producing a plurality of intermediate particles each comprising the first particle and the second particle by a spray dry method, and
a heat treatment step of performing heat treatment on the intermediate particles to obtain the secondary particles.
10. The method for producing a thermal spray powder according to claim 2 ,
wherein the preparing step further comprises:
a non-adhering particle recovery step of recovering a plurality of first non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the first additive agent, and a plurality of second non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the second additive agent; and
a powder crushing step of crushing the plurality of first non-adhering particles and the plurality of second non-adhering particles collectively.
11. A method for producing a thermal spray powder comprising:
(i) a preparing step comprising:
preparing a powder mixture comprising a first particle made from a zirconia-based ceramic comprising a first additive agent and a second particle made from a zirconia-based ceramic comprising a second additive agent, the powder mixture having a 10% cumulative particle diameter of more than 0 μm and not more than 10 μm;
a non-adhering particle recovery step of recovering a plurality of first non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the first additive agent, and a plurality of second non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from the zirconia-based ceramic comprising the second additive agent; and
a powder crushing step of crushing the plurality of first non-adhering particles and the plurality of second non-adhering particles collectively; and
(ii) a secondary-particle producing step of producing a plurality of secondary particles each of which comprises the first particle and the second particle sintered with each other.
12. The method for producing a thermal spray powder according to claim 11 ,
wherein, in the non-adhering particle recovery step, a plurality of third non-adhering particles which remain unattached to a spray target after spraying a plurality of particles made from metal is recovered along with the plurality of first non-adhering particles and the plurality of second non-adhering particles, and
wherein the method further comprises a selecting step of separating the plurality of third non-adhering particles from the plurality of first non-adhering particles and the second non-adhering particles.
13. The method for producing a thermal spray powder according to claim 11 , further comprising:
a secondary-particle classifying step of obtaining a powder having a 10% cumulative particle diameter of not less than 20 μm and not more than 150 μm from the secondary particles obtained in the secondary-particle producing step,
wherein the preparing step further comprises an irregular-particle recovery step of recovering irregular particles excluded in the secondary-particle classifying step, and
wherein, in the powder crushing step, the plurality of first non-adhering particles, the plurality of second non-adhering particles, and the irregular particles are crushed collectively.
14. The method for producing a thermal spray powder according to claim 11 ,
wherein, in the non-adhering particle recovery step, the plurality of first non-adhering particles and the plurality of second non-adhering particles are recovered by a dust collector.
15. The method for producing a thermal spray powder according to claim 11 ,
wherein the first additive agent is yttrium oxide, and
wherein the second additive agent is ytterbium oxide.
16. The method for producing a thermal spray powder according to claim 11 ,
wherein the powder mixture has a 10% cumulative particle diameter of not more than 5 μm.
17. The method for producing a thermal spray powder according to claim 11 ,
wherein the secondary-particle producing step comprises:
a powder agglomeration step of producing a plurality of intermediate particles each comprising the first particle and the second particle by a spray dry method, and
a heat treatment step of performing heat treatment on the intermediate particles to obtain the secondary particles.
18. The method for producing a thermal spray powder according to claim 11 , further comprising a secondary-particle classifying step of obtaining a powder having a 10% cumulative particle diameter of not less than 20 μm and not more than 150 μm from the secondary particles obtained in the secondary-particle producing step.