Wear-resistant Cu—Ni—Sn coating
The present disclosure relates to a method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process. Briefly, a copper-nickel-tin alloy feedstock is converted into a powder or droplet form, then sprayed onto a substrate to form a coating thereon.
1. A method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process, the steps comprising:
applying heat to a copper-nickel-tin alloy provided as a feedstock in the shape of a wire;
mixing the heated copper-nickel-tin alloy with a carrier gas to form a copper-nickel-tin alloy mixture; and
spraying the resulting copper-nickel-tin alloy mixture upon a substrate to provide a spinodal outer coating thereon.
2. The coating method of claim 1 , wherein the copper-nickel-tin alloy is about 8 wt % to about 22 wt % nickel, about 4 wt % to about 10 wt % tin, and the remaining balance is copper.
3. The coating method of claim 1 , wherein the thermal spray process is a cold spray, plasma spray, warm spray, detonation spray, high-velocity oxy fuel spray, or arc spray process.
4. The coating method of claim 1 , wherein the spraying occurs at a pressure of about 20 bar to about 40 bar.
5. The coating method of claim 1 , wherein the alloy mixture has a temperature of about 350° C. to about 700° C.
6. The coating method of claim 1 , wherein the coating has a thickness of about 100 micrometers to about 2000 micrometers.
7. The coating method of claim 1 , wherein the alloy mixture is sprayed at a velocity of 50 m/s to 1500 m/s.
8. A method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process, the steps comprising:
applying heat to a copper-nickel-tin alloy;
mixing the heated copper-nickel-tin alloy with a carrier gas to form a copper-nickel-tin alloy mixture; and
spraying the resulting copper-nickel-tin alloy mixture upon a substrate to provide a spinodal outer coating thereon, wherein the spraying occurs at a pressure of about 20 bar to about 40 bar.
9. The coating method of claim 8 , wherein the copper-nickel-tin alloy is about 8 wt % to about 22 wt % nickel, about 4 wt % to about 10 wt % tin, and the remaining balance is copper.
10. The coating method of claim 8 , wherein the thermal spray process is a cold spray, plasma spray, warm spray, detonation spray, high-velocity oxy fuel spray, or arc spray process.
11. The coating method of claim 8 , wherein the alloy mixture has a temperature of about 350° C. to about 700° C.
12. The coating method of claim 8 , wherein the coating has a thickness of about 100 micrometers to about 2000 micrometers.
13. The coating method of claim 8 , wherein the alloy mixture is sprayed at a velocity of 50 m/s to 1500 m/s.
14. A method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process, the steps comprising:
applying heat to a copper-nickel-tin alloy;
mixing the heated copper-nickel-tin alloy with a carrier gas to form a copper-nickel-tin alloy mixture; and
spraying the resulting copper-nickel-tin alloy mixture upon a substrate to provide a spinodal outer coating thereon, wherein the coating has a thickness of about 100 micrometers to about 2000 micrometers.
15. The coating method of claim 14 , wherein the copper-nickel-tin alloy is about 8 wt % to about 22 wt % nickel, about 4 wt % to about 10 wt % tin, and the remaining balance is copper.
16. The coating method of claim 14 , wherein the thermal spray process is a cold spray, plasma spray, warm spray, detonation spray, high-velocity oxy fuel spray, or arc spray process.
17. The coating method of claim 14 , wherein the spraying occurs at a pressure of about 20 bar to about 40 bar.
18. The coating method of claim 14 , wherein the alloy mixture has a temperature of about 350° C. to about 700° C.
19. The coating method of claim 14 , wherein the alloy mixture is sprayed at a velocity of 50 m/s to 1500 m/s.
20. A method of applying a wear-resistant copper-nickel-tin coating to a substrate using a thermal spray process, the steps comprising:
applying heat to a copper-nickel-tin alloy;
mixing the heated copper-nickel-tin alloy with a carrier gas to form a copper-nickel-tin alloy mixture; and
spraying the resulting copper-nickel-tin alloy mixture upon a substrate to provide a spinodal outer coating thereon, wherein the alloy mixture is sprayed at a velocity of 50 m/s to 1500 m/s.
21. The coating method of claim 20 , wherein the copper-nickel-tin alloy is about 8 wt % to about 22 wt % nickel, about 4 wt % to about 10 wt % tin, and the remaining balance is copper.
22. The coating method of claim 20 , wherein the thermal spray process is a cold spray, plasma spray, warm spray, detonation spray, high-velocity oxy fuel spray, or arc spray process.
23. The coating method of claim 20 , wherein the spraying occurs at a pressure of about 20 bar to about 40 bar.
24. The coating method of claim 20 , wherein the alloy mixture has a temperature of about 350° C. to about 700° C.
25. The coating method of claim 20 , wherein the coating has a thickness of about 100 micrometers to about 2000 micrometers.