Sprayable composition

Abstract

The present invention provides a sprayable composition comprising a ceramic particulate including albite, illite, and quartz, and a metallic composition, including nickel, chromium, iron, and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire. The present invention further provides an abradable coating formed on a metal substrate according to a method comprising the step of depositing a bond coat on the metal substrate by thermal spraying of a bond coat composition comprising nickel, chromium and optionally aluminum and yttrium on the metal substrate and depositing the abradable coating on the bond coat by thermal spraying of a sprayable composition comprising a ceramic particulate including albite, illite, and quartz, and a metallic composition, including nickel, chromium, iron and silicon. The sprayable composition may be a composite particle, a blend, or a cored wire. The abradable coating may be applied to the top of the bond coat that is applied to a metal substrate such as steel, nickel-based alloys, and titanium.

1 . A method of producing an abradable coating adhered to a metal substrate comprising the steps of: 
 depositing a bond coat on the metal substrate by thermally spraying a sprayable composition comprising about 60 to about 85 wt % nickel, about 15 to about 25 wt % chromium, about 0 to about 15 wt % aluminum and about 0 to about 2 wt % yttrium; and    depositing an abradable coating on the bond coat by thermal spraying a sprayable abradable composition comprising: 
 a ceramic particulate including albite, illite, and quartz; and  
 a metallic composition including nickel, chromium, iron and silicon.  
   
   
   
       2 . The method as claimed in  claim 1 , in which the bond coat comprises about 67 wt % nickel, about 22 wt % chromium, about 10 wt % aluminum and about 1.0 wt % yttrium.  
   
   
       3 . The method as claimed in  claim 1 , in which the bond coat comprises about 80 wt % nickel and about 20 wt % chromium.  
   
   
       4 . The method as claimed in claims  1 ,  2  or  3 , wherein the sprayable abradable composition is a composite powder and the metallic composition is adhered to a surface of the ceramic particulate.  
   
   
       5 . The method as claimed in any one of  claims 1  to  4 , wherein the ceramic particulate consists essentially of albite, illite, and quartz.  
   
   
       6 . The method as claimed in any of  claims 1  to  4 , wherein the ceramic particulate includes about 20 to about 60 weight percent albite, about 15 to about 45 weight percent illite, and about 15 to about 45 weight percent quartz.  
   
   
       7 . The method as claimed in any of  claims 1  to  4 , wherein the ceramic particulate includes about 40 weight percent albite, about 30 weight percent illite, and about 30 weight percent quartz.  
   
   
       8 . The method as claimed in any one of  claims 1  to  7 , wherein the metallic composition includes about 14 to about 25 weight percent chromium, about 1.5 to about 4 weight percent iron, and about 0.1 to about 0.6 weight percent silicon, and the balance essentially nickel.  
   
   
       9 . The method as claimed in any one of  claims 1  to  7 , wherein the metallic composition comprises 15.0 to 18.1 wt % chromium, 2.45 to 2.71 wt % iron, 0.43 to 0.45 wt % silicon, and the balance essentially nickel.  
   
   
       10 . A metal substrate including an abradable coating adherently bonded to the metal substrate comprising a bond coat deposited on the metal substrate, said bond coat comprising about 60 to about 85 wt % nickel, about 15 to about 25 wt % chromium, about 0 to about 15 wt % aluminum and 0 to about 2 wt % yttrium, and the abradable coating adherently bonded to the bond coat, said abradable coating comprising: 
 a matrix including a metallic composition, the metallic composition including nickel, chromium, iron and silicon; and    a ceramic particulate, including albite, illite, and quartz;    wherein the ceramic particulate is dispersed within the matrix.    
   
   
       11 . The metal substrate as claimed in  claim 10 , in which the bond coat comprises about 67 wt % nickel, about 22 wt % chromium, about 10 wt % aluminum and about 1.0 wt % yttrium.  
   
   
       12 . The metal substrate as claimed in  claim 10 , in which the bond coat comprises about 80 wt % nickel and about 20 wt % chromium.  
   
   
       13 . The metal substrate as claimed in any one of  claims 10  to  12 , wherein the ceramic particulate consists essentially of albite, illite, and quartz.  
   
   
       14 . The metal substrate as claimed in any one of  claims 10  to  12 , wherein the ceramic particulate includes about 20 to about 60 weight percent albite, about 15 to about 45 weight percent illite, and about 15 to about 45 weight percent quartz.  
   
   
       15 . The metal substrate as claimed in any one of  claims 10  to  12 , wherein the ceramic particulate includes about 40 weight percent albite, about 30 weight percent illite, and about 30 weight percent quartz.  
   
   
       16 . The metal substrate as claimed in any one of  claims 10  to  15 , wherein the metallic composition includes about 14 to about 25 weight percent chromium, about 1.5 to about 4 weight percent iron, and about 0.1 to about 0.6 weight percent silicon, and the balance essentially nickel.  
   
   
       17 . The metal substrate as claimed in any one of  claims 10  to  15 , wherein the metallic composition comprises 15.0 to 18.1 wt % chromium, 2.45 to 2.71 wt % iron, 0.43 to 0.45 wt % silicon, and the balance essentially nickel.