Method of forming metallic carbide based wear resistant coating on a combustion turbine component

Abstract

A method of forming a wear resistant coating on a combustion turbine component includes melting an ingot including at least one metallic carbide to form a metallic liquid including at least one metallic carbide. The metallic liquid including at least one metallic carbide is atomized in an atmosphere to form a metallic powder including at least one metallic carbide. The metallic powder including at least one metallic carbide is milled to form a nanosized metallic powder including at least one metallic carbide. The nanosized metallic powder including at least one metallic carbide is thermally sprayed onto the combustion turbine component.

1 . A method of forming a wear resistant coating on a combustion turbine component comprising:
 melting an ingot comprising at least one metallic carbide to form a metallic liquid comprising at least one metallic carbide;   atomizing the metallic liquid comprising at least one metallic carbide in an atmosphere to form a metallic powder comprising at least one metallic carbide;   milling the metallic powder comprising at least one metallic carbide to form a nanosized metallic powder comprising at least one metallic carbide; and   thermal spraying the nanosized metallic powder comprising at least one metallic carbide onto the combustion turbine component.   
     
     
         2 . A method according to  claim 1  further comprising blending the nanosized metallic powder comprising at least one metallic carbide with at least one of carbon nanotubes and silver prior to thermal spraying. 
     
     
         3 . A method according to  claim 1  wherein atomizing comprises atomizing by vapor phase deposition; and further comprising agglomerating the nanosized metallic powder comprising at least one metallic carbide prior to thermal spraying. 
     
     
         4 . A method according to  claim 1  wherein the at least one metallic carbide comprises tungsten carbide. 
     
     
         5 . A method according to  claim 1  wherein the at least one metallic carbide comprises chromium carbide. 
     
     
         6 . A method according to  claim 1  wherein the ingot further comprises at least one of cobalt, chromium, and nickel. 
     
     
         7 . A method according to  claim 1  wherein the atmosphere comprises an inert atmosphere. 
     
     
         8 . A method according to  claim 1  wherein the atmosphere comprises an oxidizing atmosphere. 
     
     
         9 . A method according to  claim 1  wherein milling the metallic powder comprises at least one of cryomilling, ball milling, and jet milling. 
     
     
         10 . A method according to  claim 1  wherein thermal spraying comprises at least one of thermal combustion spraying, thermal plasma spraying, air plasma spraying, and high velocity oxygen fuel spraying. 
     
     
         11 . A method of forming a wear resistant coating on a combustion turbine component comprising:
 melting an ingot comprising tungsten carbide and cobalt to form a metallic liquid comprising tungsten carbide and cobalt;   atomizing the metallic liquid comprising tungsten carbide and cobalt in an inert atmosphere to form a metallic powder comprising tungsten carbide and cobalt;   milling the metallic powder comprising tungsten carbide and cobalt to form a nanosized metallic powder comprising tungsten carbide and cobalt; and   thermal spraying the nanosized metallic powder comprising tungsten carbide and cobalt onto the combustion turbine component.   
     
     
         12 . A method according to  claim 11  further comprising blending the nanosized metallic powder comprising tungsten carbide and cobalt with at least one of carbon nanotubes and silver prior to thermal spraying. 
     
     
         13 . A method according to  claim 11  wherein atomizing comprises atomizing by vapor phase deposition; and further comprising agglomerating the nanosized metallic powder comprising tungsten carbide and cobalt prior to thermal spraying. 
     
     
         14 . A method according to  claim 11  wherein milling the metallic powder comprises at least one of cryomilling, ball milling, and jet milling. 
     
     
         15 . A method according to  claim 11  wherein thermal spraying comprises at least one of thermal combustion spraying, thermal plasma spraying, air plasma spraying, and high velocity oxygen fuel spraying. 
     
     
         16 . A method of forming a wear resistant coating on a combustion turbine component comprising:
 melting an ingot comprising chromium carbide, nickel, and chromium to form a metallic liquid comprising chromium carbide, nickel, and chromium;   atomizing the metallic liquid comprising chromium carbide, nickel, and chromium in an oxidizing atmosphere to form a metallic powder comprising chromium carbide, nickel, and chromium;   milling the metallic powder comprising chromium carbide, nickel, and chromium to form a nanosized metallic powder comprising chromium carbide, nickel, and chromium; and   thermal spraying the nanosized metallic powder comprising chromium carbide, nickel, and chromium onto the combustion turbine component.   
     
     
         17 . A method according to  claim 16  further comprising blending the nanosized metallic powder comprising chromium carbide, nickel, and chromium with at least one of carbon nanotubes and silver prior to thermal spraying. 
     
     
         18 . A method according to  claim 16  wherein atomizing comprises atomizing by vapor phase deposition; and further comprising agglomerating the nanosized metallic powder comprising chromium carbide, nickel, and chromium prior to thermal spraying. 
     
     
         19 . A method according to  claim 16  wherein milling the metallic powder comprises at least one of cryomilling, ball milling and jet milling. 
     
     
         20 . A method according to  claim 16  wherein thermal spraying comprises at least one of thermal combustion spraying, thermal plasma spraying, air plasma spraying, and high velocity oxygen fuel spraying.