Method for forming thermal sprayed coating

Abstract

Provided is a method for forming a thermal sprayed coating, including a step of spraying a non-oxide ceramic material on a substrate to form a coating by a high velocity oxy-fuel spraying process. An average particle size of the non-oxide ceramic material is 0.1 to 5.0 μm, and a particle size distribution of the non-oxide ceramic material contains one or more peaks in each of: a particle size range of 0.1 μm or more and less than 1.0 μm; and a particle size range of 1.0 μm or more and less than 10.0 μm. The non-oxide ceramic material is dispersed in a solvent to prepare slurry 11, and the slurry 11 is fed from the exterior to flame 10 jetted from a thermal spray gun 2 to form a dense thermal sprayed coating structure.

1 . A method for forming a thermal sprayed coating, comprising a step of spraying a non-oxide ceramic material on a substrate to form a coating by a high velocity oxy-fuel spraying process, wherein
 an average particle size of the non-oxide ceramic material is  0 . 1  to  5 . 0  μm, and   a particle size distribution of the non-oxide ceramic material contains one or more peaks in each of:
 a particle size range of 0.1 μm or more and less than 1.0 μm; and 
 a particle size range of 1.0 μm or more and less than 10.0 μm. 
   
     
     
         2 . The method for forming a thermal sprayed coating according to  claim 1 , wherein in the non-oxide ceramic material, a volume ratio of a material having a particle size in a range of 1.0 μm or more and less than 10.0 μm to a material having a particle size in a range of 0.1 μm or more and less than 10.0 μm is 60% or more. 
     
     
         3 . The method for forming a thermal sprayed coating according to  claim 1 , wherein a suspension in which the non-oxide ceramic material is dispersed in a solvent is fed to flame. 
     
     
         4 . The method for forming a thermal sprayed coating according to  claim 3 , wherein the suspension is fed to flame jetted from a tip of a thermal spray nozzle. 
     
     
         5 . The method for forming a thermal sprayed coating according to  claim 1 , wherein the non-oxide ceramic material comprises a material containing one or more ceramics selected from the group consisting of carbide ceramics, nitride ceramics, and boride ceramics.