Fujimi Incorporated

Tokyo Electron Limited

Tocalo Co., Ltd.

Hiroaki Mizuno

Junya Kitamura

Yoshiyuki Kobayashi

Tatsuo Suidzu

Kazuto Sato

Tsuyoshi Itsukaichi

Noriyuki Yasuo

Hiroyuki Ibe

Kazuyuki Tsuzuki

Takaya Masuda

Takeshi Takabatake

Isao Aoki

Kyohei Ota

Tatsuya Kuno

Nobuyuki Nagayama

Kazusei Tamai

Hitoshi Morinaga

Maiko Asai

Fumi Shinoda

Satoshi Tawada

Sho Hashimoto

Provided is a material for molding, without a mold, a highly uniform structure comprising a resin and a non-resin such as metals and ceramic. The molding material provided by this invention is formed of a powder comprising a resin and at least one species of non-resin selected among metals and ceramic. The resin material has a uniformity index N below 0.2. N is determined by depositting the powder in a softened or melted state to form a structure in a temperature range between the resin material's minimum molding temperature and maximum molding tempeature+100&#xb0; C.; measuring the structure's porosity Rn at 12 locations by image analysis; and dividing the variance of porosity Rn by the average porosity Rn. The minimum and maximum molding temperatures are the lowest and highest heater temperatures at which the resin material can be molded at a pressure of 3500 psi by injection molding, respectively.

Molding material for forming structure and molding method

A thermal spray powder is provided that contains, as constituent elements, a first element selected from W and Mo; a second element selected from Co, Ni, and Fe; a third element selected from C and B; and a fourth element formed of Si. The amount of the second element in the thermal spray powder is 40% by mole or less. The mole ratio of the fourth element to the second element in the thermal spray powder is 0.002 or greater and 0.03 or less. The thermal spray powder has a crystal phase containing Co, Ni, or Fe; W; and C or a crystal phase containing Co, Ni, or Fe; W or Mo; and B. In an X-ray diffraction spectrum of the thermal spray powder, the peak intensity attributed to Co, Ni, or Fe is at most 0.1 times the largest peak intensity in the same X-ray diffraction spectrum.

Powder for thermal spray, thermal spray coating film, coating film and roll in molten metal bath

A thermal spray powder is provided that contains, as constituent elements, a first element selected from W and Mo; a second element selected from Co, Ni, and Fe; a third element selected from C and B; and a fourth element selected from Al and Mg. The amount of the second element in the thermal spray powder is 20% by mole or greater. The mole ratio of the fourth element to the second element in the thermal spray powder is 0.05 or greater and 0.5 or less. The thermal spray powder has a crystal phase containing Co, Ni, or Fe; W; and C or a crystal phase containing Co, Ni, or Fe; W or Mo; and B. In an X-ray diffraction spectrum of the thermal spray powder, the peak intensity attributed to Co, Ni, or Fe is at most 0.1 times the largest peak intensity in the same X-ray diffraction spectrum.

Provided is an article having a novel surface with a texture different from conventional kinds. The article having a metal oxide-containing coating provided by the present invention comprises a substrate and a metal oxide-containing coating provided to the substrate surface. The metal oxide-containing coating has a Vickers hardness of 350 or higher, a surface roughness Ra of 300 nm or less, and a 20&#xb0; gloss value of 50 or higher.

Article comprising metal oxide-containing coating

A thermal spray slurry of the present invention contains ceramic particles having an average particle size of 200 nm or more and 5 &#x3bc;m or less. Precipitates formed when 700 mL of the thermal spray slurry is placed in a 16.5-cm-high cylindrical vessel having a volume of 1 L and is allowed to stand still at room temperature for 1 week are made to disappear by disposing, at a temperature of 20&#xb0; C. or higher and 30&#xb0; C. or lower, the cylindrical vessel so as for the central axis of the cylindrical vessel to be horizontal and by rotating the cylindrical vessel at a rotation speed of 100 rpm for 120 minutes around the central axis of the cylindrical vessel to stir the thermal spray slurry in the cylindrical vessel.

Slurry for thermal spraying, thermal sprayed coating, and method for forming thermal sprayed coating

A thermal spray slurry of the present invention contains ceramic particles in a content of 10% by mass or more and 85% by mass or less, and has a viscosity of 3,000 mPa&#xb7;s or less. The ceramic particles have an average particle size of, for example, 1 nm or more and 5 &#x3bc;m or less. The thermal spray slurry may further contain a dispersant. The thermal spray slurry may further contain a viscosity modifier. The thermal spray slurry may further contain a flocculant.

Slurry for thermal spraying, thermal spray coating, and method for forming thermal spray coating

A thermal spray powder of the present invention contains a rare earth element and a group 2 element, which belongs to group 2 of the periodic table. The thermal spray powder, which contains a rare earth element and a group 2 element, is formed, for example, from a mixture of a rare earth element compound and a group 2 element compound or from a compound or solid solution containing a rare earth element and a group 2 element. The thermal spray powder may further contain a diluent element that is not a rare earth element or a group 2 element and is not oxygen, which is at least one element selected, for example, from titanium, zirconium, hafnium, vanadium, niobium, tantalum, zinc, boron, aluminum, gallium, silicon, molybdenum, tungsten, manganese, germanium, and phosphorus.

Thermal spray powder and film that contain rare-earth element, and member provided with film

A thermal spray powder of the present invention contains a rare earth element and a diluent element that is not a rare earth element or oxygen, which is at least one element selected, for example, from zinc, silicon, boron, phosphorus, titanium, calcium, strontium, and magnesium. A sintered body of a single oxide of the diluent element has an erosion rate under specific etching conditions that is no less than 5 times the erosion rate of an yttrium oxide sintered body under the same etching conditions.

A thermal spray powder contains granulated and sintered particles composed of an oxide of any of the rare earth elements having an atomic number from 60 to 70. The average particle size of the primary particles constituting the granulated and sintered particles is 2 to 10 &#x3bc;m. The crushing strength of the granulated and sintered particles is 7 to 50 MPa. A plasma resistant member includes a substrate and a thermal spray coating provided on the surface of the substrate. The thermal spray coating is formed by thermal spraying, preferably plasma thermal spraying, the thermal spray powder.

Thermal spray powder, method for forming thermal spray coating, and plasma resistant member

A thermal spray powder including cermet particles, each of which contains metal containing at least one selected from the group consisting of cobalt, chrome, and nickel, and tungsten carbide. The ratio of the summed weight of cermet particles having a particle size of 25 &#x3bc;m or more in the thermal spray powder with respect to the summed weight of the entire cermet particles in the thermal spray powder is 0.5 to 15%. A thermal spray coating formed from the thermal spray powder is suitable for the formation of a tungsten carbide-based cermet thermal spray coating for use in rolls such as corrugated rolls.

Thermal spray powder and thermal spray coating

A thermal spray coating is made of cermet and provided on the surface of a base. The value that is gained by further dividing the value, which is gained by dividing the coefficient of thermal expansion of the thermal spray coating by the thickness of the thermal spray coating (unit: &#x3bc;m), by the coefficient of thermal expansion of the base is set to a value no less than 0.15&#xd7;10. Accordingly, peeling and cracking of the thermal spray coating can be prevented from being caused by the difference in the coefficient of thermal expansion between the thermal spray coating and the base.

Thermal spray coating and thermal spray powder

A thermal spraying powder contains granulated and sintered particles of an yttrium-aluminum double oxide formed by granulating and sintering raw-material particles. The crushing strength of the granulated and sintered particles is 15 MPa or more, and 10% particle size of the granulated and sintered particles is 6 &#x3bc;m or more. The thermal spraying powder is suitable for use in forming a thermal spray coating through plasma spraying.

Yttrium-aluminum double oxide thermal spraying powder

A thermal spraying powder contains 30 to 50% by mass of chromium carbide with the remainder being an alloy containing chromium, aluminum, yttrium, and at least one of cobalt and nickel. The thermal spraying powder has an average particle size of 20 to 60 &#x3bc;m. The thermal spraying powder may contain 20% by mass or less of yttrium oxide in place of a part of the alloy. A thermal spray coating obtained by thermal spraying of the thermal spraying powder, particularly, a thermal spray coating obtained by high-velocity flame spraying of the thermal spraying powder is suitable for the purpose of a hearth roll.

Thermal spraying powder comprising chromium carbide and alloy containing cobalt or nickel, thermal spray coating, and hearth roll

A thermal spray powder includes cermet particles. Each cermet particle includes tungsten carbide particles having a mean primary particle size of 3 to 9 &#x3bc;m and metal particles or ceramic particles containing chrome. The mean particle size of the cermet particles is preferably from 2 to 50 &#x3bc;m and the compression strength of each cermet particle is preferably from 400 to 900 MPa. Such a thermal spray powder enables the formation of a thermal sprayed coating which has both excellent cavitation erosion resistance and slurry erosion resistance.

Thermal spray powder

A thermal spraying powder includes granulated and sintered particles of an yttrium-aluminum double oxide obtained by granulating and sintering a raw powder containing yttrium and aluminum. The total volume of fine pores having a diameter of 6 &#x3bc;m or less in one gram of the granulated and sintered particles is 0.06 to 0.25 cm. The thermal spraying powder reliably forms a thermal spray coating that is suitable for use where the thermal spray coating is subjected to a thermal shock in a corrosive atmosphere or an oxidative atmosphere and for use where the thermal spray coating is subjected to a thermal shock in a state where the thermal spray coating contacts a member that has reactivity to a base material.

Growing community of inventors

Kiyosu, Japan

Hiroaki Mizuno