Ebara Corporation

Japan Science and Technology Agency

Sapporo Electroplating Industrial Co., Ltd.

Other

Dai-ichi High Frequency Co., Ltd.

Ebara Environmental Plant Co., Ltd.

Narita, Toshio

Shigenari Hayashi

Toshio Narita

Hiroshi Yakuwa

Takayuki Yoshioka

Manabu Noguchi

Michiaki Souma

Matsuho Miyasaka

Eiji Ishikawa

Takashi Kogin

Eichi Tanaka

Nobuhiro Takasaki

Michihisa Fukumoto

Kenichiro Okutsu

Masaya Kanazawa

Yasuki Miyakoshi

Hidenori Takahashi

Suzue Yoneda

Takayuki Saitou

Mohammad Emami

Provided are an alloy powder having excellent environmental resistance even in an environment where corrosion and wear are active simultaneously, and an alloy coating using the powder. A Ni&#x2014;Fe base alloy powder comprising Cr of 15% by mass or more and 35% by mass or less, Fe of 10% by mass or more and 50% by mass or less, Mo of 0% by mass or more and 5% by mass or less, Si of 0.3% by mass or more and 2% by mass or less, C of 0.3% by mass or more and 0.9% by mass or less, B of 4% by mass or more and 7% by mass or less, and a balance of Ni and incidental impurities.

Ni&#x2014;Fe base alloy powder, and method for producing alloy coating using said Ni&#x2014;Fe base alloy powder

There are provided a Ni-based thermal spraying alloy powder having excellent corrosion resistance and erosion-corrosion resistance even in an environment in which corrosion acts or corrosion and erosion act simultaneously, and a method for manufacturing an alloy coating. A Ni-based thermal spraying alloy powder comprising Cr: 15 wt % or more and 25 wt % or less, Mo: 0 wt % or more and 5 wt % or less, Si: 0.5 wt % or more and less than 2 wt %, Fe: 5 wt % or less, C: 0.3 wt % or more and 0.7 wt % or less, and B: 4 wt % or more and 7 wt % or less, with the balance being Ni and incidental impurities.

Ni-based thermal spraying alloy powder and method for manufacturing alloy coating

Disclosed is a method of forming a high-temperature corrosion-resistant film, which comprises placing a container containing a film-forming fine powder and a target member capable of being heated by an electric current heating process, in an atmosphere-controllable treatment chamber, and floating the fine powder and subjecting the target member to the electric current heating process to allow vapor of the fine powder generated by the heating to be diffused into the target member from a surface thereof so as to form a diffusion film layer, and allow the floated fine powder to be attached onto the surface so as to form a fine-powder film layer on the diffusion film layer. The target member may be masked to form the film only in a non-masked region of the target member. Alternatively, a specific region of the target member may be cooled at a temperature precluding the film formation to prevent the film from being formed in the specific region. The method of the present invention makes it possible to form a high-temperature corrosion-resistant film having an 'intended configuration' in a 'desired region' of a heat-resistant material at &#x201c;low cost&#x201d; with &#x201c;high productivity&#x201d;.

Method of forming high temperature corrosion resistant film

Disclosed is a method for forming a high-Re-content alloy film, such as a Re-based film containing Re at 98% or more by atomic composition, or an alloy film containing Re in the range of 65 to less than 98% by atomic composition and at least one of Ni, Fe and Co. The method comprises performing an electroplating process using an electroplating bath containing an aqueous solution which includes a perrhenate ion, at least one ion selected from the group consisting of Ni, Fe, Co and Cr ions, and at least one of a Li ion and a Na ion. The present invention allows a high-Re-content alloy film usable as a corrosion-resistant alloy coating for a high-temperature component or the like to be formed through an electroplating process using an aqueous solution, so as to provide heat/corrosion resistances to the component, even if it has a complicated shape, in a simplified manner at a low cost.

Method for forming Re alloy coating film having high-Re-content through electroplating

Disclosed is a Re alloy coating for diffusion barrier, such as a high-temperature equipment member, which comprises an atomic composition of 30% to less than 90% Re; and an atomic composition of 5% to less than 60% X (wherein X is at least one selected from the group consisting of Cr, Mo and W), with the remainder except for inevitable impurities being at least one selected from the group consisting of Ni, Fe and Co. Even if the alloy coating for diffusion barrier includes a diffusion layer containing at least one of the group consisting of Al, Si and Cr, a desired alloy composition of the alloy coating for diffusion barrier can be assured by a surface coating process and diffused components from the substrate while substantially preventing the diffusion of the elements of the diffusion layer during a homogenizing heat treatment. The alloy coating for diffusion barrier may include a Re-containing-alloy stress relief layer inserted between the film and the substrate. The Re alloy coating can suppress the deterioration of the substrate and the coating layer due to the reaction therebetween to provide an extended life span of the equipment member.

Re alloy coating for diffusion barrier

Disclosed is a ReCrNi alloy coating for diffusion barrier, such as a high-temperature equipment member, consisting essentially of a ternary alloy and having, except for inevitable impurities, an atomic composition of 20% to 80% Re, an atomic composition of 20% to 60% Cr, and an atomic composition of 5% to 40% Ni. Even if the alloy coating for diffusion barrier includes a diffusion layer containing at least one of the group consisting of Al, Si and Cr, a desired alloy composition of the alloy coating for diffusion barrier can be assured by a surface coating process and diffused components from the substrate while substantially preventing the diffusion of the elements of the diffusion layer during a homogenizing heat treatment. The alloy coating for diffusion barrier may include a Re-containing-alloy stress relief layer inserted between the film and the substrate. The ReCrNi alloy coating can suppress the deterioration of the substrate and the coating layer due to the reaction therebetween to provide an extended life span of the equipment member.

ReCrNi alloy coating for diffusion barrier

Disclosed is a ReCr alloy coating for diffusion barrier formed on a substrate, such as a high-temperature equipment member, which comprises an atomic composition of 50% to less than 90% Re, with the remainder consisting essentially of Cr except for inevitable impurities. Even if the alloy coating for diffusion barrier includes a diffusion layer containing at least one of the group consisting of Al, Si and Cr, a desired alloy composition of the alloy coating for diffusion barrier can be assured by a surface coating process and diffused components from the substrate while substantially preventing the diffusion of the elements of the diffusion layer during a homogenizing heat treatment. The alloy coating for diffusion barrier may include a Re-containing-alloy stress relief layer inserted between the film and the substrate. The ReCr&#x2014;Ni alloy coating can suppress the deterioration of the substrate and the coating layer due to the reaction therebetween to provide an extended life span of the equipment member.

ReCr alloy coating for diffusion barrier

Disclosed is a method for forming a Re&#x2014;Cr alloy film consisting of Re in the range of 60 to 90% by atomic composition. The method comprises performing an electroplating process using an electroplating bath containing an aqueous solution which includes a perrhenate ion and a chromium (VI) ion. The present invention allows a Re&#x2014;Cr alloy film usable as a corrosion-resistant alloy coating for a high-temperature component or the like to be formed through an electroplating process using an aqueous solution, so as to provide heat/corrosion resistances to the component, even if it has a complicated shape, in a simplified manner at a low cost.

Method for forming Re-Cr alloy film through electroplating process using bath containing Cr(VI)

Disclosed is a method for forming: a Re&#x2014;Cr alloy film consisting of Re in the range of greater than 0 (zero) to less than 98% by atomic composition, and the remainder being Cr except inevitable impurities; a Re-based film consisting of 98% or more, by atomic composition, of Re, with the remainder being Cr and inevitable impurities; or a Re&#x2014;Cr&#x2014;Ni alloy film consisting of Re in the range of 50 to less than 98% by atomic composition, Cr in the range of 2 to less than 45% by atomic composition, and the remainder being Ni except inevitable impurities. The method comprises performing an electroplating process using an electroplating bath containing an aqueous solution which includes a perrhenate ion and a chromium (III) ion. The present invention allows a Re&#x2014;Cr alloy, Re-based or Re&#x2014;Cr&#x2014;Ni alloy film usable as a corrosion-resistant alloy coating for a high-temperature component or the like to be formed through an electroplating process using an aqueous solution, so as to provide heat/corrosion resistances to the component, even if it has a complicated shape, in a simplified manner at a low cost.

Method for forming Re&#x2014;Cr alloy film or Re-based film through electroplating process

Disclosed is an alloy coating which can be advantageously applied to members for high temperature apparatuses so as to prolong the service life of the members. The alloy coating comprises an alloy. This alloy comprises: at least one member, as a base, selected from the group consisting of Re, Ir, Nb, Ta, Mo, and W; and at least one alloying element for imparting corrosion resistance. A method for forming the alloy coating, and a member for high temperature apparatuses, to which the alloy coating has been applied, are also disclosed.

Growing community of inventors

Hokkaido, Japan

Shigenari Hayashi