Thermal spraying powder, thermal spraying method, and method for forming thermal spray coating

Abstract

A thermal spraying powder is characterized in that 90% particle size D90 of the thermal spraying powder is 15 μm or less. The thermal spraying powder is also characterized in that the ratio of the total volume of particles having a particle size of 1 μm or less to the total volume of all particles in the thermal spraying powder is 2% or less. A value obtained by dividing the bulk density of the thermal spraying powder by the theoretical density of material forming the thermal spraying powder is preferably 0.15 or more. The particle size dispersion index of the thermal spraying powder is preferably 0.7 or less. A thermal spray coating that is dense and has a small surface roughness is reliably formed using the thermal spraying powder.

1 . A thermal spraying powder, wherein 90% particle size D90 of the thermal spraying powder is 15 μm or less, and the ratio of the total volume of particles having a particle size of 1 μm or less to the total volume of all particles in the thermal spraying powder is 2% or less.  
   
   
       2 . The thermal spraying powder according to  claim 1 , wherein the 90% particle size D90 of the thermal spraying powder is 13 μm or less.  
   
   
       3 . The thermal spraying powder according to  claim 1 , wherein the ratio of the total volume of particles having a particle size of 1 μm or less to the total volume of all particles in the thermal spraying powder is 1.5% or less.  
   
   
       4 . The thermal spraying powder according to  claim 1 , wherein a value obtained by dividing the bulk density of the thermal spraying powder by the theoretical density of material forming the thermal spraying powder is 0.15 or more.  
   
   
       5 . The thermal spraying powder according to  claim 1 , wherein the particle size dispersion index of the thermal spraying powder is 0.7 or less.  
   
   
       6 . The thermal spraying powder according to  claim 1 , wherein the thermal spraying powder is a granulated and sintered powder.  
   
   
       7 . The thermal spraying powder according to  claim 1 , wherein particles in the thermal spraying powder consist of cermet.  
   
   
       8 . The thermal spraying powder according to  claim 7 , wherein the content of a ceramic component in the thermal spraying powder is 92% by mass or less.  
   
   
       9 . The thermal spraying powder according to  claim 7 , wherein the content of a metal component in the thermal spraying powder is 8% by mass or more.  
   
   
       10 . The thermal spraying powder according to  claim 7 , wherein the cermet includes tungsten carbide.  
   
   
       11 . The thermal spraying powder according to  claim 7 , wherein the cermet includes at least one of cobalt, chromium, and nickel.  
   
   
       12 . The thermal spraying powder according to  claim 1 , wherein the thermal spraying powder is used for forming a thermal spray coating through high-velocity flame spraying.  
   
   
       13 . A thermal spraying method, comprising spraying a thermal spraying powder, wherein 90% particle size D90 of the thermal spraying powder is 15 μm or less, and the ratio of the total volume of particles having a particle size of 1 μm or less to the total volume of all particles in the thermal spraying powder is 2% or less.  
   
   
       14 . A method for forming a thermal spray coating, the method comprising spraying a thermal spraying powder, wherein 90% particle size D90 of the thermal spraying powder being 15 μm or less, and the ratio of the total volume of particles having a particle size of 1 μm or less to the total volume of all particles in the thermal spraying powder is 2% or less.