US2011312860A1PendingUtilityA1

Wear-resistant and low-friction coatings and articles coated therewith

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Assignee: MATHEW PAULPriority: Jun 17, 2010Filed: Jun 17, 2010Published: Dec 22, 2011
Est. expiryJun 17, 2030(~3.9 yrs left)· nominal 20-yr term from priority
Inventors:Paul MathewKrishnamurthy AnandMohandas NayakMamatha NageshShalini Thimmegowda
C23C 4/04C23C 4/06C23C 4/10C23C 30/00C23C 24/04C09D 1/00C09D 5/38C23C 4/067
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Claims

Abstract

A composition for a wear-resistant and low-friction coating is presented. The coating composition includes a hard ceramic phase, a metallic binder phase and a lubricant phase. The lubricant phase includes a multi-component oxide. An article having a wear-resistant and low-friction coating and a method of making such a coating are also described.

Claims

exact text as granted — not AI-modified
1 . A coating composition, comprising:
 a hard ceramic phase,   a metallic binder phase; and   a lubricant phase comprising a multi-component oxide.   
     
     
         2 . The coating composition of  claim 1 , wherein the metallic binder phase is present at a level in the range from about 1% by volume to about 50% by volume of the total volume of the composition. 
     
     
         3 . The coating composition of  claim 1 , wherein the hard particle phase is present at a level in the range from about 20% by volume to about 90% by volume of the total volume of the composition. 
     
     
         4 . The coating composition of  claim 1 , wherein the lubricant phase is present at a level in the range from about 1% by volume to about 20% by volume of the total volume of the composition. 
     
     
         5 . The coating composition of  claim 1 , wherein the metallic binder phase comprises at least one metal selected from the group consisting of nickel, cobalt, iron, copper, silver and combinations thereof. 
     
     
         6 . The coating composition of  claim 1 , wherein the metallic binder phase further comprises at least one metal selected from the group consisting of tantalum, titanium, chromium, niobium, zirconium, molybdenum, silicon, boron, and vanadium. 
     
     
         7 . The coating composition of  claim 1 , wherein the metallic binder phase comprises nickel and chromium. 
     
     
         8 . The coating composition of  claim 7 , wherein the metallic binder phase comprises at least about 50% by weight nickel, based on the total weight of the metallic phase. 
     
     
         9 . The coating composition of  claim 1 , wherein the hard ceramic phase comprises a carbide, a boride, or an oxide of at least one element selected from the group consisting of tungsten, aluminum, chromium, tantalum, modyblednum, vanadium, zirconium, niobium or a combination thereof. 
     
     
         10 . The coating composition of  claim 9 , wherein the hard ceramic phase comprises chromium carbide. 
     
     
         11 . The coating composition of  claim 9 , wherein the boride is selected from the group consisting of titanium diboride, zirconium diboride, tantalum boride, tungsten boride, and a combination thereof. 
     
     
         12 . The coating composition of  claim 1 , wherein the hard ceramic phase comprises particles having a particle size in the range from about 0.1 micron to about 100 microns. 
     
     
         13 . The coating composition of  claim 1 , wherein the metallic binder phase comprises particles having a particle size in the range from about 0.1 micron to about 5 microns. 
     
     
         14 . The coating composition of  claim 1 , wherein the multi-component oxide comprises at least one oxide having ionic potential greater than about 4 k′. 
     
     
         15 . The coating composition of  claim 14 , wherein the multi-component oxide comprises at least one oxide having ionic potential greater than about 5 k′. 
     
     
         16 . The coating composition of  claim 1 , wherein the multi-component oxide is a binary oxide, a ternary oxide or a tetranary oxide. 
     
     
         17 . The coating composition of  claim 16 , wherein the multi-component oxide comprises at least a metal oxide selected from the group consisting of nickel oxide, alumina, titanium oxide, tantalum oxide, zinc oxide, molybdenum oxide and magnesium oxide. 
     
     
         18 . The coating composition of  claim 1 , wherein the multi-component oxide is a binary oxide. 
     
     
         19 . The coating composition of  claim 18 , wherein the binary oxide is selected from the group consisting of NiO—B 2 O 3 , NiO—TiO 2 , NiO—Ta 2 O 5  and MgO—SiO 2 . 
     
     
         20 . The coating composition of  claim 18 , wherein the binary oxide comprises constituent oxides present in a ratio (by weight) varying from about 1:1 to about 1:10. 
     
     
         21 . The coating composition of  claim 20 , wherein the binary oxide comprises constituent oxides present in a ratio (by weight) varying from about 1:1 to about 1:5. 
     
     
         22 . The coating composition of  claim 1 , wherein the lubricant phase comprises particles having a particle size in the range from about 0.05 microns to about 20 microns. 
     
     
         23 . The coating composition of  claim 22 , wherein the lubricant phase comprises particles having a particle size in the range from about 0.1 microns to about 10 microns. 
     
     
         24 . An article comprising:
 a metallic substrate; and   a wear-resistant and low-friction coating disposed on the substrate, wherein the coating composition comprises:
 a hard ceramic phase, 
 a metallic binder phase; and 
 a lubricant phase comprising a multi-component oxide. 
   
     
     
         25 . The article of  claim 24 , wherein the metallic substrate comprises a component of turbine engine. 
     
     
         26 . The article of  claim 24 , wherein the metallic substrate comprises a superalloy based on nickel, cobalt, iron, aluminum, or titanium. 
     
     
         27 . The article of  claim 24 , wherein the multi-component oxide is a binary oxide. 
     
     
         28 . The article of  claim 27 , wherein the binary oxide is selected from the group consisting of NiO—B 2 O 3 , NiO—TiO 2 , NiO—Ta 2 O 5  and MgO—SiO 2 . 
     
     
         29 . The article of  claim 27 , wherein the binary oxide comprises constituent oxides present in a ratio (by weight) varying from about 1:1 to about 10:1. 
     
     
         30 . The article of  claim 29 , wherein the binary oxide comprises constituent oxides present in a ratio (by weight) varying from about 1:1 to about 1:5. 
     
     
         31 . A method of making a composition for a wear-resistant and low-friction coating, comprising the step of:
 milling a hard ceramic phase and a metallic binder phase to make a mixture; and   dispersing a lubricant phase in the mixture, wherein the lubricant phase comprises a multi-component oxide.   
     
     
         32 . The method of  claim 31 , wherein milling is carried out in a high energy mill. 
     
     
         33 . The method of  claim 31 , wherein dispersing comprises adding and milling the lubricant phase with the mixture.

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