Thermal Spray of Repair and Protective Coatings

Abstract

This invention provides a method for graphene or graphene oxide reinforcement in a metallic thermal spray coating. The incredible properties of graphene and graphene oxide make them attractive options to increase the mechanical properties in a variety of materials. Recent developments in the manufacturing of graphene oxide and reduced graphene oxide powders have greatly reduced their cost, making them viable additives in thermal spray powders for widespread use in industry.

What is claimed is: 
     
         1 . A method of depositing a composite on a surface comprising:
 providing a surface;   providing graphene/graphene oxide flakes;   providing metal and/or metal oxide powder; and   thermally spraying the graphene/graphene oxide flakes together with the metal and/or metal oxide material on the surface, whereby the resulting composite has enhance mechanical and corrosion resistant properties.   
     
     
         2 . The method of  claim 1 , wherein the graphene/graphene oxide flakes and the metal and/or metal oxide material are dry mixed together prior to spraying. 
     
     
         3 . The method of  claim 1 , wherein the metal and/or metal oxide powder is Ni/Al 2 O 3  powder. 
     
     
         4 . The method of  claim 1 , wherein the graphene/graphene oxide flakes are introduced as an atomization of a suspension separately from the metallic powder. 
     
     
         5 . The method of  claim 4 , wherein the graphene/graphene oxide flakes are suspended in water or another polar solvent. 
     
     
         6 . The method of  claim 5 , wherein the concentration of the graphene/graphene oxide flakes suspension is from 0.1% and 0.5% wt. 
     
     
         7 . The method of  claim 6 , wherein the graphene/graphene oxide flakes has an oxidation level >1% wt. 
     
     
         8 . The method of  claim 4 , wherein the graphene/graphene oxide flakes are suspended in ethanol or another non-polar solvent. 
     
     
         9 . The method of  claim 8 , wherein the concentration of the graphene/graphene oxide flakes suspension is from 0.1% and 0.5% wt. 
     
     
         10 . The method of  claim 8 , wherein the graphene/graphene oxide flakes has an oxidation level >1% wt. 
     
     
         11 . A method of depositing a composite on a surface comprising:
 providing a surface;   providing crystalline graphene oxide flakes suspended in water or another polar solvent;   providing metal and/or metal oxide powder; and   thermally spraying the crystalline graphene oxide flakes together with the metal and/or metal oxide material on the surface, whereby the resulting composite has enhance mechanical and corrosion resistant properties.   
     
     
         12 . The method of  claim 11 , wherein the crystalline graphene/graphene oxide flakes and the metal and/or metal oxide material are dry mixed together prior to spraying. 
     
     
         13 . The method of  claim 11 , wherein the metal and/or metal oxide powder is Ni/Al 2 O 3  powder. 
     
     
         14 . The method of  claim 11 , wherein the crystalline graphene/graphene oxide flakes are introduced as an atomization of a suspension separately from the metallic powder. 
     
     
         15 . The method of  claim 14 , wherein the crystalline graphene/graphene oxide flakes are suspended in water are from 0.1% to 0.5% wt to volume. 
     
     
         16 . The method of  claim 15 , wherein the concentration of crystalline graphene/graphene oxide flakes in the suspension is from 0.1% to 0.5% wt to volume in a polar solvent. 
     
     
         17 . The method of  claim 16 , wherein the crystalline graphene/graphene oxide flakes has an oxidation level >1% wt. 
     
     
         18 . The method of  claim 14 , wherein the crystalline graphene/graphene oxide flakes are suspended in ethanol or another non-polar solvent. 
     
     
         19 . The method of  claim 18 , wherein the concentration of the crystalline graphene/graphene oxide flakes suspension is from 0.1% and 0.5% wt. 
     
     
         20 . The method of  claim 18 , wherein the crystalline graphene/graphene oxide flakes has an oxidation level >1% wt.