Flame spray powder of cobalt-molybdenum mixed metal agglomerates using a molybdenum salt binder and process for producing same

Claim 2

A flame spray powder consisting essentially of particle agglomerates of finely divided particulates of a metal selected from the group consisting of molybdenum and its alloys, and a compound of cobalt selected from the group consisting of cobalt oxides, cobalt hydroxides and cobalt oxalates, the agglomerates held together by at least one binder consisting essentially of spray dried ammonium molybdate, the spray dried ammonium molybdate being present in an amount equivalent to at least 5 weight percent of molybdenum trioxide based on total weight of powder, whereby upon heating in a reducing atmosphere the spray dried ammonium molybdate and the cobalt compound are reduced to base metal.

Claim 3

The flame spray powder of claim 1 wherein the cobalt compound is a cobalt oxide.

Claim 4

Process for producing a flame spray powder comprising (a) spary drying a slurry of finely divided particulates of a metal selected from the group consisting of molybdenum and its alloys, and a compound of cobalt selected from the group consisting of cobalt oxides, cobalt hydroxides and cobalt oxalates, in an aqueous solution of a least one binder consisting essentially of ammonium molybdate in an amount equivalent to at least 5 weight percent of molybdenum trioxide based on the total weight of the powder, whereby particle agglomerates of the particulates are formed, held together by the spray dried ammonium molybdate; (b) classifying the agglomerates to obtain agglomerates within a desired particle size distribution; and (c) subjecting agglomerates outside the desired particle size distribution to at least one recycling operation, said recycling comprising reslurrying out-sized agglomerates, spray drying the reslurry to reform agglomerates, and classifying the reformed agglomerates.

Claim 5

Process for producing a flame spray powder comprising (a) spary drying a slurry of finely divided particulates of a metal selected from the group consisting of molybdenum and its alloys, and a compound of cobalt selected from the group consisting of cobalt oxides, cobalt hydroxides and cobalt oxalates, in an aqueous solution of a least one binder consisting essentially of ammonium molybdate in an amount equivalent to at least 5 weight percent of molybdenum trioxide based on the total weight of the powder, whereby particle agglomerates of the particulates are formed, held together by the spray dried ammonium molybdate; (b) classifying the agglomerates to obtain agglomerates within a desired particle size distribution; and (c) subjecting agglomerates outside the desired particle size distribution to at least one recycling operation, said recycling comprising reslurrying out-sized agglomerates, spray drying the reslurry to reform agglomerates, and classifying the reformed agglomerates.

Claim 6

The process of claim 3 wherein the cobalt compound is a cobalt oxide.

Claim 7

The process of claim 3 wherein the spray dried powder is heated in a reducing atmosphere to reduce the spray dried ammonium molybdate and cobalt compound to base metal.