Claims Analysis
Total Claims: 10
Claim 1
Independent Claim
102 words
A method for preparing an intimate mixture of powders of nickel-chromium-boron-silicon alloy, molybdenum metal powder, and chromium carbide/nichrome alloy suitable for thermal spray coatings, said method comprising: a milling a starting mixture of said nickel-chromium-boron-silicon alloy, molybdenum powder, and the chromium carbide/nichrome alloy to produce a milled mixture wherein the average particle size is less than about 10 micro- meters in diameter; b forming an aqueous slurry of the resulting milled mixture and a binder selected from the group consisting of an ammoniacal molybdate compound and polyvinyl alcohol; and c agglomerating said milled mixture and said binder to produce said intimate mixture.
Claim 2
Independent Claim
102 words
A method for preparing an intimate mixture of powders of nickel-chromium-boron-silicon alloy, molybdenum metal powder, and chromium carbide/nichrome alloy suitable for thermal spray coatings, said method comprising: a milling a starting mixture of said nickel-chromium-boron-silicon alloy, molybdenum powder, and the chromium carbide/nichrome alloy to produce a milled mixture wherein the average particle size is less than about 10 micro- meters in diameter; b forming an aqueous slurry of the resulting milled mixture and a binder selected from the group consisting of an ammoniacal molybdate compound and polyvinyl alcohol; and c agglomerating said milled mixture and said binder to produce said intimate mixture.
Claim 3
Dependent Claim
53 words
The method of claim 1 comprising the additional step of sintering said intimate mixture and said binder in a reducing atmosphere at a temperature of about 800° C. to about 950° C. for a sufficient time to form a sintered partially alloyed mixture wherein the bulk density is greater than about 1.2 g/cc.
Claim 4
Dependent Claim
101 words
The method of claim 2 comprising the additional steps of: a entraining the resulting sintered mixture in an inert carrier gas; b passing said sintered mixture and said carrier gas into a plasma flame wherein the plasma gas is selected from the group consisting of argon and a mixture of argon and hydrogen, and maintaining said sintered mixture in said plasma flame for a sufficient time to melt essentially all of the powder particles of said sintered mixture to form spherical particles of the melted portion, and to further alloy said sintered mixtures; and c cooling the resulting further alloyed mixture.
Claim 5
Dependent Claim
11 words
The method of claim 1 wherein said binder is ammonium paramolybdate.
Claim 6
Dependent Claim
11 words
The method of claim 1 wherein said binder is polyvinyl alcohol.
Claim 7
Dependent Claim
16 words
The method of claim 1 wherein said agglomerating is done by spray drying said aqueous slurry.
Claim 8
Dependent Claim
56 words
The method of claim 1 wherein said nickel-chromium-boron-silicon alloy consists essentially of in percent by weight about 1 to 20 chromium, about 2 to 5 boron, and 2 to about 5 silicon, about 0.1 to 2 carbon, and the balance nickel, and wherein the chromium carbide/nichrome alloy consists of 75-80% Cr 3 C 2 /20-25% NiCr.
Claim 9
Dependent Claim
52 words
The method of claim 1 wherein said starting mixture of said nickel-chromium-boron-silicon alloy, the chromium carbide/nichrome alloy and said molybdenum powder consists essentially of in percent by weight about 10 to about 30 of said nickel-chromium-boron-silicon alloy, 1-20 wt % of Cr 3 C 2 /NiCr and the balance said molybdenum powder.
Claim 10
Dependent Claim
40 words
The method of claim 8 wherein said starting mixture consists essentially of in percent by weight about 10 to about 20 of said nickel-chromium-boron-silicon alloy, 5-20% weight by of Cr 3 C 2 /NiCr and the balance said molybdenum powder.