Plasma spray coating for sealing a defect area in a workpiece
원문보기
IPC분류정보
국가/구분
United States(US) Patent
등록
국제특허분류(IPC7판)
B44C-001/22
C03C-015/00
C03C-025/68
C23F-001/00
C23C-004/134
C23C-004/01
H01J-037/32
C23C-004/18
출원번호
US-0423954
(2017-02-03)
등록번호
US-10041163
(2018-08-07)
발명자
/ 주소
Offer, Henry Peter
Keck, David Jonathan
Horn, Ronald Martin
출원인 / 주소
GE-HITACHI NUCLEAR ENERGY AMERICAS LLC
대리인 / 주소
Harness, Dickey & Pierce, P.L.C.
인용정보
피인용 횟수 :
0인용 특허 :
65
초록▼
A method for applying a coating to a defect area of a reactor component includes forming a patch on the reactor component at the defect area using a plasma-spray coating process. The plasma-spray coating process includes grounding the reactor component and a power supply of a plasma gun to a common
A method for applying a coating to a defect area of a reactor component includes forming a patch on the reactor component at the defect area using a plasma-spray coating process. The plasma-spray coating process includes grounding the reactor component and a power supply of a plasma gun to a common ground such that a potential difference exists between the reactor component and a cathode of the plasma gun, and concurrently directing an ion-etching stream and a coating stream towards the region of the reactor component using the plasma gun while maintaining a desired distance between the plasma gun and the region of the reactor component. The directing the ion-etching stream includes heating the region of the reactor component using a plasma stream exiting a spray nozzle of the plasma gun. The coating stream includes droplets of a coating material.
대표청구항▼
1. A method for applying a coating to a defect area of a reactor component, the method comprising: arranging a plasma gun to face a region of the reactor component that includes at least a portion of the defect area such that the plasma gun and the region of the reactor component are separated by a
1. A method for applying a coating to a defect area of a reactor component, the method comprising: arranging a plasma gun to face a region of the reactor component that includes at least a portion of the defect area such that the plasma gun and the region of the reactor component are separated by a desired distance;forming a patch on the reactor component at the defect area using a plasma-spray coating process, the plasma-spray coating process including, grounding the reactor component and a power supply of the plasma gun to a common ground such that a potential difference exists between the reactor component and a cathode of the plasma gun,directing an ion-etching stream and a coating stream towards the region of the reactor component using the plasma gun while maintaining the desired distance between the plasma gun and the region of the reactor component, the directing the ion-etching stream and the coating stream being performed concurrently,the directing the ion-etching stream including heating the region of the reactor component using a plasma stream exiting a spray nozzle of the plasma gun, andthe directing the coating stream including transferring droplets of a coating material injected into the plasma gun to impinge the region of the reactor component. 2. The method of claim 1, wherein a thickness of the patch is in a range of 0.1 mm to 100 mm,a width of the patch is in a range of 1 mm to 250 mm. 3. The method of claim 1, wherein the forming the patch is performed without at least one of using a fusion-welding process and forming a gas shroud. 4. The method of claim 1, wherein the reactor component is an internal reactor component for use inside a nuclear reactor, andthe reactor component has been highly irradiated. 5. The method of claim 1, wherein the coating material includes at least one metal. 6. The method of claim 5, wherein the at least one metal includes a noble metal. 7. The method of claim 5, wherein the forming the patch includes performing the plasma spray process so the directing the ion-etching stream heats the reactor component to a temperature below a melting point of the reactor component. 8. The method of claim 5, wherein the reactor component includes at least one of stainless steel, carbon steel, nickel-based steel, low-alloy steel, chromium-based steel, austenitic steel, or duplex steel,the forming the patch includes, forming a primer layer that connects to the reactor component and extends over the defect area, andforming a first coating layer on the primer layer using the plasma-spray coating process and a first coating material, the first coating material is at least a part of the coating material,the primer layer is formed using a material that has a high bond strength to a material of the reactor component,the first coating material includes a material that has greater strain compliance than the primer layer, andthe material of the primer layer is different than the first coating material. 9. The method of claim 8, wherein the forming the patch includes forming the primer layer using a non-plasma method without using a fusion-welding process. 10. The method of claim 9, wherein the forming the patch includes forming the primer layer using a friction-welding process. 11. The method of claim 8, wherein the forming the patch includes forming a second coating layer on the first coating layer using the plasma-spray coating process and a second coating material,the second coating material is at least a part of the coating material, andthe first coating material and the second coating material have different compositions. 12. The method of claim 11, wherein the first coating material includes first particles and the second coating material includes second particles, anda size of the first particles is greater than a size of the second particles. 13. The method of claim 1, wherein the defect area is one of a crack, a gap, and a hole defined in the reactor component, andthe forming the patch includes forming the patch to have a pattern that corresponds to a shape of the defect area. 14. The method of claim 1, wherein the region of the reactor component includes a higher density of defects compared to a portion of the reactor component outside of the region of the reactor component, andthe forming the patch includes forming the patch on an external surface of the region of the reactor component without forming the patch on an external surface of the portion of the reactor component outside of the region. 15. The method of claim 1, wherein the desired distance is in a range of about 10 mm to about 20 mm. 16. The method of claim 1, wherein the reactor component is one of a shroud or a steam separator. 17. The method of claim 1, further comprising: performing a stress mitigation process on the patch, whereinthe stress mitigation process includes improving a surface finish of the patch using one of, a sanding, and a surface-treatment process. 18. A method for applying a coating on a workpiece using a plasma gun to reduce leakage through a defect area defined in the workpiece, the method comprising: grounding the workpiece and a power supply of the plasma gun to a common ground such that a potential difference exists between the workpiece and a cathode of the plasma gun;arranging the plasma gun to face a region of the workpiece that is separated by a distance sufficiently short that the plasma gun is configured to generate a plasma stream that exits the plasma gun during plasma gun operation and will impinge directly on a surface of the region of the workpiece, the region of the workpiece including at least a portion of the defect area;ion etching the surface of the region of the workpiece by heating the surface with the plasma stream exiting a spray nozzle of the plasma gun to transform oxide-forming atoms on the surface of the region of the workpiece into positive ions, the distance separating the plasma gun and the workpiece being such that the positive ions leave the surface of the region of the workpiece under the influence of the potential difference between the region of the workpiece and the cathode; andsplattering the surface of the region of the workpiece with droplets of coating material injected into the plasma gun, the ion etching and splattering the surface being performed concurrently with maintaining the potential difference between the workpiece and the cathode.
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