Claims
- 1. A substantially uniform thermal spray powder consisting essentially of:dicalcium silicate, a sodium compound or alloy, and a further ingredient selected from the group consisting of a phosphorous compound and a zirconium compound, wherein the dicalcium silicate in the powder is stabilized in a larnite phase that comprises a majority of the powder by volume.
- 2. The powder of claim 1, wherein the further ingredient is the phosphorous compound.
- 3. The powder of claim 2 wherein the sodium compound is disodium monoxide present in an amount of about 0.2% to 0.8%, and wherein the phosporous compound is phosphorous pentoxide present in an amount of about 2.5% to 4%, the percentages being by weight based on the total composition.
- 4. The thermal spray powder of claim 1, further consisting essentially of incidental ingredients associated with the phosphorous compound or the zirconium compound.
- 5. The powder of claim 4, wherein the incidental ingredient is aluminum oxide present in an amount of up to about 2% by weight based on the total composition.
- 6. The powder of claim 4, wherein the incidental ingredient is magnesium oxide present in an amount of up to about 0.5% by weight based on the total composition.
- 7. The powder of claim 1, wherein the further ingredient is the zirconium compound.
- 8. The powder of claim 7 wherein the sodium compound is disodium monoxide present in an amount of about 0.2% to 0.8%, and the zirconium compound is zirconium dioxide present in an amount of about 10% to 50%, the percentages being by weight based on the total composition.
- 9. The powder of claim 7, wherein at least part of the zirconium is in the form of zirconium dioxide containing calcium oxide as a stabilizer.
- 10. The powder of claim 7, wherein at least part of the zirconium is in the form of zirconium dioxide containing ytrium oxide as a stabilizer.
- 11. The powder of claim 1, wherein the particle size distribution of the powder is within a range between about 10 and 100 μm.
- 12. A thermal spray powder comprising a mixture of(a) a substantially uniform powder composition consisting essentially of dicalcium silicate, a sodium compound, and a further ingredient selected from the group consisting of phosphorous compounds and zirconium compounds, such that the dicalcium silicate is stabilized in a larnite phase that is majority by volume; and (b) a powder of stabilized zirconium oxide present in an amount of about 10% to 50% of the total weight of the thermal spray powder.
CROSS REFERENCE TO RELATED APPLICATION
This application is a divisional application of U.S. patent application Ser. No. 09/338,615 filed on Jun. 23, 1999, now U.S. Pat. No. 6,194,084.
US Referenced Citations (8)