WO2009064415A1

WO2009064415A1 - Coating for substrate

Info

Publication number: WO2009064415A1
Application number: PCT/US2008/012707
Authority: WO
Inventors: Michael W. Seitz
Original assignee: Seitz Michael W
Priority date: 2007-11-13
Filing date: 2008-11-13
Publication date: 2009-05-22
Also published as: US8518496B2; US20130306002A1; US9951943B2; US20080163792A1

Abstract

A nonhomogeneous coating composition comprising discrete discernable layers of slightly segregated incomplete alloy compositions, said coating comprising, in bulk on a weight basis, 39 to 66% Nickel, 35 % to 51% Cr, and 3 to 8% B, the discrete layers hardness varying and being in the range of from 30 RC to 72 RC. The coating can be applied to thicknesses in excess of 2.5 mm and is highly resistant to micro-through-cracks and spalling at such thickness.

Description

DESCRIPTION

COATING FOR SUBSTRATE

Technical Field

In one aspect, the invention relates to preventing tube failure in boilers, especially circulating fluidized bed boilers, as these are especially susceptible to tube failure in areas of high erosion. In another aspect, the invention relates to a coating material that can be used on boiler tubes.

Background Art

In US patent 7,256,369 a composite wire for producing a coating is disclosed which comprises a tubular metallic outer sheath encapsulating a powdered inner core, said inner core comprising a mixture of boron carbide of at least 35% by weight, and chrome carbide in an amount between about 67% and about 185% by weight of the amount of boron carbide. The wire was sprayed in example 2 to produce a coating of thickness up to 2000 μm (2 mm, 0.079 inches).

Disclosure of Invention

In one embodiment of the invention, a coating is formed by providing a cored wire and applying it to the substrate by an arc based spray technique. The cored wire contains all the alloy constituents that comprise the final coating deposit. The cored wire contains a chrome constituent and a boron constituent in the core of the wire and further comprises a metal or metal alloy outer sheath. The wire is arc melted by thermal spray technique to form a molten alloy coating composition. The molten alloy coating composition is applied onto a substrate and permitted to solidify to form the alloy coating deposit. The alloy coating deposit comprises at least 10 discrete discemable layers of different alloy compositions. The thickness of the layers can be changed by adjusting spray parameters, e.g., the air pressure of the arc spray equipment.

The coating can be beneficially applied to the erosion-prone sections of boiler tubes, with care being taken to avoid discontinuities on the outer surface of the tubes. This can be accomplished, for example, by applying an alloy coating which gradually and smoothly tapers to the nominal outside diameter of the tube. This coating build up progressively alters the localized erosion mechanism which in turn mitigates further erosion and slows significant on-going tube damage and possible premature failure.

Certain embodiments of the invention are carried out by applying an alloy coating to build up the sidewall thickness of the tube and/or to provide a tapering section which gradually and smoothly tapers to the nominal outside diameter of the tube. The alloy coating is preferably applied only to the fire side of the tube. Any alloy coating having adequate temperature and erosion resistance which can be built up to the required thickness can be used for this purpose. However, according to another embodiment of the invention, a highly desirable coating, applied using an arc based spray method, which can be applied to required thicknesses and resists throughcracking and spalling, comprises a non-homogenous coating comprising discrete discernable layers of slightly varying alloy compositions, with typically more than 10 such layers being discernable in the thickest part of the coating cross section. The coating comprises, in bulk on a weight basis, 39 to 66% Nickel, 35 % to 51% Cr, and 3 to 8% B. The discrete layers vary in Rockwell hardness (and provide the coating with layers having differing hardnesses from each other) over the range of from 30 RC to 72 RC.

Brief Description of Drawings

Figure 1 (prior art) is a pictorial view of a lower section of a water wall in a circulating fluidized bed boiler in new condition. Figure 2 (prior art) is a cross sectional view along lines 2-2 of Figure 1 of one of the tubes in the boiler.

Figure 3 (prior art) is a pictorial view of the lower section of the water wall as in Figure 1 after the tubes have been damaged by erosion.

Figure 4 (prior art) is a cross sectional view along lines 4-4 of Figure 3 of one of the tubes in the boiler.

Figure 5 is a pictorial view of a lower section of a water wall in a circulating fluidized bed boiler in new condition, according to an embodiment of the invention.

Figure 6 is a cross sectional view along lines 6-6 of Figure 5 of one of the tubes in the boiler.

Figure 7 is a pictorial view of the lower section of the water wall as in Figure 5 after the tube coating has been desirably modified by erosion.

Figure 8 is a cross sectional view along lines 8-8 of Figure 7 of one of the tubes in the boiler.

Figure 9 is a pictorial view of the lower section of the water wall as in Figure 7 after the damaged tube coating has been repaired according to certain maintenance aspects of the invention.

Figure 10 is a cross sectional view along lines 10-10 of Figure 9 of one of the tubes in the boiler. Figure 11 is a cross sectional view of a boiler tube according to another embodiment of the invention.

Figure 12 is a cross sectional view of a boiler tube according to another embodiment of the invention.

Figure 13 is a cross sectional view of a boiler tube according to another embodiment of the invention.

Figure 14 is a cross sectional view of the tube shown in Figure 6 along lines 14-14.

Figure 15 is a photomicrograph of a thick coating according to certain aspects of the invention after it has been stressed, showing microcracks but no through-cracks.

Figure 16 is a photomicrograph of a coating as shown in US published Application

No.: US 2008-0098926 Al (11/810,210).

Best Mode for Carrying out the Invention

With reference to Figures 1 through 4, which are prior art, the invention relates to the wear/erosion 2 seen on boiler tubes 4 located above the refractory ledge 6 (1-3" typically) (2.54 - 7.62 cm) of circulating fluidized bed boilers (CFB's). Figures 1 and 2 show the tube wall as installed. Figures 3 and 4 show the tubes after the occurrence of erosion. The erosion is specifically seen in certain CFB designs, where a "step" is created at the top of the refractory ledge where the boiler tubes are exposed. The illustrated step or shelf is one of the configurations typically used, but several other variations are used which include changing the inclination angle of the termination ledge. The severe wear occurs on the boiler tubes (steel) that extend above the refractory (i.e., above the step), the wear pattern generally resembling at least one, generally a pair of, deep "thumb prints" 8, 10 on each boiler tube. Design variation in the angle of the refractory ledge, and the thickness of the refractory wall, can influence the actual vertical location of the "thumb print", the location of the thumb prints typically being 0 to 5 inches (0 - 12.7 cm) above the refractory. These wear marks just above the refractory usually lead to boiler tube leaks, sometimes in periods as short as a few weeks in severe cases (typically these units need to run for one year between outages). In the prior art, as shown in Figures 1-4, the tubes had a uniform sidewall thickness over their length.

According to certain aspects of the invention, and with reference to Figures 5-10, a vertically positioned water tube wall 20 is provided having an upper end and a lower end. The water wall is formed from a plurality of vertically positioned parallel metal tubes 22 interconnected by a metal webbing 24. The webbing can be formed from steel bars connected diametrically to the tubes. The water tube wall has a fire side 26 in front of the webbing and a cold side 28 behind the webbing. A vertically positioned refractory wall 30 is positioned against the lower end of the water tube wall. The wall as illustrated has a generally flat upper end 32 normally adjacent to the lower end of the water tube wall. However, the upper end of the wall could be positively or negatively inclined at an angle if desired, and need not be flat. The tubes extend into the refractory wall and the wall covers a front side of the lower end of the tubes, protecting the front side of the lower ends of the tubes against erosion and excessive heat.

In a first embodiment of the invention, the improvement is to provide the water wall with tubes 22 having a section 34 of increased sidewall thickness just above the upper end of the refractory wall. The section of increased sidewall thickness has an increased thickness of at least 0.100 inches (2.54 mm)and smoothly and gradually tapers to a section of the tubes having a uniform sidewall thickness. By "just above" the upper end of the refractory wall, in all embodiments, is meant from 0 to about 5 inches (0 - 12.7 cm). Alternatively, the improvement is to provide tubes 124 having a section 134 of increased sidewall thickness and lesser inside diameter just above the upper end of the refractory wall 130, the outside diameter of the tubes being constant. See Figure 12. In this embodiment, also, the section of increased sidewall thickness has an increased thickness of at least 0.100 inches (2.54 mm).

In the alternate embodiment, (Figure 12) the tubes preferably have an inner surface defining a first generally cylindrical portion 136 and a section defined by a second generally cylindrical portion 138 having a smaller inside diameter than the first generally cylindrical portion. The section defined by the second generally cylindrical portion is positioned so that the tube has a thickened sidewall beginning at a location from below the upper end of the refractory wall. The thickened section preferably extends above the refractory wall for a length in the range of from 3 to 30 inches (7.62 - 76.2 cm).

In one way of carrying out the first noted embodiment of the invention, (see Figure 13) a section 240 of the outside surface of the tube 222 tapers away from the area of maximum sidewall thickness in a direction away from the refractory wall 230. The tubes have a non-uniform sidewall thickness over their length and have an inside diameter which is uniform and an outer surface defining a first generally cylindrical portion 242, a second generally cylindrical portion 244 positioned at a location just above the upper end of the refractory wall having a larger outside diameter than the first generally cylindrical portion, and a tapering portion 246 extending between the first generally cylindrical portion and the second generally cylindrical portion. The second generally cylindrical portion can be provided in the form of a tubing section or collar 248 which is welded to the first generally cylindrical portion. The tapering portion preferably comprises a metal alloy cladding applied by spray technique which has a length of at least 12 inches (30.5 cm). The cladding can extend over the second generally cylindrical portion, as illustrated in Figure 13. An additional way is to pad weld a 180 degree tubular saddle onto the tube, followed by spray overlay.

In another way of carrying out the first noted embodiment, and as illustrated in Figures 5-10, the section of increased tube wall thickness can be provided totally in the form of cladding. In such a case, the section of increased sidewall thickness comprises a first layer (the wall of tube 22) and a second layer 50. The first layer is tubular and has a uniform sidewall thickness. The second layer comprises a coating positioned radially outwardly from the first layer and can be generally saddle-shaped. The second layer has a maximum thickness portion and a tapering thickness portion.

The maximum thickness portion is positioned at a location just above the upper end of the refractory wall, generally in the range of 0 to 5 inches (0 - 12.7 cm) above the wall. The exact location depends on where the greatest erosion would be expected to occur, and depends on the width and angle of the ledge, for example. The maximum thickness portion has a thickness, as measured radially from the longitudinal axis of the tube, which is at least 0.060 inches (1.52 mm). The length of the portion having a thickness of at least 0.060 inches (1.52 mm), as measured parallel to the axis of the tube, is at least 2inches (5.08 cm). The tapering thickness portion preferably transitions smoothly to nil thickness over a length, as measured longitudinally, which is at least 12 inches (30.5 cm). The second layer generally further gradually tapers circumferentially and can be thinnest facing directly away from the wall. In practice, the section of increased thickness as shown in Figures 6, 8 and 10 can extend to below the surface of the refractory, as shown in Figure 11, for example.

The second layer preferably comprises a coating applied by spray technique. The coating is preferably present on the fire side half of the tube wall, but not the cold side hah⁰, and bridges the web/membrane. See Figure 14. The second layer in a further preferred embodiment forms a pad which provides a sacrificial area of maximum thickness as measured radially from the longitudinal axis of the tube. In the area of greatest thickness, the second layer is at least 0.060 inches (1.52 mm) thick, and the length of the area having a thickness of at least 0.060 inches (1.52 mm)as measured parallel to the axis of the tube is at least 2 inches (5.08 cm).

The saddle extends circumferentially around the tubular sidewall and generally spans an angle which is approximately 180 degrees and extends over the web. The sides of the saddle on the tubes are generally of greatest thickness and are bounded by the webbing, which may be similarly thickly cladded during the application step. The cladding is generally thicker on the webbing and on the quarter round portions of the tube in front of the webbing than it is on the portion of the tube facing directly away from the webbing, (crown of the tube), as erosion is generally more severe on the quarter-sides of the tubes than on the crown of the tube.

After erosion has occurred, and during a maintenance opportunity, an additional layer

162 of cladding can be applied to refurbish or freshen the tubes. See Figure 10. In such case, the tube near the refractory ledge will comprise 3 or more layers. The thick buildup of cladding disproportionately against the webbing in the troughs at the lower end of the wall through application and reapplication of the cladding during repairs results in a flattening of the undulations in the wall is a desirable effect that is allowed to occur.

The saddle preferably comprises a nickel/chrome/boron cladding, because nickel alloys can have their thickness measured with readily available equipment for measuring coating thickness, an important concern for quality control purposes. The saddle provides the tube with an outside surface which is non-cylindrical. During use, erosion processes form one or more thumbprint-shaped depressions in each tube, for example, depressions 52, 54 resembling eye sockets in the thickened area. The generally thumbprint shaped depressions are longitudinally elongated along a generally spiral path just above the discontinuity such as the refractory wall. At least one, generally a pair of generally circumferentially extending eyebrow-shaped ridges 56, 58 extend from a front central location on the tube, these being positioned over the thumbprint- shaped depression(s). These depressions and eyebrows act to reduce the erosive process, and their formation is a requirement for the future reduction in wear.

Therefore, to immediately establish a lower wear condition, this geometry can also be formed during the fabrication process, or maintained when the tubes are freshened. See Figure 10, eyebrow 160.

The first noted embodiment of the invention can be carried out by providing the tubes with an increased thickness section having an increased sidewall thickness of at least 0.100 inches (2.54 mm)at locations in the fluidized bed boiler where the tubes are susceptible to gouging, and further providing the tubes with a tapered section connected to the increased thickness section which smoothly and gradually tapers away from the locations where the tubes are susceptible to gouging to nil over a distance of at least 12 inches (30.5 cm). Preferably, the tapered section is between 12 inches and 48 inches (30.5 - 122 cm)long. The increased thickness section preferably provides the tubes with a greatest sidewall thickness in the locations where the tubes are susceptible to gouging.

For application to a fluidized bed boiler, a tube wall comprising a vertically positioned plurality of parallel tubes is provided in the boiler. Each tube of the plurality has a section of greater sidewall thickness compared to a different section of the tube. The section of greater sidewall thickness has an increased sidewall thickness of at least 0.100 inches (2.54 mm), as compared to the balance of the tube. The tube wall has an upper end portion and a lower end portion. At least the front side of the lower end portion of the tube wall is covered by a refractory wall. The refractory wall has an upper end defining the refractory ledge and a lower end. The upper end of the refractory wall is positioned adjacent to the lower end sections of the tubes of greater sidewall thickness, so that a section of each tube above the upper end of the refractory wall has an increased sidewall thickness of at least 0.100 inches (2.54 mm) and extends up sufficiently beyond the areas subject to severe gouging (thumb prints). The tapered section of each tube converges toward the axis of each tube in an upward direction, away from the refractory wall.

In one embodiment of the invention, (See Figures 11-13) the upper end of the refractory wall 130, 230, 330 is positioned on the tube sections 144, 244, 244 having the increased sidewall thickness, and the tube sections of increased sidewall thickness extend for a distance of at least 2 inches (5.08 cm) above the upper end of the refractory wall and for a distance below the upper end of the refractory wall.

In the embodiment of the invention wherein the greater thickness is provided in the form of a saddle shaped coating with at least an upwardly tapering end section applied by spray technique, the saddle shaped coating generally has a maximum thickness in the range of 0.060 to 0.200 inches (1.52 - 5.08 mm). The coating is preferably thick and erosion resistant and can be provided in a pattern that resembles eyebrows directly above the areas of the tubes that are susceptible to gouging. In such case, the coating will have its maximum thickness in the areas resembling the eyebrows.

The coating can be provided by applying a thick erosion resistant coating to a fire side of the tubes which extends from a location above the top of the refractory ledge into which the tubes extend to above the locations where the tubes are susceptible to gouging. As previously described, subsequent operation of the boiler forms gouges in the provided thick erosion resistant coating that resemble thumbprints near the top of the refractory ledge and provides a pattern in the erosion resistant coating closely above the gouges that resembles eyebrows. The coating provides extreme resistance to further erosion once the gouges have reached a depth of greater than about 0.080 inches (2.03 mm). The coating is preferably applied to a maximum thickness in the range of 0.080 to 0.200 inches (2.03 - 5.08 mm) near the top of the refractory ledge and is tapered above the maximum thickness to a nil thickness over a distance of at least 12 inches (30.5 cm). The maximum thickness is preferably on a fire side the tube, directly facing an erosive environment in the fluidized bed boiler.

Usually, the boiler tubes are formed from steel. A preferred coating can be applied to such tubes from a wire having a metallic outer sheath and a powdered inner core. The inner core comprises at least about 28% by weight of boron and chrome in an amount between about 67% and about 185% by weight of the amount of the boron.

The wire is melted using an electric arc heat source to form a melt. The melt is atomized and sprayed onto the tubes by compressed gas. The composite wire is selected to form a coating on the substrate comprising the metal of the sheath, chrome, and boron. The coating is then permitted to solidify. In a preferred embodiment, the metal of the sheath comprises nickel and at least one of the compound of boron and the compound of chrome comprises a carbide. The resultant coating comprises a nickel/chrome/boron cladding.

As noted above, certain embodiments of the invention are carried out by applying an alloy coating to increase the sidewall thickness of the tube and/or to provide a tapering section which gradually and smoothly tapers to the nominal outside diameter of the tube. Any alloy coating having adequate temperature and erosion resistance which can be built up to the required thickness can be used for this purpose. However, according to another embodiment of the invention, a highly desirable coating, which can be applied to required thicknesses and resists throughcracking and spalling, comprises a nonhomogeneous coating comprising discrete discernable layers of slightly segregated incomplete alloy compositions. The coating comprises, on bulk on a weight basis, 39 to 66% Nickel, 35 % to 51% Cr, and 3 to 8% B. The discrete layers vary in hardness and are in the range of 30 RC to 72 RC, the NiCr layers being in the lower end of the range, the boride-containing layers being in the upper end of the range. Preferably, the layers of coating vary widely in hardness over the range 30 RC to 72 RC, and at least 10 discrete discernable layers per 1.52 mm of coating, for example, 10-20 layers. The coating is formed, according to another embodiment of the invention, by providing a cored wire and applying it to the substrate by an arc based spray technique. The cored wire contains all the alloy constituents that comprise the final coating deposit. The cored wire contains a chrome constituent and a boron constituent in the core of the wire and further comprises a nickel or nickel alloy outer sheath. The wire is arc melted by thermal spray technique to form a molten alloy coating composition. The molten alloy coating composition is applied onto a substrate and permitted to solidify to form the alloy coating deposit. The alloy coating deposit comprises discrete discernable layers of segregated alloy compositions, and is as previously described.

In the coating, a portion of the Ni and a portion of the Cr preferably exist as hard borides. The coating composition can further comprise, in bulk on a weight basis, at least one additional constituent selected from the group consisting of up to 6% Si, up to 10% Mo, up to 6% Nb, up to 5% Al, up to 4% Ti, up to 9% Fe, up to 10% W, and up to 4% C. If any such additional constituent is present, it will generally be in the range of 0.5 to 6% Si, 0.5 to 10% Mo, 0.5 to 6% Nb, 0.5 to 5% Al, 0.5 to 4% Ti,

0.5 to 9% Fe, 0.5 to 10% W, and 0.5% to 4% C.

The coating composition is corrosion, erosion and abrasion resistant. It resists the formation of coating through-cracks and possible spalling by arresting microcracking at the layers having a RC in the lower end of the stated range.

Figure 15 is an electron micrograph of a cross-section of the coating according to embodiments of the invention. The brightness of the image tends to increase with atomic number. Thus, layers averaging a lower atomic number appear darker in the image. The image thus shows contrast between areas in the coating with differing chemical composition. Layering is apparent, appearing eyebrow-shaped in the cross sectional view over a range of gray scales, indicating that the coating comprises the desired varying layered chemical composition in the coating.

Figure 16 is a micrograph from the parent application of a coating cross-section formed by spraying a substrate with an alloy 625/boron carbide-chrome carbide composite wire. This photograph was taken using a different technique which does not emphasize compositional differences as much, and therefore the coating in Figure 16 appears to show much greater homogeneity than the coating in Figure 15.

However, while not made as apparent in the parent application photograph, the coating produced using the alloy 625/boron carbide-chrome carbide composite wire does have the same layered properties that are desired for this application when sprayed through an arc based thermal spray system.

Preferred embodiments of the invention relate to a modified thermal spray approach which is made possible through the use of coating materials that are erosion resistant, and can be sprayed to high thickness (>100 mils) without spalling (see US Patent 7,256,369, the disclosure of which is incorporated by reference herein, for a material). Thick nickel-based coatings are not currently sprayed, with traditional high wear nickel based coatings being sprayed to a max of 30 mils (0.762 mm). For the invention, a thick coating section is sprayed across the tubes which typically extends from the refractory top, up at least 2 inches (5.08 cm) at full thickness (the thick section will be referred to as a "wear pad"), then tapering down over an extended area above the wear pad to a zero thickness higher up (known as a taper zone). The "wear pad" acts as a very thick sacrificial coating band, which is expected to wear down locally in the thumbprint locations (in a similar way that the tube wears) during the running of the boiler. The depths of the thumbprints vary, depending on the severity of the wear process. The resulting wear pattern in the coating producing a wear pattern resembles an "eyebrow" on each tube (the "thumbprints" resembling eye sockets). Once the thumbprints have worn approximately 100 mils (2.54 mm) into the wear pad, this pattern of eyebrows and thumbprints reduces further erosion because the pattern alters the erosion process and significantly slows it. While eyebrows may be directly sprayed onto boiler tubes initially (as part of this invention), i.e., no wear pad, it has been determined that it is simpler to spray a thick wear pad, and then to allow the pattern to develop during normal running of the boiler. To form the eyebrows, if desired, the lower end of the tubes is masked, say, using a steel bar, to a height just above where the thumbprints are formed, and a buildup of cladding laid down in the area, thickest just above the top of the mask. The mask is then removed, and a broad band of coating applied, providing the masked area with some cladding protection against the reduced, but still present, wear.

Once the eyebrow geometry has formed, future annual spray work maintains the geometry, (slow wear requires maintenance of the geometry).

This invention has been made possible because of the ability to spray very thick coatings, and the discovery that the formation of "eyebrows" limits wear which would result in parent tube damage. The saving to clients is large if no parent tube damage occurs during outages.

This invention provides an area of thick cladding or buildup, referred to a wear pad; along with a transition section, typically a tapering cladding section above the wear pad, referred to a taper zone; the wear pad and trapper zone being attached to the outer surface of a tube wall, division wall or wing wall of a circulating bed boiler; directly above the refractory wall. The wear pad is provided as a sacrificial wear pad, and as such, is intended to wear during the initial period of normal boiler operation; the wear pattern in a circulating bed boiler above the refractory producing a desired geometry resembling "thumb prints" or "eye sockets," with "eyebrows" above the sockets. As the eyebrow and sockets develop in the wear pad layer, the wear mechanism significantly slows, slowing sufficiently over time to prevent any wear of the underlying boiler tube. Thick cladding is considered greater than 60 mils (1.52 mm); and may be upwardly adjusted to ensure that the wear mechanism is sufficiently snuffed out to prevent wear of the underlying parent tube. The taper region extends over distance of more than 12 inches (30.5 cm), upwardly tapering in any geometry from the thickest cladding section to zero. The taper is required to prevent any form of discontinuity created by the presence of the wear pad.

The taper may extend to any height over the minimum of 12 inches (30.5 cm), even extending the fall wall height, to provide general wear protection of the tubes, and as such may comprise various constant thickness sections and multiple tapers.

The wear pad is intended to be refurbished from time to time by building up the wear pad and taper. The eyebrow geometry obtained during the initial application or as the result of erosion processes may be preserved, since this is a desirable geometry to reduce erosion severity.

Using masks, or skilled cladding applicators, the wear pad may be applied with the eyebrow geometry at the initial installation, removing the requirement for a "wear-in" period described above.

A wear pad may be incorporated into the original design of the tube by creating a thick section of tube which will act as a wear pad with a sacrificial area.

Considering the above, the thicker tube section may be provided for by using a tube with a reduced inner bore diameter, or using a thick wall tube section with a larger outside diameter, and a taper zone tube section that provides a gradual reduction in OD of the tube above the wear pad section. A wear resistant coating may be applied to extend overall tube life and provides a means of refurbishment for general long term wear.

A corrosion, erosion and abrasion resistant coating that is produced using a wire arc based spray technique; the alloy constituents being sourced specifically from a cored wire containing all the alloy constituents that comprise the final coating deposit; the average bulk composition of the coating alloy containing 39 to 66% Nickel, between 35 % and 51% Cr, and 3-8% B, in an amount effective for precipitating borides of Cr, and Ni. Further Si additions between 0.5% and 6%, 0.5-10% Mo, and 0.5-6%Nb, 0.5- 5%A1, 0.5-4%Ti, Fe 0.5-9% may be added, C 0.5%-4%, either singularly or in combination. Other minor alloying (<10%) can be considered if they do not affect the performance expected from the alloy; the final coating deposit comprising discernable layers of slightly segregated alloy compositions, so as to produce a nonhomogeneous coating composition, these layers being essential to the performance of the alloy as the layers act to arrest direct through-cracking and spalling as micro cracks will have a tendency to arrest at softer layers; the discrete layers hardness varying, preferably varying widely, over the range from 30 RC to 72 RC; the layered effect being achieved by specifically placing the Boron and Chrome constituents into the core of the wire so that during arc based spraying segregation or incomplete alloying can be guaranteed in the final deposit.

The coatings according to the present invention are specifically designed for articles subjected to wear and/or corrosion. Such articles include, for example, boiler tubes, hydraulic piston rods, pump casings, rollers in the paper and steel industry, wear plates, journals and shafts, and turbine blades and casings.

In one application, the coatings are designed to protect boiler tubes against erosion- corrosion related wastage and are applied to the boiler tubes by means of a conventional arc spraying apparatus. However, it will be appreciated from the description below that the coatings could also be applied to the boiler tubes by other thermal spraying apparatus employing wires as the feed material and arc melting processes. Arc spraying methods and apparatus are well documented in the art, see for example, U.S. Pat. Nos. 6,156,443 (Dallaire, et al.); 5,837,326 (Dallaire, et al.); European Patent No. EP 0 522 438 (Zurecki et al ); and PCT Patent No. WO

98/00574 (Seitz), the disclosures of which are incorporated by reference.

The coatings of the present invention are formed from composite wires, which are fed through a conventional arc spraying apparatus, such as the apparatus disclosed in PCT Patent No. WO 01/08810 (Seitz), the disclosure of which is incorporated herein by reference.

The cored wires may be formed in a conventional manner by placing the mix, which need not be an agglomerated mix, onto an alloy 690 strip, or a strip of some other outer sheath alloy, which is drawn continuously through a plurality of wire drawing dies to form an outer wire sheath around an inner powdered core. The final outer diameter of the cored wire will depend upon the application for which it is used. For most applications, the cored wire final diameter ranges between about 0.8 mm to about 6.4 mm. Conventional cored wire manufacturing techniques are disclosed in U.S. Patent Application Nos. 6,156,443 (Dallaire et al.) and 6,513,728 (Hughes et al.), of which both disclosures are hereby incorporated by reference.

The composite wires of the BC/CrC (boron carbide/chromium carbide) embodiment of the present invention comprise an outer sheath formed from a metal or alloy. In this embodiment of the invention, which is particularly suited for the high temperature erosion-corrosion environment found in boiler applications, the cored wires comprise an outer tubular sheath formed from a chromium bearing, nickel base alloy such as an alloy 690, and an inner core, which comprises boron carbide and chrome carbide. The preferred inner core formulation preferably comprises chrome carbide in an amount between about 25% and about 400% by weight of the amount of boron carbide. In other words, the ratio of chrome carbide to boron carbide preferably ranges between about 1:4 to about 4:1. More preferably, the inner core comprises chrome carbide in an amount between about 67% and about 230% by weight of the amount of boron carbide. In other words, the ratio of chrome carbide to boron carbide preferably ranges between about 1:1.5 to about 2.3: 1. In one preferred embodiment, the inner core comprises about 100% by weight of chrome carbide relative to the amount of boron carbide, in other words the amounts of chrome carbide and boron carbide are substantially equivalent.

Example 1

A composite wire of the BC/CrC embodiment of the present invention was formed with an outer sheath comprising of INCONEL (R) alloy 690 and an inner core comprising a substantially equivalent mixture of chrome carbide and boron carbide.

INCONEL (R) alloy 690 is a product of the Special Metals Corporation and contains

0.02% C, 1.0% Mn, 7.0%-l 1.0% Fe, 0.015% S, 0.5% Si, 0.5% Cu, 27%-31% Cr, bal. Ni. This composite wire provided coatings with good toughness characteristics, low oxides, and good wear characteristics due to the novel carbide formulation of the inner core. In addition, there was an increase in the hardness of the metal binder due to the boron content. The coatings also exhibited good bonding characteristics. The following table illustrates the improved wear resistance of a coating deposited by a composite wire of the present BC/CrC embodiment of the invention (row 3 and row 4) compared to the wear resistance of other coatings: ASTM G65 Wear Test (15 minutes):

Weight Loss (grams lost/6000 wheel revolutions)

Coating

I) Fe Cr B (Arc) 0.43

2) Fe Cr Mo W Mn B (HVOF) 0.32

3) BC/CrC-Alloy 690 (Arc) 0.29

4) BC/CrC-Fe Cr (Arc) 0.21

After Fusing

3) BC/CrC-Alloy 690 (Arc) 0.18

4) BC/CrC -Fe Cr (Arc) 0.17

Note that coatings of the BC/CrC embodiment of the present invention, as discussed above, have low oxide content and thus have superior fusing characteristics. The wear resistances of the BC/CrC— Alloy 690 coating and the BC/CrC~Fe Cr coating were substantially improved upon fusing.

In addition to the improvement to wear resistance, the overall strength of the metal binder was also substantially increased. The coating deposited with the BC/CrC-- Alloy 690 composite wire exhibited average hardness measurements in the range of 800 - 880 100 g/Vickers/10 seconds. Whereas, coatings of pure alloy 690 are typically on the order of 280-350 100 g/Vickers/10 seconds. Example 2

To illustrate bond strength, dean, bright smooth stainless steel coupons were coated, without any surface roughness, to establish how thick a coating could be sprayed before spalling occurred (i.e., bond failure). The first coupon was arc sprayed with pure alloy 690 and the second coupon was sprayed with a composite wire comprising an alloy 690 outer sheath and an inner core comprising 40% by weight boron carbide and 60% by weight chromium carbide. The first coupon exhibited delamination at 300 μm, whereas the coating applied in accordance with the BC/CrC embodiment of the present invention was sprayed up to 2000 μm without any appearance of spalling.

Example 3

Two clean steel coupons were coated, with grit-blasted surfaces; the first with pure alloy 690 and the second with a composite wire comprising an alloy 690 outer sheath and an inner core comprising 40% by weight boron carbide and 60% by weight chromium carbide. The coupons were mechanically damaged by cracking off the coating with a hammer and chisel. The pure 690 coating was peeled off of the first coupon as a continuous layer, while the composite wire sprayed coating could not be disjoined from the coupon. Rather, the composite wire sprayed coupon only sustained damage to the impact site, thus illustrating the high bond strength.

As stated above, in addition to good toughness, wear resistance, increased metal binder hardness, and improved bonding of the coating to the substrate, the inner core formulation of the BC/CrC embodiment of the present invention also inhibits oxide formation. As stated above, the metal binder material for the BC/CrC embodiment is not limited to nickel base alloys, rather the outer sheath may be constructed of any metal or alloy. Additional suitable binder material includes, but is not limited to, iron, carbon and low alloy steels, stainless steels, nickel, copper, copper alloys (e.g., brasses, bronzes, and aluminum bronzes), aluminum, aluminum alloys (e.g., aluminum-copper, aluminum- manganese, aluminum-manganese-magnesium, aluminum-silicon, aluminum- manganese-magnesium-chrome, aluminum-magnesium-silicon, and aluminum-zinc- manganese-magnesium-copper), titanium, titanium alloys (e.g., titanium alloyed with palladium, molybdenum, nickel, aluminum, vanadium, niobium, tantalum, tin, zirconium, chromium and iron), cobalt, cobalt alloys (e.g., cobalt alloyed with chromium, nickel, molybdenum, and tungsten), zirconium, zirconium alloys, tantalum and tantalum alloys. The combination of any of these binders with the inner core powder of the present invention results in coatings having superior physical properties over conventional coatings.

Claims

1. A nonhomogeneous coating composition comprising discrete discernable layers of slightly segregated incomplete alloy compositions, said coating comprising, in bulk on a weight basis, 39 to 66% Nickel, 35 % to 51% Cr, and 3 to 8% B, the discrete layers hardness varying and being in the range of from 30 RC to 72 RC.

2. A coating composition as in claim 1 wherein a portion of the Ni and a portion of the Cr exist as borides.

3. A coating composition as in claim 1 wherein said coating composition further comprises, in bulk on a weight basis, at least one additional constituent selected from the group consisting of up to 6% Si, up to 10% Mo, up to 6% Nb, up to 5% Al, up to 4% Ti, up to 9% Fe, up to 10% W, and up to 4% C.

4. A coating composition as in claim 1 wherein said coating composition further comprises, in bulk on a weight basis, at least one additional constituent selected from the group consisting of 0.5 to 6% Si, 0.5 to 10% Mo, 0.5 to 6% Nb, 0.5 to 5% Al, 0.5 to 4% Ti, 0.5 to 9% Fe, 0.5 to 10% W, and 0.5% to 4% C.

5. A coating composition as in claim 1 which resists the formation of coating through-cracks, and, by extension, spalling, by arresting microcracking at the layers having a RC in the lower end of the stated range.

6. A method for providing a throughcrack resistant coating on a substrate, said method comprising providing a cored wire containing a chrome constituent and a boron constituent in the core of the wire, said wire further comprising a nickel or nickel alloy outer sheath, melting the wire by an arc-based thermal spray technique to form a molten alloy coating composition, and applying the molten alloy coating composition onto a substrate and permitting it to solidify to form an alloy coating deposit, wherein the alloy coating deposit comprises

a nonhomogeneous coating composition according to claim 1 having

at least 10 discrete discernable layers per 1.52 mm thickness of coating,

the cored wire contains all the alloy constituents that comprise the final coating deposit.

7. A method as in claim 6 wherein the substrate comprises a steel tube and the deposit forms a saddle on the tube.

8. A method as in claim 6 wherein the substrate comprises

a vertically positioned water tube wall having an upper end and a lower end, said water tube wall comprising a plurality of vertically positioned parallel metal tubes interconnected by a metal webbing and having a fire side in front of the webbing and a "cold" side behind the webbing, a vertically positioned refractory wall positioned against the lower portion of the water tube wall, said refractory wall having an upper end, wherein the wall covers at least a front side of a lower end of the tubes,

at a location just above the refractory wall on the fire side.

9. A method as in claim 8 wherein the deposit has a thickness of at least 2.54 mm and smoothly and gradually tapers to a section of the tubes having a uniform sidewall thickness.

10. A method as in claim 9 wherein the deposit has a tapered section leading from a section of increased thickness where the tubes are more susceptible to gouging which smoothly and gradually tapers away from the locations where the tubes are susceptible to gouging to nil over a distance of at least 30.5 cm.

11. A method as in claim 10 wherein coating having a maximum thickness in locations where the tubes are more susceptible to gouging which in the range of 1.52 to 5.08 mm.

12. A method as in claim 8 wherein the coating is applied to form a deposit having a thickness in the range of 1.52 to 5.08 mm.

13. A method as in claim 8 wherein the coating is applied to form a deposit having a thickness in the range of 2.03 to 5.08 mm.

14. A method as in claim 8 wherein the coating is applied to form a deposit having a thickness in the range of 2.54 to 5.08 mm.

15. A method as in claim 8 wherein the coating is applied to form a deposit having in range of 10 to 20 discrete discernable layers per 1.52 mm thickness of coating.