Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C19/00—Alloys based on nickel or cobalt
  • C22C19/03—Alloys based on nickel or cobalt based on nickel
  • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
  • C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
  • C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C19/00—Alloys based on nickel or cobalt
  • C22C19/03—Alloys based on nickel or cobalt based on nickel
  • C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
• • C—CHEMISTRY; METALLURGY
  • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
  • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
  • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
  • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
  • C23C4/06—Metallic material

Definitions

• Embodiments of this disclosure generally relate to nickel-based alloys that can serve as effective feedstock for hardfacing processes, such as for plasma transferred arc (PTA), laser cladding hardfacing processes including high speed laser cladding, and thermal spray processes such as high velocity oxygen fuel (HVOF) thermal spray.
• PTA plasma transferred arc
• HVOF high velocity oxygen fuel
• Abrasive and erosive wear is a major concern for operators in applications that involve sand, rock, or other hard media wearing away against a surface.
• Applications which see severe wear typically utilize materials of high hardness to resist material failure due to the severe wear. These materials typically contain carbides and/or borides as hard precipitates which resist abrasion and increase the bulk hardness of the material. These materials are often applied as a coating, known as hardfacing, through various welding processes or cast directly into a part.
• a feedstock material comprising, in wt. %, Ni, C: 0.5 - 2, Cr: 10 - 30, Mo: 5.81 - 18.2, Nb + Ti: 2.38 - 10.
• the feedstock material may further comprise, in wt. %, C: about 0.8 - about 1.6, Cr: about 14 - about 26, and Mo: about 8 - about 16.
• the feedstock material may further comprise, in wt. %, C: about 0.84 - about 1.56, Cr: about 14 - about 26, Mo: about 8.4 - about 15.6, and Nb + Ti: about 4.2 - about 8.5.
• the feedstock material may further comprise, in wt. %, C: about 8.4 - about 1.56, Cr: about 14 - about 26, Mo: about 8.4 - about 15.6, Nb: about 4.2 - about 7.8, and Ti: about 0.35 - about 0.65.
• the feedstock material may further comprise, in wt. %, C: about 1.08 - about 1.32, Cr: about 13 - about 22, Mo: about 10.8 - about 13.2, and Nb: about 5.4 - about 6.6.
• the feedstock material may further comprise, in wt. %, C: about 1.2, Cr: about 20, Mo: about 12, Nb: about 6, and Ti: about 0.5.
• the feedstock material is a powder. In some embodiments, the feedstock material is a wire. In some embodiments, the feedstock material is a combination of a wire and a powder.
• the hardfacing layer can comprise a nickel matrix comprising hard phases of 1,000 Vickers hardness or greater totaling 5 mol. % or greater, 20 wt. % or greater of a combined total of chromium and molybdenum, isolated hypereutectic hard phases totaling to 50 mol. % or more of a total hard phase fraction, a WC/Cr 3 C 2 ratio of 0.33 to 3, an ASTM G65A abrasion loss of less than 250 mm 3 , and a hardness of 650 Vickers or greater.
• the hardfacing layer can have a corrosion rate of below 0.1 mpy in a 3.5% sodium chloride solution for 16 hours according to G-59/G-61. In some embodiments, the hardfacing layer can have a corrosion rate of below 0.08 mpy in a 3.5% sodium chloride solution for 16 hours according to G-59/G-61.
• the nickel matrix can have a matrix proximity of 80% or greater as compared to a corrosion resistant alloy defined by Ni: BAL, X > 20 wt. %, wherein X represents at least one of Cu, Cr, or Mo.
• the corrosion resistant alloy is selected from the group consisting of Inconel 625, Inconel 622, Hastelloy C276, Hastelloy X, and Monel 400.
• the hardfacing layer can be applied onto a hydraulic cylinder, tension riser, mud motor rotor, or oilfield component application.
• a feedstock material comprising nickel; wherein the feedstock material is configured to form a corrosion resistant matrix which is characterized by having, under thermodynamic equilibrium conditions hard phases of 1,000 Vickers hardness or greater totaling 5 mol. % or greater, and a matrix proximity of 80% or greater when compared to a known corrosion resistant nickel alloy.
• the known corrosion resistant nickel alloy can be represented by the formula Ni: BAL X > 20 wt. %, wherein X represents at least one of Cu, Cr, or Mo.
• the feedstock material can be a powder.
• the powder can be made via an atomization process.
• the powder can be made via an agglomerated and sintered process.
• the corrosion resistant matrix can be a nickel matrix comprising 20 wt. % or greater of a combined total of chromium and molybdenum. In some embodiments, under thermodynamic equilibrium conditions, the corrosion resistant matrix can be characterized by having isolated hypereutectic hard phases totaling to 50 mol. % or more of a total hard phase fraction.
• the known corrosion resistant nickel alloy can be selected from the group consisting of Inconel 625, Inconel 622, Hastelloy C276, Hastelloy X, and Monel 400.
• the feedstock material can comprise C: 0.84-1.56, Cr: 14-26, Mo: 8.4-15.6, Nb: 4.2-7.8, and Ti: 0.35-0.65.
• the feedstock material can further comprise B: about 2.5 to about 5.7, and Cu: about 9.8 to about 23.
• the feedstock material can further comprise Cr: about 7 to about 14.5.
• the corrosion resistant matrix can be characterized by having hard phases totaling 50 mol. % or greater, and a liquidus temperature of 1550 K or lower.
• the feedstock material can comprise a blend of Monel and at least one of WC or Cr 3 C 2 .
• the feedstock material is selected from the group consisting of, by wt. 75-85% WC + 15-25% Monel, 65-75% WC + 25-35% Monel, 60-75% WC + 25-40% Monel, 75-85% Cr 3 C 2 + 15-25% Monel, 65-75% Cr C 2 + 25-35% Monel, 60- 75% Cr C 2 + 25-40% Monel, 75-85% WC/Cr C 2 + 15-25% Monel, 65-75% WC/Cr C 2 + 25- 35% Monel, and 60-75% WC/Cr C 2 + 25-40% Monel.
• a WC/Cr 3 C 2 ratio of the corrosion resistant matrix can be 0.0.2 to 5 by volume.
• the thermal spray feedstock material can comprise a wire. In some embodiments, the thermal spray feedstock material can comprise a combination of a wire and powder.
• the hardfacing layer can comprise an ASTM G65A abrasion loss of less than 250 mm 3 , and two cracks or fewer per square inch when forming the hardfacing layer from a PTA or laser cladding process.
• the hardfacing layer can further comprise a hardness of 650 Vickers or greater, and an adhesion of 9,000 psi or greater when forming the hardfacing layer from a HVOF thermal spray process.
• the hardfacing layer can be applied onto a hydraulic cylinder, tension riser, mud motor rotor, or oilfield component application.
• the hardfacing layer can comprise a hardness of 750 Vickers or greater, and a porosity of 2 volume % or less, preferably 0.5 % or less when forming the hardfacing layer from a HVOF thermal spray process.
• Figure 1 illustrates a phase mole fraction vs. temperature diagram of alloy P82-X6 showing the mole fraction of phases present in an alloy at different temperatures.
• Figure 2 illustrates a phase mole fraction vs. temperature diagram of alloy P76-X23 showing the mole fraction of phases present in an alloy at different temperatures.
• Figure 3 shows an SEM image of one embodiment of an alloy P82-X6 with hard phases, hypereutectic hard phases, and a matrix.
• Figure 4 shows an optical microscopy image of P82-X6 laser welded from the gas atomized powder per example 1, parameter set 1.
• Figure 5 shows SEM images of the gas atomized powder 501 and resultant coating 502 of the P76-X24 alloy per example 2.
• Figure 6 shows an SEM image of an HVOF coating deposited from agglomerated and sintered powder of WC/Cr 3 C 2 + Ni alloy per example 3, specifically a blend of 80 wt. % WC/Cr 3 C 2 (50/50 vol%) mixed with 20 wt. % Monel.
• Embodiments of the present disclosure include but are not limited to hardfacing/hardbanding materials, alloys or powder compositions used to make such hardfacing/hardbanding materials, methods of forming the hardfacing/hardbanding materials, and the components or substrates incorporating or protected by these hardfacing/hardbanding materials.
• nickel-based alloys that have been developed to provide abrasive and corrosion resistance. Industries which would benefit from combined corrosion and wear resistance include marine applications, power industry coatings, oil & gas applications, and coatings for glass manufacturing.
• alloys disclosed herein can be engineered to form a microstructure which possesses both a matrix chemistry similar to some known alloys, such as Inconel and Hastelloys, while also including additional elements to improve performance.
• carbides can be added into the matrix of the material.
• improved corrosion resistance and improved abrasion resistance can be formed.
• nickel-based alloys as described herein may serve as effective feedstock for the plasma transferred arc (PTA), laser cladding hardfacing processes including high speed laser cladding, and thermal spray processing including high velocity oxygen fuel (HVOF) thermal spray, though the disclosure is not so limited.
• PTA plasma transferred arc
• HVOF high velocity oxygen fuel
• Some embodiments include the manufacture of nickel-based alloys into cored wires for hardfacing processes, and the welding methods of nickel-based wires and powders using wire fed laser and short wave lasers.
• alloy can refer to the chemical composition of a powder used to form a metal component, the powder itself, the chemical composition of a melt used to form a casting component, the melt itself, and the composition of the metal component formed by the heating, sintering, and/or deposition of the powder, including the composition of the metal component after cooling.
• the term alloy can refer to the chemical composition forming the powder disclosed within, the powder itself, the feedstock itself, the wire, the wire including a powder, the combined composition of a combination of wires, the composition of the metal component formed by the heating and/or deposition of the powder, or other methodology, and the metal component.
• alloys manufactured into a solid or cored wire (a sheath containing a powder) for welding or for use as a feedstock for another process may be described by specific chemistries herein.
• the wires can be used for a thermal spray.
• the compositions disclosed below can be from a single wire or a combination of multiple wires (such as 2, 3, 4, or 5 wires).
• the alloys can be applied by a thermal spray process to form a thermal spray coating, such as HVOF alloys.
• a thermal spray coating such as HVOF alloys.
• the alloys can be applied as a weld overlay.
• the alloys can be applied either as a thermal spray or as a weld overlay, e.g., having dual use.
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise Ni and in weight percent:
• Mn 0 - 1.08 (or about 0 - about 1.08);
• Nb 0 - 27 (or about 0 - about 27);
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise Ni and in weight percent:
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise Ni and in weight percent:
• Nb + Ti 2 - 10 (or about 2 - about 10).
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise Ni and in weight percent:
• Nb + Ti 4.2 - 8.5 (or about 4.2 - about 8.5).
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise Ni and in weight percent:
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise Ni and in weight percent:
• Nb 5.4 - 6.6 (or about 5.4 - about 6.6).
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise Ni and in weight percent:
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise one of the following, in weight percent:
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise Ni and in weight percent
• B 3.5, Cu: 14 (or B: about 3.5, Cu: about 14);
• B 4.0, Cr: 10, Cu 16 (or B: about 4.0, Cr: about 10, Cu about 16);
• an article of manufacture such as a composition of a feedstock as disclosed herein, can comprise agglomerated and sintered blends of, in weight percent:
• hard phases are one or more of the following: Tungsten Carbide (WC) and/or Chromium Carbide (Cr 3 C 2 ).
• Monel is a nickel copper alloy of the target composition Ni BAL 30 wt.% Cu with a common chemistry tolerance of 20-40 wt.% Cu, or more preferably 28-34 wt.% Cu with known impurities including but not limited to C, Mn, S, Si, and Fe. Monel does not include any carbides, and thus embodiments of the disclosure add in carbides, such as tungsten carbides and/or chromium carbides.
• Tungsten carbide is generally described by the formula W: BAL, 4-8 wt.% C. In some embodiments, tungsten carbide can be described by the formula W: BAL, 1.5 wt.% C.
• the article of manufacture can be, in weight percent:
• Ni 10.5 - 28 (or about 10.5 - about 28);
• the article of manufacture can be, in weight percent:
• Ni 10.5 - 28 (or about 10.5 - about 28);
• W 52.1 - 73.78 (or about 52.1 - about 73.79).
• Table I lists a number of experimental alloys, with their compositions listed in weight percent.
• Table I List of Experimental Nickel-Based Alloy Compositions in wt. %
• P76 alloys can be thermal spray alloys and P82 alloys can be weld overlay alloys (such as PTA or laser).
• PTA plasma transferred arc
• HVOF high velocity oxygen fuel
• the disclosed compositions can be the wire/powder, the coating or other metallic component, or both.
• the disclosed alloys can incorporate the above elemental constituents to a total of 100 wt. %.
• the alloy may include, may be limited to, or may consist essentially of the above named elements.
• the alloy may include 2 wt.% (or about 2 wt.%) or less, 1 wt.% (or about 1 wt.%) or less, 0.5 wt.% (or about 0.5 wt.%) or less, 0.1 wt.% (or about 0.1 wt.%) or less or 0.01 wt.% (or about 0.01 wt.%) or less of impurities, or any range between any of these values.
• Impurities may be understood as elements or compositions that may be included in the alloys due to inclusion in the feedstock components, through introduction in the manufacturing process.
• the Ni content identified in all of the compositions described in the above paragraphs may be the balance of the composition, or alternatively, where Ni is provided as the balance, the balance of the composition may comprise Ni and other elements. In some embodiments, the balance may consist essentially of Ni and may include incidental impurities.
• alloys can be characterized by their equilibrium thermodynamic criteria. In some embodiments, the alloys can be characterized as meeting some of the described thermodynamic criteria. In some embodiments, the alloys can be characterized as meeting all of the described thermodynamic criteria.
• a first thermodynamic criterion pertains to the total concentration of extremely hard particles in the micro structure.
• extremely hard particles may be defined as phases that exhibit a hardness of 1000 Vickers or greater (or about 1000 Vickers or greater).
• the total concentration of extremely hard particles may be defined as the total mole% of all phases that meet or exceed a hardness of 1000 Vickers (or about 1000 Vickers) and is thermodynamically stable at 1500K (or about 1500K) in the alloy.
• the extremely hard particle fraction is 3 mole% or greater (or about 3 mole% or greater), 4 mole% or greater (or about 4 mole% or greater), 5 mole% or greater (or about 5 mole% or greater), 8 mole% or greater (or about 8 mole% or greater), 10 mole% or greater (or about 10 mole% or greater), 12 mole% or greater (or about 12 mole% or greater) or 15 mole% or greater (or about 15 mole% or greater), 20 mole% or greater (or about 20 mole% or greater), 30 mole% or greater (or about 30 mole% or greater), 40 mole% or greater (or about 40 mole% or greater), 50 mole% or greater (or about 50 mole% or greater), 60 mole% or greater (or about 60 mole% or greater), or any range between any of these values.
• the extremely hard particle fraction can be varied according to the intended process of the alloy.
• the hard particle fraction can be between 40 and 60 mol. % (or between about 40 and about 60 mol.%).
• the hard particle phase fraction can be between 15 and 30 mol. % (or between about 15 and about 30 mol.%).
• a second thermodynamic criterion pertains to the amount of hypereutectic hard phases that form in the alloy.
• a hypereutectic hard phase is a hard phase that begins to form at a temperature higher than the eutectic point of the alloy. The eutectic point of these alloys is the temperature at which the FCC matrix begins to form.
• hypereutectic hard phases total to 40 mol. % or more (or about 40% or more), 45 mol. % or more (or about 45% or more), 50 mol. % or more (or about 50% or more), 60 mol. % or more (or about 60% or more), 70 mol. % or more (or about 70% or more), 75 mol. % or more (or about 75% or more) or 80 mol. % or more (or about 80% or more) of the total hard phases present in the alloy, or any range between any of these values.
• a third thermodynamic criterion pertains to the corrosion resistance of the alloy.
• the corrosion resistance of nickel-based alloys may increase with higher weight percentages of chromium and/or molybdenum present in the FCC matrix.
• This third thermodynamic criterion measures the total weight% of chromium and molybdenum in the FCC matrix at 1500K (or about 1500K).
• the total weight% of chromium and molybdenum in the matrix is 15 weight% or greater (or about 15 weight% or greater), 18 weight% or greater (or about 18 weight% or greater), 20 weight% or greater (or about 20 weight% or greater), 23 weight% or greater (or about 23 weight% or greater), 25 weight% or greater (or about 25 weight% or greater), 27 weight% or greater (or about 27 weight% or greater) or 30 weight% or greater (or about 30 weight% or greater), or any range between any of these values.
• a fourth thermodynamic criterion relates to the matrix chemistry of the alloy.
• it may be beneficial to maintain a similar matrix chemistry to a known alloy such as, for example, Inconel 622, Inconel 625, Inconel 686, Hastelloy C276, Hastelloy X, or Monel 400.
• the matrix chemistry of alloys at 1300K was compared to those of a known alloy. Comparisons of this sort are termed Matrix Proximity.
• such superalloys can be represented by the formula, in wt. %, Ni: BAL, Cr: 15-25, Mo: 8-20.
• the matrix proximity is 50% (or about 50%) or greater, 55% (or about 55%) or greater, 60% (or about 60%) or greater, 70% (or about 70%) or greater, 80% (or about 80%) or greater, 85% (or about 85%) or greater, 90% (or about 90%) or greater, of any of the above known alloys.
• Matrix proximity can be determined in a number of ways, such as energy dispersive spectroscopy (EDS).
• m is the number of solute elements used in the comparison.
• a fifth thermodynamic criterion relates to the liquidus temperature of the alloy, which can help determine the alloy’s suitability for the gas atomization manufacturing process.
• the liquidus temperature is the lowest temperature at which the alloy is still 100% liquid.
• a lower liquidus temperature generally corresponds to an increased suitability to the gas atomization process.
• the liquidus temperature of the alloy can be 1850 K (or about 1850 K) or lower.
• the liquidus temperature of the alloy can be 1600 K (or about 1600 K) or lower.
• the liquidus temperature of the alloy can be 1450 K (or about 1450 K) or lower.
• the thermodynamic behavior of alloy P82-X6 is shown in Figure 1.
• the diagram depicts a material which precipitates a hypereutectic FCC carbide 101 in a nickel matrix 103, which is greater than 5% at 1500K.
• 101 depicts the FCC carbide fraction as a function of temperature, which forms an isolated hypereutectic phase.
• 102 specifies the total hard phase content at 1300 K, which includes the FCC carbide in addition to an M6C carbide.
• the hypereutectic hard phases make up more than 50% of the total hard phases of the alloy.
• 103 species the matrix of the alloy, which is FCC_Ll2 Nickel matrix.
• the matrix proximity of the alloy 103 is greater than 60% when compared to Inconel 625.
• a M 6 C type carbide also precipitates at a lower temperature to form a total carbide content of about 15 mol. % at 1300K (12.6% FCC carbide, 2.4% M 6 C carbide).
• the FCC carbide representing the isolated carbides in the alloy and forming the majority (>50%) of the total carbides in the alloy.
• the arrow points specifically to the point at which the composition of the FCC_Ll2 matrix is mined for insertion into the matrix proximity equation. As depicted in this example, the volume fraction of all hard phases exceeds 5 mole %, with over 50% of the carbide fraction forming as a hypereutectic phase known to form an isolated morphology with the remaining FCC_Ll2 matrix phase possessing over 60% proximity with Inconel 625.
• the chemistry of the FCC_Ll2 matrix phase is mined.
• the matrix chemistry is 18 wt. % Cr, 1 wt. % Fe, 9 wt. % Mo, and 1 wt. % Ti, balance Nickel. It can be appreciated that the matrix chemistry of P82- X6 is completely different than the bulk chemistry of P82-X6. P82-X6 is designed to have corrosion performance similar to Inconel 625 and the matrix proximity with Inconel 625 is 87%.
• the thermodynamic behavior of alloy P76-X23 is shown in Figure 2.
• the diagram depicts a material which precipitates a eutectic Ni 3 B 203 in a nickel matrix 201.
• 201 calls out the liquidus temperature of the alloy, which is below 1850K according to a preferred embodiment.
• 202 depicts the mole fraction of hard phases in the alloy, in this case nickel boride (Ni 3 B) which exceeds 5 mol. % at 1200K.
• 203 depicts the matrix phase fraction in which case the matrix chemistry is mined at 1200K and the matrix proximity is over 60% with Monel.
• the liquidus temperature of the alloy is 1400 K which makes the material very suitable for gas atomization.
• Ni3B is that hard phase in this example and is present at a mole fraction of 66% at 1300K.
• the matrix chemistry is 33 wt. % Cu, balance Nickel. It can be appreciated that the matrix chemistry of P76-X23 is completely different than the bulk chemistry of P76-X23.
• P76-X23 is designed to have corrosion performance similar to Monel 400 and the matrix proximity of P76-X23 with Monel 400 is 100%.
• alloys can be described by their microstructural criterion. In some embodiments, the alloys can be characterized as meeting some of the described microstructural criteria. In some embodiments, the alloys can be characterized as meeting all of the described microstructural criteria.
• a first microstructural criterion pertains to the total measured volume fraction of extremely hard particles.
• extremely hard particles may be defined as phases that exhibit a hardness of 1000 Vickers or greater (or about 1000 Vickers or greater).
• the total concentration of extremely hard particles may be defined as the total mole% of all phases that meet or exceed a hardness of 1000 Vickers (or about 1000 Vickers) and is thermodynamically stable at 1500K (or about 1500K) in the alloy.
• an alloy possesses at least 3 volume% (or at least about 3 volume%), at least 4 volume% (or at least about 4 volume%), at least 5 volume% (or at least about 5 volume%), at least 8 volume% (or at least about 8 volume%), at least 10 volume% (or at least about 10 volume%), at least 12 volume% (or at least about 12 volume%) or at least 15 volume% (or at least about 15 volume%) of extremely hard particles, at least 20 volume% (or at least about 20 volume%) of extremely hard particles, at least 30 volume% (or at least about 30 volume%) of extremely hard particles, at least 40 volume% (or at least about 40 volume%) of extremely hard particles, at least 50 volume% (or at least about 50 volume%) of extremely hard particles, or any range between any of these values.
• the extremely hard particle fraction can be varied according to the intended process of the alloy.
• the hard particle fraction can be between 40 and 60 vol. % (or between about 40 and about 60 vol. %).
• the hard particle phase fraction can be between 15 and 30 vol. % (or between about 15 and about 30 vol.%).
• a second micro structural criterion pertains to the fraction of hypereutectic isolated hard phases in an alloy. Isolated, as used herein, can mean that the particular isolated phase (such as spherical or partially spherical particles) remains unconnected from other hard phases. For example, an isolated phase can be 100% enclosed by the matrix phase. This can be in contrast to rod-like phases which can form long needles that act as low toughness “bridges,” allowing cracks to work through the micro structure.
• isolated hypereutectic hard phases total 40 vol. % (or about 40%) or more, 45 vol. % (or about 45%) or more, 50 vol. % (or about 50%) or more, 60 vol. % (or about 60%) or more, 70 vol. % (or about 70%) or more, 75 vol. % (or about 75%) or more or 80 vol. % (or about 80%) or more of the total hard phase fraction present in the alloy, or any range between any of these values.
• a third micro structural criterion pertains to the increased resistance to corrosion in the alloy.
• An Energy Dispersive Spectrometer (EDS) was used to determine the total weight % of chromium and molybdenum in a matrix.
• the total content of chromium and molybdenum in the matrix may be 15 weight% or higher (or about 15 weight% or higher), 18 weight% or higher (or about 18 weight% or higher), 20 weight% or higher (or about 20 weight% or higher), 23 weight% or higher (or about 23 weight% or higher), 25 weight% or higher (or about 25 weight% or higher), 27 weight% or higher (or about 27 weight% or higher) or 30 weight% or higher (or about 30 weight% or higher), or any range between any of these values.
• a fourth microstructural criterion pertains to the matrix proximity of an alloy compared to that of a known alloy such as, for example, Inconel 625, Inconel 686, or Monel.
• An Energy Dispersive Spectrometer (EDS) was used to measure the matrix chemistry of the alloy.
• the matrix proximity is 50% (or about 50%) or greater, 55% (or about 55%) or greater, 60% (or about 60%) or greater, 70% (or about 70%) or greater, 80% (or about 80%) or greater, 85% (or about 85%) or greater or 90% (or about 90%) or greater of the known alloy, or any range between any of these values.
• the matrix proximity is similar to what is described in the thermodynamic criteria section, in this case it is calculated.
• the difference between‘matrix chemistry’ and ‘matrix proximity’ is that the chemistry is the actual values of Cr, Mo or other elements found in solid solution of the Nickel matrix.
• the proximity is the % value used as a quantitative measure to how closely the Nickel matrix of the designed alloy matches the chemistry of a known alloy possessing good corrosion resistance.
• the known alloys such as Inconel are single phase alloys so the alloy composition is effectively the matrix composition, all the alloying elements are found in solid solution. This is not the case with the alloys described here in which we are precipitating hard phases for wear resistance.
• Figure 3 shows an SEM image of a microstructure for the P82-X6 as produced via PTA welding.
• the alloy was created as a powder blend for experimental purposes.
• 301 highlights the isolated Niobium carbide precipitates, which have a volume fraction at 1500K of greater than 5%
• 302 highlights the hypereutectic hard phases, which makes up more than 50% of the total hard phases in the alloy
• 303 highlights the matrix, which has a matrix proximity greater than 60% when compared to Inconel 625.
• the carbide precipitates form a combination of isolated (larger size) and eutectic morphology (smaller size) both contributing to the total hard phase content.
• the hard phases of isolated morphology make up over 50 vol.% of the total carbide fraction.
• a hardfacing layer is produced via a weld overlay process including but not limited to PTA cladding or laser cladding.
• an alloy can have a number of advantageous performance characteristics. In some embodiments, it can be advantageous for an alloy to have one or more of 1) a high resistance to abrasion, 2) minimal to no cracks when welded via a laser cladding process or other welding method, and 3) a high resistance to corrosion.
• the abrasion resistance of hardfacing alloys can be quantified using the ASTM G65A dry sand abrasion test.
• the crack resistance of the material can be quantified using a dye penetrant test on the alloy.
• the corrosion resistance of the alloy can be quantified using the ASTM G48, G59, and G61 tests. All of the listed ASTM tests are hereby incorporated by reference in their entirety.
• a hardfacing layer may have an ASTM G65A abrasion loss of less than 250mm 3 (or less than about 250mm 3 ), less than 100 mm 3 (or less than about 100 mm 3 ), less than 30 mm 3 (or less than about 30mm 3 ), or less than 20mm 3 (or less than about 20mm 3 ).
• the hardfacing layer may exhibit 5 cracks per square inch, 4 cracks per square inch, 3 cracks per square inch, 2 cracks per square inch, 1 crack per square inch or 0 cracks per square inch of coating, or any range between any of these values.
• a crack is a line on a surface along which it has split without breaking into separate parts.
• the hardfacing layer may have a corrosion resistance of 50% (or about 50%) or greater, 55% (or about 55%) or greater, 60% (or about 60%) or greater, 70% (or about 70%) or greater, 80% (or about 80%) or greater, 85% (or about 85%) or greater, 90% (or about 90%) or greater, 95% (or about 95%) or greater, 98% (or about 98%) or greater, 99% (or about 99%) or greater or 99.5% (or about 99.5%) or greater than a known alloy, or any range between any of these values.
• Corrosion resistance is complex and can depend on the corrosive media being used.
• the corrosion rate of embodiments of the disclosed alloys can be nearly equivalent to the corrosion rate of the comparative alloy they are intended to mimic.
• P82-X6 can have a corrosion resistance of 1.25 mpy or lower to yield a corrosion resistance of 80%.
• Corrosion resistance is defined as 1 / corrosion rate for the purposes of this disclosure.
• the alloy can have a corrosion resistance in a 3.5% sodium chloride solution for 16 hours according to G-59/G-61 of below 0.1 mpy (or below about 0.1 mpy). In some embodiments, the alloy can have a corrosion resistance in a 3.5% sodium chloride solution for 16 hours according to G-59/G-61 of below 0.08 mpy (or below about 0.08 mpy).
• a hardfacing layer is produced via a thermal spray process including but not limited to high velocity oxygen fuel (HVOF) thermal spray.
• HVOF high velocity oxygen fuel
• the hardness of the coating can be 650 (or about 650) Vickers or higher. In some embodiments, the hardness of the thermal spray process can be 700 (or about 700) Vickers or higher. In some embodiments, the hardness of the thermal spray process can be 900 (or about 900) Vickers or higher.
• the adhesion of the thermal spray coating can be 7,500 (or about 7,500) psi or greater. In some embodiments, the adhesion the adhesion of the thermal spray coating can be 8,500 (or about 8,500) psi or greater. In some embodiments, the adhesion the adhesion of the thermal spray coating can be 9,500 (or about 9,500) psi or greater.
• Alloy P82-X6 was gas atomized into a powder of 53-150 pm particle size distribution as suitable for PTA and/or laser cladding.
• the alloy was laser clad using two parameter sets: 1) 1.8 kW laser power and 20L/min flow rate, and 2) 2.2 kW laser power and 14 L /min flow rate. In both cases, the coating showed fine isolated niobium / titanium carbide precipitates 401 in a Nickel matrix 402 as intended as shown in Figure 4.
• the 300 grams force Vickers hardness of the laser claddings was 435 and 348 for parameter sets 1 and 2, respectively.
• the ASTM G65 tests were 1.58 g lost (209 mm 3 ) and 1.65 g (200 mm 3 ) lost for parameters sets 1 and 2, respectively.
• Alloys P76-X23 and P76-X24 were gas atomized into powders of 15-45 pm particle size distribution as suitable for HVOF thermal spray processing. Both powders forms an extremely fine scale morphology where a nickel matrix phase and nickel boride phase appear to be both present as predicted via the computational modelling, but very difficult to distinguish and measure quantitatively.
• the P76-X24 alloy in addition to the matrix and Ni boride phase 504 (e.g., the eutectic nickel/nickel boride structure of the gas atomized powder), the P76-X24 alloy also forms chromium boride precipitates 503 as predicted by the model as fine isolated particles.
• 505 highlights a region of primarily nickel / nickel boride eutectic structure in the HVOF sprayed coating, and 506 highlights a region containing many chromium boride precipitates in the coating.
• Both alloys were HVOF sprayed to about 200-300 pm coating thickness and formed dense coatings.
• the 300 grams force Vickers hardness of the coatings were 693 and 726 for P76-X23 and P76-X24 respectively.
• P76-X23 adhesion tests result in glue failure up to 9,999 psi
• P76-X24 showed 75% adhesion, 25% glue failure in two tests reaching 9,576 and 9,999 psi.
• ASTM G65A (converted from an ASTM G65B test) testing showed 87 mm 3 lost for P76-X24.
• ASTM G65A testing uses 6,000 revolutions, procedure B uses 2,000 revolutions and is typically used for thin coatings such as thermal spray coatings.
• Example 3 HVOF Spraying of a WC/Cr3C2, Ni alloy matrix blends.
• a blend of a blend of 80 wt. % WC/Cr3C2 (50/50 vol%) mixed with 20 wt. % Monel was agglomerated and sintered into 15 - 45 pm as suitable for thermal spray processing.
• the HVOF coating as shown in Figure 6, possessed a 300 gram Vickers hardness of 946 forming a dense coating of 0.43% measured porosity.
• the HVOF coating produced an ASTM G65A mass loss of about 12 mm 3 .
• Figure 6 illustrates an SEM image of an agglomerated and sintered powder of WC/Cr 3 C 2 + Ni alloy per example 3, specifically a blend of 80 wt. % WC/Cr3C2 (50/50 vol%) mixed with 20 wt. % Monel.
• Example 4 Weld Studies of P82-X13, 14, 15, 18, 19 in comparison with Inconel 625
• a weld study was conducted evaluating several alloys of differing carbide contents and morphologies in comparison to Inconel 625. All of the alloys in the study were intended to form a matrix similar to Inconel 625, which is quantified by the matrix proximity, 100% equating to a matrix which is exactly similar to the Inconel 625 bulk composition. All the alloys were laser welded in three overlapping layers to test for crack resistance. Similarly, two layer welds of each alloy were produced via plasma transferred arc welding to test for cracking and other properties.
• the P82-X18 represents an embodiment of this disclosure producing favorable results at the conclusion of this study.
• P82-X18 is significantly harder than Inconel 625 in both processes, PTA and laser. Despite the increased hardness, no cracking was evident in the laser or PTA clad specimens.
• P82-X18 exhibits improved abrasion resistance as compared to Inconel 625 in both processes.
• the general trend for increased hardness is true for all the tested alloys as demonstrated in Table 3. However, surprisingly, the increased hardness does not generate an increased abrasion resistance in all cases.
• P82-X13, P82-X14, and P82-X15 all exhibited higher wear rates than Inconel 625 despite being harder and containing carbides. This result demonstrates the discovered advantageous carbide morphology as compared to total carbide fraction and alloy hardness.
• Alloy P82-X18 meets thermodynamic, microstructural, and performance criteria of this disclosure.
• P82-X18 is predicted to form 8.1 mol.% isolated carbides and indeed forms 8-12% isolated carbides in the studied and industrially relevant weld processes.
• the alloy is also predicted to form 9.9 mol% grain boundary hard phases, and indeed forms grain boundary hard phases of 10 vol. % or less.
• the isolated carbide content is in excess of 40% of the total carbide content in the alloy. This elevated ratio of isolated carbide fraction provides enhanced wear resistance beyond what can be expected of total carbide fraction alone.
• the matrix of P82-X18 was measured via Energy Dispersive Spectroscopy which yielded Cr: 19-20 wt. %, Mo: 10-12 wt., %, Ni: Balance.
• the matrix composition is quite similar and somewhat overlapping with a typical Inconel 625 manufacturing range which is: Cr: 20-23, Mo: 8-10, Nb+Ta: 3.15-4.15, Ni: BAL.
• P82-X18 was tested in G-48 ferric chloride immersion testing for 24 hours and, similar to Inconel 625, showed no corrosion.
• P82-X18 was corrosion tested in a 3.5% Sodium Chloride solution for 16 hours according to G-59/G-61 ASTM standard and measured a corrosion rate of 0.075 - 0.078 mpy (mils per year).
• the measured corrosion rate of the material in a 3.5% Sodium Chloride solution for 16 hours according to G-59/G-61 is below 0.1 mpy. In some embodiments, the measured corrosion rate of the material in a 3.5% Sodium Chloride solution for 16 hours according to G-59/G-61 is below 0.08 mpy.
• the alloys disclosed herein can be used in exchange for nickel or other common materials as the metal component in carbide metal matrix composites (MMCs).
• MMCs carbide metal matrix composites
• Common examples of the type of MMCs include by weight WC 60 wt.%, Ni 40 wt.%. Utilizing P82-X18 in this example would yield an MMC of the type: WC 60 wt.%, P82-X18 40 wt.%.
• a variety of carbide ratios and carbide types can be used.
• P82-X18 was thermally sprayed using the hydrogen fueled HVOF process.
• the resultant coating had an adhesion strength of 10,000 psi, 700 HV300 Vickers hardness, and an ASTM G65B mass loss of 0.856 (10.4.6 g/mm 3 volume loss).
• Two powders were manufactured via the agglomeration and sintering process according to the formulas: 1) 65-75% WC/Cr 3 C 2 + 25-35% NiCu alloy and 2) 65- 75% Cr 3 C 2 + 25-35% NiCu alloy.
• 65-75% of the total volume fraction of the agglomerated and sintered particle is carbide, the remainder being the NiCu metal alloy.
• the carbide content of the particle is itself composed of a combination of both WC and Cr 3 C 2 carbide types.
• the WC/Cr 3 C 2 ratio is from 0 to 100 by volume. In some embodiments, the WC/Cr 3 C 2 ratio is about 0.33 to 3 by volume.
• the WC/Cr 3 C 2 ratio is about 0.25 to 5 by volume. In some embodiments, the WC/Cr 3 C 2 ratio is about 0.67 to 1.5.
• the composition of the NiCu alloy is Cu: 20-40 wt.%, preferably Cu: 25-35 wt. %, still preferably: Cu: 28-34 wt.%, balance Nickel with other common impurities below 3 wt.% each.
• alloys described in this disclosure can be used in a variety of applications and industries. Some non-limiting examples of applications of use include: surface mining, marine, power industry, oil and gas, and glass manufacturing applications.
• Wear resistant sleeves and/or wear resistant hardfacing for slurry pipelines include the following components and coatings for the following components: Wear resistant sleeves and/or wear resistant hardfacing for slurry pipelines, mud pump components including pump housing or impeller or hardfacing for mud pump components, ore feed chute components including chute blocks or hardfacing of chute blocks, separation screens including but not limited to rotary breaker screens, banana screens, and shaker screens, liners for autogenous grinding mills and semi- autogenous grinding mills, ground engaging tools and hardfacing for ground engaging tools, wear plate for buckets and dump truck liners, heel blocks and hardfacing for heel blocks on mining shovels, grader blades and hardfacing for grader blades, stacker reclaimers, sizer crushers, general wear packages for mining components and other comminution components.
• Conditional language such as“can,”“could,”“might,” or“may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include or do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.
• the above recited ranges can be specific ranges, and not within a particular % of the value. For example, within less than or equal to 10 wt./vol. % of, within less than or equal to 5 wt./vol. % of, within less than or equal to 1 wt./vol. % of, within less than or equal to 0.1 wt./vol. % of, and within less than or equal to 0.01 wt./vol. % of the stated amount.

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