WO2021007209A1 - Iron-based alloys designed for wear and corrosion resistance - Google Patents

Iron-based alloys designed for wear and corrosion resistance Download PDF

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Publication number
WO2021007209A1
WO2021007209A1 PCT/US2020/041006 US2020041006W WO2021007209A1 WO 2021007209 A1 WO2021007209 A1 WO 2021007209A1 US 2020041006 W US2020041006 W US 2020041006W WO 2021007209 A1 WO2021007209 A1 WO 2021007209A1
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WIPO (PCT)
Prior art keywords
feedstock
coating
alloy
matrix
less
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Ceased
Application number
PCT/US2020/041006
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English (en)
French (fr)
Inventor
James Nathaniel VECCHIO
Justin Lee Cheney
Cameron EIBL
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Oerlikon Metco US Inc
Original Assignee
Oerlikon Metco US Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Oerlikon Metco US Inc filed Critical Oerlikon Metco US Inc
Priority to JP2021576786A priority Critical patent/JP7572384B2/ja
Priority to CN202080058914.7A priority patent/CN114341385A/zh
Priority to CA3144793A priority patent/CA3144793A1/en
Priority to AU2020310863A priority patent/AU2020310863B2/en
Priority to KR1020227003973A priority patent/KR102870036B1/ko
Priority to US17/625,319 priority patent/US12569942B2/en
Priority to MX2022000309A priority patent/MX2022000309A/es
Priority to EP20743558.7A priority patent/EP3997252B1/en
Publication of WO2021007209A1 publication Critical patent/WO2021007209A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/30—Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
    • B23K35/3053—Fe as the principal constituent
    • B23K35/308—Fe as the principal constituent with Cr as next major constituent
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K10/00—Welding or cutting by means of a plasma
    • B23K10/02—Plasma welding
    • B23K10/027—Welding for purposes other than joining, e.g. build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/0006—Working by laser beam, e.g. welding, cutting or boring taking account of the properties of the material involved
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K26/00—Working by laser beam, e.g. welding, cutting or boring
    • B23K26/34—Laser welding for purposes other than joining
    • B23K26/342—Build-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261—Rods, electrodes or wires
    • B23K35/0272—Rods, electrodes or wires with more than one layer of coating or sheathing material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24—Selection of soldering or welding materials proper
    • B23K35/32—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550°C
    • B23K35/327—Selection of soldering or welding materials proper with the principal constituent melting at more than 1550°C comprising refractory compounds, e.g. carbides
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/04—Welding for other purposes than joining, e.g. built-up welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/167—Arc welding or cutting making use of shielding gas and of a non-consumable electrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/16—Arc welding or cutting making use of shielding gas
    • B23K9/173—Arc welding or cutting making use of shielding gas and of a consumable electrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/18—Submerged-arc welding
    • B23K9/182—Submerged-arc welding making use of a non-consumable electrode
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00—Arc welding or cutting
    • B23K9/18—Submerged-arc welding
    • B23K9/186—Submerged-arc welding making use of a consumable electrodes
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0292—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with more than 5% preformed carbides, nitrides or borides
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/22—Ferrous alloys, e.g. steel alloys containing chromium with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/24—Ferrous alloys, e.g. steel alloys containing chromium with vanadium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/26—Ferrous alloys, e.g. steel alloys containing chromium with niobium or tantalum
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/28—Ferrous alloys, e.g. steel alloys containing chromium with titanium or zirconium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/32—Ferrous alloys, e.g. steel alloys containing chromium with boron
    • 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
    • C23C24/00—Coating starting from inorganic powder
    • C23C24/08—Coating starting from inorganic powder by application of heat or pressure and heat
    • C23C24/10—Coating starting from inorganic powder by application of heat or pressure and heat with intermediate formation of a liquid phase in the layer
    • C23C24/103—Coating with metallic material, i.e. metals or metal alloys, optionally comprising hard particles, e.g. oxides, carbides or nitrides
    • 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
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B22F2009/0824—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid with a specific atomising fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00—Aspects linked to processes or compositions used in powder metallurgy
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2101/00—Articles made by soldering, welding or cutting
    • B23K2101/006—Vehicles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K2103/00—Materials to be soldered, welded or cut
    • B23K2103/02—Iron or ferrous alloys
    • B23K2103/04—Steel or steel alloys
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2211/00—Microstructure comprising significant phases
    • C21D2211/004—Dispersions; Precipitations
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2211/00—Microstructure comprising significant phases
    • C21D2211/005—Ferrite
    • 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
    • C23C4/067—Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
    • 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
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/134—Plasma spraying

Definitions

  • Embodiments of the disclosure generally relate to ferritic, iron-based alloys having high wear resistance.
  • a cladding feedstock comprising Fe and, in wt. % Cr: about 10 to about 26, Nb + Ti + V: about 2 to about 12, and C: about 0.5 to about 1.5.
  • the feedstock comprises Fe and, in wt. % Cr: about 16 to about 26, Ti: about 0.4 to about 2.4, Mo: 0.8 to 3.6, Nb: about 4 to about 6, and C: about 0.6 to about 1.2.
  • the feedstock comprises Fe and, in wt. % Cr: about 18 to about 25, Ti: about 0.45 to about 2.2, Mo: 0.9 to 3.3, Nb: about 4.5 to about 5.5, and C: about 0.7 to about 1.1.
  • the feedstock further comprises, in wt.%, B: 0.3 -
  • a cladding feedstock comprising Fe and, in wt. %: Cr: about 10 to about 25; Ni: up to about 4; Nb + Ti + V: about 2 to about 10; and C: about 0.5 to about 1.5.
  • the feedstock can comprise Fe and, in wt. %: Cr: about 13.6 to about 20.4; Ni: about 1.2 to about 1.6; Ti: about 1.6 to about 2.4; Nb: about 4 to about 6; and C: about 0.8 to about 1.2.
  • the feedstock comprises Fe and, in wt. %: Cr: about 15.3 to about 18.7; Ni: about 1.35 to about 1.65; Ti: about 1.8 to about 2.2; Nb: about 4.5 to about 5.5; and C: about 0.9 to about 1.1.
  • the feedstock can be characterized by having, under thermodynamic conditions, a total ferrite phase mole fraction of about 50 mol.
  • the total ferrite phase mole fraction can be about 60 mol. % or higher at all temperatures below the solidus and above 500 K. In some embodiments, the total ferrite phase mole fraction can be about 70 mol. % or higher at all temperatures below the solidus and above 500 K. In some embodiments, the feedstock can be characterized by having, under thermodynamic conditions, a total ferrite phase mole fraction of about 90 mol. % or higher at elevated temperatures just below the solidus temperature.
  • the feedstock can be characterized by having, under thermodynamic conditions, a primary carbide formation temperature between about 1750 K and about 2100 K. In some embodiments, the primary carbide formation temperature can be between about 1850 K and about 2000 K.
  • the feedstock can be characterized by having, under thermodynamic conditions, a total primary carbide mole fraction of about 5 mol. % or higher at 1300 K. In some embodiments, the total primary carbide mole fraction can be about 7.5 mol. % or higher at 1300 K. In some embodiments, the total primary carbide mole fraction can be about 10 mol. % or higher at 1300 K.
  • the feedstock can be formed through gas atomization process.
  • the coating can comprise a ferrite matrix, and a plurality of primary carbides, wherein the primary carbides are embedded in the ferrite matrix.
  • the plurality of primary carbides can comprise at least one of Nb, Ti, and V. In some embodiments, the plurality of primary carbides can comprise an isolated and spherical morphology.
  • the coating can have a total primary carbide volume fraction of at least about 5 vol. %. In some embodiments, the total primary carbide volume fraction can be at least about 7.5 vol. %. In some embodiments, the total primary carbide volume fraction can be at least about 10 vol. %. In some embodiments, the coating can have a Cr content of the ferrite matrix of at least about 12 wt. %. In some embodiments, the Cr content of the ferrite matrix can be at least about 15 wt. %. In some embodiments, the Cr content of the ferrite matrix is at least about 19 wt. %.
  • the coating can have a hardness of about 450 HV 0.3 or lower. In some embodiments, the hardness can be about 400 HV 0.3 or lower. In some embodiments, the hardness can be about 350 HV 0.3 or lower.
  • the coating can have an ASTM G65 Procedure A volume loss of about 200 mm 3 or less. In some embodiments, the ASTM G65 Procedure A volume loss can be about 150 mm 3 or less. In some embodiments, the ASTM G65 Procedure A volume loss can be about 100 mm 3 or less.
  • the coating can be configured to be formed through a deposition process. In some embodiments, the coating can be configured to be formed by a process selected from the group consisting of thermal spray, plasma transferred arc welding, laser cladding, and ultra-high speed laser cladding.
  • the feedstock can be a powder. In some embodiments, the feedstock can be one or more wires.
  • thermal spray feedstock material comprising Fe and, in wt. %, Cr: about 14 - about 35, Mo+W: about 0 - about 16, and B: about 0.2 - about 2.8.
  • the feedstock material can further comprise Cr: about 20 - about 34, Mo + W: about 0 - about 6, B: about 0.8 - about 1.8, and Nb + Ti: about 1 - about 4.
  • the feedstock material can further comprise Cr: about 15 - about 34, Mo + W: about 1 - about 16, B: about 0.3 - about 2.7, Nb + Ti: about 1 - about 10, and C: about 0 - about 1.2.
  • the feedstock material can further comprise Cr: about 15 - about 30, Mo + W: about 0 - about 6, B: about 0.2 - about 1.0, Nb + Ti: about 5 - about 12, and C: about 0.4 - about 1.4.
  • the feedstock material includes less than about 1 wt. % C. In some embodiments, the feedstock material includes less than about 0.5 wt. % C. In some embodiments, the feedstock material includes less than about 0.25 wt. % C. In some embodiments, the feedstock material includes less than about 0.1 wt. % C. In some embodiments, the feedstock material includes less than about 5 wt. % Ni. In some embodiments, the feedstock material includes less than about 1 wt. % Ni. In some embodiments, the feedstock material includes less than about 0.1 wt. % Ni.
  • the feedstock material is a powder.
  • the feedstock material is configured to form a matrix and is characterized by having, under thermodynamic equilibrium conditions a pitting resistance equivalent number as defined by the equation Cr + 3.3 * (Mo + 0.5 * W) + 16 * N of greater than about 17, less than 25 mole percent intermetallic phases, between about 7 and about 35 mole % hard phases, between about 2 and about 25 mole % borides, between about 1 and about 15 mole % MC carbides, and a liquidus temperature of less than about 2000K.
  • the feedstock material is configured to form a matrix and is characterized by having, under thermodynamic equilibrium conditions a pitting resistance equivalent number as defined by the equation Cr + 3.3 * (Mo + 0.5 * W) + 16 * N of greater than about 25, less than 8 mole percent intermetallic phases, between about 10 and about 22 mole % hard phases, a liquidus temperature of less than about 1900K.
  • the feedstock material has a composition, in wt. %, of Cr: about 20.1, Nb: about 5.6, Mo: about 2.1, B: about 0.44, C: about 0.81, Ti: about 1.6, Fe: balance.
  • the coating comprises a volume fraction of hard phases between about 5 and about 35%, and a porosity of less than about 3%. In some embodiments, the coating comprises a volume fraction of hard phases between about 10 and about 25%, and a porosity of less than about 1%.
  • the coating is applied to a brake disc.
  • inventions of a method of applying a metallic coating on a substrate comprising thermally spraying the feedstock material disclosed herein on the substrate.
  • an iron based alloy feedstock comprising a matrix PREN greater than 20 at 1300K under equilibrium or near equilibrium solidification conditions, a mole fraction of hard phase between 5% and 25% at 1300K under equilibrium or near equilibrium solidification conditions, and a solidus less than 2000K under equilibrium or near equilibrium solidification conditions.
  • the alloy feedstock comprises, in weight percent, between 1.0 and 10.0 niobium plus titanium.
  • the matrix at 1300K has, in weight percent, greater than 15% Cr.
  • a mole fraction of intermetallic phases at 800 deg. K is less than 25% under equilibrium or near equilibrium solidification conditions.
  • the alloy is atomized to form a powder.
  • the alloy feedstock is deposited on to a substrate to form a wear and corrosion resistant coating.
  • an arc melted microstmcture of the alloy feedstock comprises between 8% and 30% hardphases by volume.
  • an arc melted ingot microstmcture comprises a matrix PREN greater than 20.
  • the alloy feedstock is configured to be deposited via laser cladding or ultra-high speed laser cladding. In some embodiments, the alloy feedstock is deposited onto a brake disc wear surface.
  • the alloy feedstock comprises, at 1300K under equilibrium solidification conditions, between 3 and 26% mole fraction borides. In some embodiments, the alloy feedstock comprises less than 10% FCC austenite at 1300k under equilibrium conditions.
  • a cladding feedstock comprising Fe and, under thermodynamic conditions a total ferrite mole fraction of above about 50%, a ferrite matrix comprising at least about 12 wt.% Cr, and a mole fraction of hard phases precipitating from liquid greater than about 5%.
  • the hard phases are carbides.
  • the carbides are FCC carbides.
  • the hard phases are borides.
  • the hard phases comprise both borides and carbides.
  • Figure 1 shows an embodiment of a thermodynamic profile of an alloy of the disclosure.
  • Figure 2 shows a thermodynamic profile of 431 stainless steel.
  • Figure 3 shows an embodiment of a microstmcture of an alloy of the disclosure as a PTA weld overlay coating.
  • Figure 4 illustrates an embodiment of a thermodynamic solidification diagram of an alloy of the disclosure.
  • Figure 5 illustrates an embodiment of a thermodynamic solidification diagram of an alloy of the disclosure.
  • Figure 6 illustrates microstmcture of an arc melted ingot of an alloy of the disclosure.
  • Figure 7 illustrates microstmcture of an arc melted ingot of an alloy of the disclosure.
  • Figure 8 illustrates an embodiment of a Schaeffer diagram.
  • an alloy having a ferritic structure rather than a martensitic matrix, and consequently a lower hardness than typical hardfacing products.
  • embodiments of the disclosure have excellent wear resistance, where the wear resistance is provided in the form of hard carbide or hard boride or a combination of both hard carbide and hard boride particles. Due to the ferritic structure, the coating can be ground and machined much quicker than harder coatings known in the art, which is advantageous for many applications, including for use with hydraulic rods.
  • the alloys described herein can be used as a hardbanding or hardfacing layers or coatings. In some embodiments, the alloy can be applied on a hydraulic rod as a layer or coating.
  • the alloys can have high corrosion resistance, for example similar to that of 431 stainless steel. This can be achieved, for example, through one or more of the in situ formation of a corrosion resistant matrix, controlled fraction of hard phases, and tough microstmcture. Accordingly, embodiments of the disclosure can be an iron hardfacing alloy resistant to corrosion and having high wear resistance.
  • the hard phases can be borides which are beneficial from a design standpoint as boron has a very low solid solution solubility with iron and iron alloys driving the precipitation of boride phases, even under the rapid cooling rates inherent in laser cladding and ultra-high speed laser cladding.
  • strong carbide formers may also be present to ensure precipitation during processing and minimal retained carbon in the matrix. With the presence of these beneficial phases, deleterious phases can be reduced or eliminated.
  • An additional consideration addressed in this disclosure relates to the manufacturability of an alloy via atomization by controlling the liquidus temperature of the alloy.
  • the alloys described herein can be configured to form a coating with two contrasting physical behaviors: 1) reduced hardness with the end result of an easily machinable coating (e.g., faster grinding/honing times of a clad coating), and 2) high abrasion/wear resistance.
  • reduced hardness will result in low abrasion resistance.
  • embodiments of the alloys described herein are able to maintain a low hardness while exhibiting higher abrasion resistance than typical iron-based materials.
  • Other advantageous features described herein can include crack resistance, compatibility with a gas atomization process, compatibility with laser and PTA welding, and corrosion resistance.
  • the alloys disclosed herein can be manufactured into a powder form using, for example, a gas atomization process, though the particular process is not limiting and other processes can be used as well.
  • the powder can then be used in a variety of deposition processes, including thermal spray, high velocity oxygen fuel (“HVOF”), high velocity air fuel (“HVAF”), plasma spray, plasma transferred arc welding (“PTA”), laser cladding, and ultra-high speed laser cladding (“EHLA”) to form a coating with certain microstmctural features and performance characteristics.
  • HVOF high velocity oxygen fuel
  • HVAF high velocity air fuel
  • PTA plasma transferred arc welding
  • EHLA ultra-high speed laser cladding
  • the term alloy can refer to the chemical composition forming the powder disclosed within, the powder itself, the feedstock itself, a wire, the wire including a powder, the composition of the metal component formed by the heating and/or deposition of the powder (for example hardbanding/hardfacing layer), 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).
  • alloys can be fully characterized by their compositional ranges.
  • the alloy can include, in weight percent:
  • Nb + Ti + V 2 - 10 (or about 2 - about 10);
  • the above composition may include no nickel. In some embodiments, the above composition may include up to 4 wt. % nickel.
  • the alloy can include, in weight percent:
  • Nb + Ti + V 2 - 12 (or about 2 - about 12);
  • the above composition may include no nickel. In some embodiments, the above composition may include up to 4 wt. % nickel. [0062] In some embodiments, the alloy can include, in weight percent:
  • Nb 4 - 6 (or about 4 - about 6);
  • the above composition may include no nickel. In some embodiments, the above composition may include 1.2 - 1.6 (or about 1.2 - about 1.6) wt. % nickel.
  • the alloy may be described by the composition, in weight percent:
  • Nb 4.5 - 5.5 (or about 4.5 - about 5.5);
  • the above composition may include no nickel. In some embodiments, the above composition may include 1.35 - 1.65 (or about 1.35 about 1.65) wt. % nickel.
  • the alloy can include, in weight percent:
  • Nb 4 - 6 (or about 4 - about 6);
  • the alloy can include, in weight percent:
  • Nb 4.5 - 5.5 (or about 4 - about 6);
  • the alloy can include, in weight percent: Fe: BAL;
  • Nb 4 - 6 (or about 4 - about 6);
  • the alloy can include, in weight percent: Fe: BAL;
  • Nb 4.5 - 5.5 (or about 4.5 - about 5.5);
  • the alloy can include, in wt. %:
  • the alloy can include, in wt. %:
  • Nb + Ti 1 - 4 (or about 1 - about 4).
  • the alloy can include, in wt. %: Fe;
  • Nb + Ti 5 - 12 (or about 5 - about 12);
  • the alloy can include, in wt. %: Fe;
  • Mo + W 1 - 16 (or about 1 - about 16);
  • Nb + Ti 1 - 10 (or about 1 - about 10);
  • the alloy can include, in wt.% Fe;
  • B+C 0.8 - 2 (or about 0.8 - about 2);
  • Nb + Ti +V 0.5 - 8.5 (or about 0.5 - about 8.5).
  • the alloy can include, in wt. %: Fe;
  • Mo + W 0 - 2.4 (or about 0 - about 2.4);
  • Nb + Ti + V 0.8 - 8.4 (or about 0.8 - about 8.4).
  • the alloy can include, in wt. %: Fe; C: 0.8 - 1.2 (or about 0.8 - about 1.2);
  • B+C 0.8 - 1.68 (or about 0.8 - about 1.68);
  • Mo+W 0 - 2.4 (or about 0 - about 2.4);
  • Nb 4 - 6 (or about 4 - about 6);
  • Nb+Ti+V 4 - 8.4 (or about 4 - about 8.4).
  • Mo+W may be greater than 1 wt. % (or greater than about 1 wt. %) or greater than 3 wt. % (or greater than about 3 wt. %).
  • the alloy can include Mo+W in wt.% from 1.6 to 2.4 (or about 1.6 to about 2.4). In some embodiments, the alloy can include Mo in wt.% from 1.6 to 2.4 (or about 1.6 to about 2.4). In some embodiments, the alloy can include C in wt.% from 0.8 to 1.2 (or about 0.8 to about 1.2). In some embodiments, the alloy can include Cr in wt.% from 13.6 to 24 (or about 13.6 to about 24). In some embodiments, the alloy can include Nb in wt.% from 4 to 6 (or about 4 to about 6). In some embodiments, the alloy has a Nb/C ratio from 4 to 6 (or about 4 to about 6). In some embodiments, the alloy has a Nb/C ratio from 4.5 to 5.5 (or about 4.5 to about 5.5).
  • the alloy can include in wt.% B from 0.8 to 1.2 (or about 0.8 to about 1.2). In any of the above embodiments, the alloy can include in wt.% B from 0.3 - 0.5 (or about 0.3 to about 0.5). In some embodiments, the alloy can include in wt.% Ti from 1.6 to 2.4 (or about 1.6 to about 2.4).
  • the disclosed compositions can be the wire/powder, the coating or other metallic component, or both.
  • alloys disclosed have chemistries altered by dilution with the substrate after deposition.
  • the substrate dilution may be between 0 and 50 volume percent.
  • Embodiments of the disclosure may be designed to handle dilution with substrates having high levels of carbon such as gray cast iron.
  • the carbon in the substrate wants to form deleterious phases that reduce Cr, Mo, and/or W content of the matrix, reducing corrosion performance and/or forming phases that reduce the toughness or wear performance of the alloy.
  • embodiments of the disclosure can work undiluted, diluted with low carbon steel, and diluted with high carbon ferrous alloys such as gray cast iron while maintaining good properties in all cases.
  • the alloy can include, in weight percent, less than 1% carbon (or less than about 1% carbon). In some embodiments, the alloy can include, in weight percent, less than 0.5% carbon (or less than about 0.5% carbon). In some embodiments, the alloy can include, in weight percent, less than 0.25% carbon (or less than about 0.25% carbon). In some embodiments, the alloy can include, in weight percent, less than 0.1% carbon (or less than about 0.1% carbon).
  • nickel can be limited in all wear surfaces. Some embodiments of this disclosure specifically limit the nickel content of the feedstock powder.
  • the alloy can include less than 5 wt.% nickel (or less than about 5 wt.% nickel). In some embodiments, the alloy can include less than 2 wt.% nickel (or less than about 2 wt.% nickel). In some embodiments, the alloy can include less than 1 wt.% nickel (or less than about 1 wt.% nickel). In some embodiments, the alloy can include less than 0.5 wt.% nickel (or less than about 0.5 wt.% nickel). In some embodiments, the alloy can include less than 0.2 wt.% nickel (or less than about 0.2 wt.% nickel).
  • the alloy can include less than 0.15 wt.% nickel (or less than about 0.15 wt.% nickel). In some embodiments, alloy can include less than 0.1 wt.% nickel (or less than about 0.1 wt.% nickel).
  • Table 1 shows some embodiments of chemistries of arc melted alloys.
  • Table 2 shows embodiments of chemistries for laser cladding.
  • titanium can be reduced through the increased in Nb or the inclusion of V.
  • 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.
  • an impurity may be Co, Mn, Mo, Ta, V, and/or W.
  • the Fe content identified in all of the compositions described in the above paragraphs may be the balance of the composition as indicated above, or alternatively, where Fe is provided as the balance, the balance of the composition may comprise Fe and other elements. In some embodiments, the balance may consist essentially of Fe and may include incidental impurities. Thermodynamic Criteria
  • alloys can be fully characterized by their thermodynamic criteria.
  • the hardness of embodiments of the alloy can be maintained at a relatively low level by designing for a stable ferrite phase.
  • austenite is present at high temperatures. Upon sufficiently fast cooling rates, austenite transforms to martensite. Martensite is present in almost all hardfacing alloys as it is the hardest metallic iron phase.
  • Typical laser cladding conditions are sufficiently rapid such that martensite will typically form in many iron alloys, 431 stainless steel being a relevant example.
  • the alloy technology described herein will not form martensite, even under rapid cooling conditions, as the ferritic structure is thermodynamically stable at high temperatures and that stability extends to low temperatures. Thus, in some embodiments the alloy will form only a ferritic matrix with hard phases.
  • FIG. 1 An example of the stability of the ferrite phase is shown in Figure 1, which shows a thermodynamic calculation for an alloy of the disclosure. This diagram plots the phase mole fraction as a function of temperature for a given composition. As shown the ferrite phase is present at 90 mol. % at elevated temperatures just below the solidus temperature of the alloy. The ferrite phase is consistently present in excess of 70 mol. % down to a lower temperature of 500K. Some austenite [104] and BCC Cr [105] are also present through this temperature range, but the majority of the phase composition is ferrite over the entire temperature window.
  • thermodynamic profile for 431 stainless steel a common hardfacing alloy used for hydraulic rod applications
  • 431 stainless steel forms delta ferrite [201] at high temperatures, which transitions to austenite [202] at lower temperatures, and then back to alpha ferrite [203] upon further cooling.
  • 431 stainless steel will form ferrite, austenite, martensite, or some mixture depending on the cooling rate of the process.
  • 431 stainless is generally intended to form martensite in application providing high hardness for hardfacing applications.
  • 431 stainless can be made to form a ferritic structure under controlled slow cooling conditions or via heat treatment, but it will not form a ferritic structure under relevant fast cooling process such as PTA welding. Alloys of this disclosure are different in the ferrite formation behavior, in that ferrite forms in even under rapid cooling conditions. This behavior is advantageous when it is desired to form a low hardness coating via such processes.
  • the ferrite phase fraction is 50 (or about 50) mol. % or higher. In some embodiments, the ferrite phase fraction is 60 (or about 60) mol. % or higher. In some embodiments, the ferrite phase fraction is 70 (or about 70) mol. % or higher.
  • the alloy of the disclosure reaches a minimum of 72.9 mol. % within the prescribed temperature window. 431 stainless steel reaches a minimum 4.47 mol. % of ferrite.
  • the alloy matrix can be 100% ferritic at 1300K (or about 100%). In some embodiments, the alloy matrix can be greater than 95% ferritic at 1300K (or greater than about 95%). In some embodiments, the alloy matrix can be greater than 90% ferritic at 1300K (or greater than about 90%). In some embodiments, the alloy matrix can be greater than 80% ferritic at 1300K (or greater than about 80%). This ferritic matrix can be maintained in the coating microstmcture.
  • FCC austenite present between 1000 and 1400K there can be 0 mol.% (or about 0 mol.%) FCC austenite present between 1000 and 1400K (or about 1000 and about 1400K). In some embodiments the maximum mole fraction of FCC austenite present between 1000 and 1400K (or about 1000 and about 1400K) is less than 5 mol.% (or less than about 5 mol.%). In some embodiments the maximum mole fraction of FCC austenite present between 1000 and 1400K (or about 1000 and about 1400K) is less than 10 mol.% (or less than about 10 mol.%).
  • the maximum mole fraction of FCC austenite present between 1000 and 1400K is less than 15 mol.% (or less than about 15 mol.%).
  • the alloy matrix chemistry at 1300k falls within the ferrite region of the Schaeffler diagram, shown in Figure 8. In some embodiments of this disclosure, the alloy matrix chemistry at 1300k falls within the ferrite region or ferrite plus martensite are of the Schaeffler diagram. In some embodiments of this disclosure the alloy matrix chemistry at 1300k is not in the austenite, austenite plus martensite, or martensitic region of the Schaeffler diagram.
  • a second feature of alloys of the disclosure is the formation of primary FCC carbides, also known as MC type carbides.
  • Such carbides can provide the enhanced abrasion resistance desired in application despite the low hardness.
  • FIG 1 the thermodynamic behavior of the FCC carbides is shown, where they form at relatively high temperatures [103] and ultimately form at -10 mol. % in the alloy of the disclosure.
  • the carbide formation temperature it can be advantageous for the carbide formation temperature to be high. This encourages the morphology of the carbides to form an isolated and spherical morphology. Such a morphology provides abrasion resistance but does not drastically decrease the toughness of the coating.
  • the formation temperature may not be driven too high as it will make the alloy incompatible with industrial gas atomization processes. The balance of maximizing formation temperature for idealized structure while minimizing it to avoid atomization difficulties was determined through the course of inventive effort.
  • the primary carbide formation temperature can be between 1750 K and 2100 K (or between about 1750 K and about 2100 K). In some embodiments, the primary carbide formation temperature can be between 1850 K and 2000 K (or between about 1850 K and about 2000K).
  • the primary carbide mole fraction measure at 1300K can be 5 (or about 5) mol. % or higher. In some embodiments, the primary carbide mole fraction measure at 1300K can be 7.5 (or about 7.5) mol. % or higher. In some embodiments, the primary carbide mole fraction measure at 1300K can be 10 (or about 10) mol. % or higher.
  • the alloy of the disclosure forms 9.6 mol. % primary carbide fraction and the formation temperature the primary carbide is 2000K. 431 stainless steel forms no primary carbides.
  • the mole fraction of MC carbides under equilibrium or near equilibrium solidification conditions can be between 1% and 15% (or between about 1% and about 15%).
  • the mole fraction of MC carbides under equilibrium or near equilibrium solidification conditions can be between 1% and 6% (or between about 1% and about 6%). In some embodiments the mole fraction of MC carbides under equilibrium or near equilibrium solidification conditions can be between 5% and 15% (or between about 5% and about 15%). In some embodiments the mole fraction of MC carbides under equilibrium or near equilibrium solidification conditions can be between 7% and 12% (or about 7% and about 12%).
  • the primary carbides of the alloy of the disclosure can contain Nb and Ti as the metallic species. It is possible to form FCC primary carbides with Nb, Ti, V, or any combination thereof. However, the ratio of such metallic species effects the formation temperature. Accordingly, in some embodiments instead of forming niobium carbide, which has a very high formation temperature, other FCC carbide formers, such as titanium, can be added to lower the formation temperature of the carbide.
  • thermodynamics of the alloy technology yield the advantageous microstmcture as shown in Figure 3 with a ferritic matrix [301] with embedded primary carbides [302].
  • Figure 3 shows a PTA coating of the alloy of the disclosure using parameters described later in the disclosure. Energy dispersive spectroscopy was used to measure the composition of the ferritic matrix itself, particularly with an interest on the chromium content. The Cr content was measured at 19 wt.% in the PTA coating. It is generally advantageous to have a high Cr content in the ferrite matrix to provide elevated corrosion resistance.
  • the Cr content of the ferrite matrix can be at least 12 (or at least about) wt.%. In some embodiments, the Cr content of the ferrite matrix can be at least 15 (or about 15) wt.%. In some embodiments, the Cr content of the ferrite matrix can be at least 19 (or about 19) wt.%. It should be noted that ferrite matrix content is often different from the alloy Cr composition, and Cr in the form of Cr carbides or other phases do not enhance to the corrosion resistance of the alloy. [0104] Corrosion performance of ferrous alloys can be predicted with a pitting resistance equivalent number (PREN).
  • PREN pitting resistance equivalent number
  • the matrix phase is defined as the FCC or BCC iron rich metallic phase. This allows the matrix PREN value to accurately predict the relative corrosion performance of multi-phase materials. In some embodiments of this disclosure the matrix phase is BCC ferrite.
  • the alloy of the disclosure the matrix PREN is calculated as 34.3 at 1300K [401] based on the chemistry of the BCC phase, the only matrix phase present under equilibrium solidification conditions.
  • the matrix PREN is calculated as 27.0 at 1300K [501] based on the chemistry of the BCC phase. See Table 5 below for all alloys produced via arc melting and their calculated PREN at 1300K under equilibrium solidification conditions.
  • the matrix PREN at 1300K is greater than 17 (or greater than about 17). In some embodiments of this disclosure, the matrix PREN at 1300K is greater than 20 (or greater than about 20). In some embodiments of this disclosure, the matrix PREN at 1300K is greater than 23 (or greater than about 23). In some embodiments of this disclosure, the matrix PREN at 1300K is greater than 25 (or greater than about 25).
  • chromium content Another way of predicting the corrosion performance of a ferrous alloy is by the chromium content.
  • the chromium content can be calculated for the matrix phase under equilibrium solidification conditions, and is further shown in Table 5.
  • the matrix can include, in weight percent, greater than 13% chromium (or greater than about 13%). In some embodiments at 1300K, the matrix can include, in weight percent, greater than 15% chromium (or greater than about 15%). In some embodiments at 1300K, the matrix can include, in weight percent, greater than 17% chromium (or greater than about 17%). In some embodiments at 1300K, the matrix can include, in weight percent, greater than 18% chromium (or greater than about 18%). In some embodiments at 1300K, the matrix can include, in weight percent, greater than 20% chromium (or greater than about 20%). In some embodiments, the chromium discussed herein can be in the final coating.
  • intermetallic phase mole fraction is defined as the sum under equilibrium solidification conditions of all chi, sigma, and laves phases. In some applications such as brake discs, the surface may reach 800K during extreme braking events, as a result it is critical that intermetallic phases do not precipitate out in service.
  • intermetallic phases present at 800K are a sigma phase [402] and a laves phase [403] so the intermetallic mole phase fraction at 800K is calculated as 18.5%.
  • Figure 5 shows that in the alloy of the disclosure there is both a laves phase [502] and sigma phase [503] so the total calculated mole fraction is 8.6%.
  • the alloy can include, in mole percent, less than 25% (or less than about 25%) intermetallic phases. In some embodiments at 800K the alloy can include, in mole percent, less than 20% (or less than about 20%) intermetallic phases. In some embodiments at 800K the alloy can include, in mole percent, less than 15% (or less than about 15%) intermetallic phases. In some embodiments at 800K the alloy can include, in mole percent, less than 10% (or less than about 10%) intermetallic phases. In some embodiments at 800K the alloy can include, in mole percent, less than 8% (or less than about 8%) intermetallic phases.
  • hard phases such as borides, carbides, borocarbides, oxides, and nitrides can improve the wear resistance of an alloy. There are practical limits to the fraction of hard phases where excessively high values may lead to the alloy cracking after deposition or in service, especially when exposed to cyclical and rapid changes in temperature. Hard phases in this disclosure can be calculated as the sum of all borides, carbides, borocarbides, oxides, and/or nitrides under equilibrium solidification conditions.
  • the alloy of the disclosure there are two hard phases present at 1300K, an M 3 B 2 phase [405] and an M 2 B phase [404], the sum of these hard phases is 21.7 mol%.
  • the hard phases present are M 2 B [504] and MC carbide (FCC_A1#2) [505] so the mole fraction of hard phases at 1300K is 15.1%.
  • the mole fraction of hard phases under equilibrium or near equilibrium solidification conditions can be between 7 and 35% (or about 7 and about 35%). In some embodiments of this disclosure the mole fraction of hard phases can be between 7 and 25% (or about 7 and about 25%). In some embodiments of this disclosure the mole fraction of hard phases can be between 10 and 22% (or about 10 and about 22%). In some embodiments of this disclosure the mole fraction of hard phases can be between 7 and 22% (or about 7 and about 22%).
  • borides can advantageously form due to the low solid solution solubility of boron in iron which improves precipitation of certain phases during rapid cooling rates such as those present in laser cladding and EHLA processes.
  • the hard phases may be only borides, or a combination of borides and carbides.
  • the mole fraction of borides under equilibrium or near equilibrium solidification conditions can be between 2% and 25% (or about 2% and about 25%). In some embodiments the mole fraction of borides under equilibrium or near equilibrium solidification conditions can be between 2% and 10% (or about 2% and about 10%). In some embodiments the mole fraction of borides under equilibrium or near equilibrium solidification conditions can be between 2% and 6% (or about 2% and about 6%). In some embodiments the mole fraction of borides under equilibrium or near equilibrium solidification conditions can be between 8% and 24% (or about 8% and about 24%). In some embodiments the mole fraction of borides under equilibrium or near equilibrium solidification conditions can be between 8% and 16% (or about 8% and about 16%). In some embodiments the mole fraction of borides under equilibrium or near equilibrium solidification conditions can be between 10% and 22% (or about 10% and about
  • MC type carbides where M comprises Nb and/or Ti, are can advantageously form due to their advantageous low aspect ratio and isolated morphology.
  • This morphology can have relatively high crack resistance compared to hypo eutectic or eutectic morphologies present for other carbides and other hard phases.
  • the mole fraction of MC carbides under equilibrium or near equilibrium solidification conditions can be between 1% and 15% (or between about 1% and about 15%). In some embodiments the mole fraction of MC carbides under equilibrium or near equilibrium solidification conditions can be between 1% and 6% (or between about 1% and about 6%). In some embodiments the mole fraction of MC carbides under equilibrium or near equilibrium solidification conditions can be between 5% and 15% (or between about 5% and about 15%). In some embodiments the mole fraction of MC carbides under equilibrium or near equilibrium solidification conditions can be between 7% and 12% (or about 7% and about 12%).
  • Liquidus temperature is defined thermodynamically as the lowest temperature where the alloy is 100% liquid. In an alloy of the disclosure the liquidus temperature is 1950 [506] and another alloy of the disclosure the liquidus temperature is 1650K [406]
  • the liquidus temperature of the alloy can be less than 2000K (or less than about 2000K). In some embodiments, the liquidus temperature of the alloy can be less than 1975K (or less than about 1975K). In some embodiments, the liquidus temperature of the alloy can be less than 1950K (or less than about 1950K). In some embodiments, the liquidus temperature of the alloy can be less than 1925K (or less than about 1925K). In some embodiments, the liquidus temperature of the alloy can be less than 1900K (or less than about 1900K).
  • the matrix is 100% ferritic (BCC) at 1300K and the composition falls within the ferrite zone on a Schaeffer diagram.
  • alloy matrix can be 100% ferritic at 1300K (or about 100%). In some embodiments of this disclosure alloy matrix can be greater than 95% ferritic at 1300K (or greater than about 95%). In some embodiments of this disclosure alloy matrix can be greater than 90% ferritic at 1300K (or greater than about 90%). In some embodiments of this disclosure alloy matrix can be greater than 80% ferritic at 1300K (or greater than about 80%). This ferritic matrix can be maintained in the coating microstmcture.
  • FCC austenite present between 1000 and 1400K there can be 0 mol.% (or about 0 mol.%) FCC austenite present between 1000 and 1400K (or about 1000 and about 1400K). In some embodiments the maximum mole fraction of FCC austenite present between 1000 and 1400K (or about 1000 and about 1400K) is less than 5 mol.% (or less than about 5 mol.%). In some embodiments the maximum mole fraction of FCC austenite present between 1000 and 1400K (or about 1000 and about 1400K) is less than 10 mol.% (or less than about 10 mol.%). In some embodiments the maximum mole fraction of FCC austenite present between 1000 and 1400K (or about 1000 and about 1400K) is less than 15 mol.% (or less than about 15 mol.%).
  • the alloy matrix chemistry at 1300k falls within the ferrite region of the Schaeffler diagram, shown in Figure 8. In some embodiments of this disclosure, the alloy matrix chemistry at 1300k falls within the ferrite region or ferrite plus martensite are of the Schaeffler diagram. In some embodiments of this disclosure the alloy matrix chemistry at 1300k is not in the austenite, austenite plus martensite, or martensitic region of the Schaeffler diagram.
  • alloys of this disclosure can be deposited on substrates comprising high levels of carbon, such as gray cast iron or nodular cast iron, it can be advantageous to maintain good properties after dilution and corresponding carbon content increase in the overlay.
  • a ferritic structure has advantages in certain applications where austenite would increase galling and/or martensite would present cracking and/or toughness issues.
  • Certain embodiments of this disclosure also describe maintaining a ferritic structure after dilution with a substrate.
  • This substrate may be a mild steel, HSLA steel, cast iron, nodular iron, white iron, or other iron based substrate.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.15% (or about 0.15%) carbon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition less than or equal to 0.15% (or about 0.15%) carbon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.20% (or about 0.20%) carbon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.20% (or about 0.20%) carbon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.25% (or about 0.25%) carbon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.25% (or about 0.25%) carbon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.30% (or about 0.30%) carbon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.30% (or about 0.30%) carbon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.35% (or about 0.35%) carbon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.35% (or about 0.35%) carbon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 17 (or about 17) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.35% (or about 0.35%) carbon from substrate dilution.
  • alloys of this disclosure are deposited on substrates comprising high levels of carbon and silicon, such as gray cast iron or nodular cast iron, it can be advantageous to maintain good corrosion properties after dilution and corresponding carbon content increase in the overlay.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.15% (or about 0.15%) carbon and silicon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition less than or equal to 0.15% (or about 0.15%) carbon and silicon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.20% (or about 0.20%) carbon and silicon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.20% (or about 0.20%) carbon and silicon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%)ferrite at 1300K, after the addition of less than or equal to 0.25% (or about 0.25%) carbon and silicon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.25% (or about 0.25%) carbon and silicon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.30% (or about 0.30%) carbon and silicon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.30% (or about 0.30%) carbon and silicon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 20 (or about 20) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.35% (or about 0.35%) carbon and silicon from substrate dilution. In some embodiments, alloys of this disclosure have matrix PREN values at 1300K greater than 23 (or about 23) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.35% (or about 0.35%) carbon and silicon from substrate dilution.
  • alloys of this disclosure have matrix PREN values at 1300K greater than 17 (or about 17) and a matrix with greater than 90% (or about 90%) ferrite at 1300K, after the addition of less than or equal to 0.35% (or about 0.35%) carbon and silicon from substrate dilution.
  • high levels of Nb and/or Ti can be present in the alloy.
  • alloys of this disclosure are clad on high carbon substrates such as gray iron, the Nb and/or Ti can bind to a portion of the carbon added via dilution with the substrate. This can result in an increased fraction of MC carbide where M comprises Nb and/or Ti compared to the same level of dilution with a low carbon substrate.
  • This MC phase formation can reduce the weight percent of carbon in the matrix, improving the stability of ferrite and leading to beneficial properties.
  • carbides comprising chromium such as M7C3 and M23C6 which would reduce the PREN after deposition on high carbon substrates.
  • the mole fraction MC after diluting with gray iron can be higher than would be present given the same weight fraction of dilution with low carbon steel.
  • the mole fraction of the sum of M7C3 and M23C6 at 1300k is 0% (or about 0%). In some embodiments the mole fraction of the sum of M7C3 and M23C6 at 1300k less than 2% (or about 2%). In some embodiments the mole fraction of the sum of M7C3 and M23C6 at 1300k less than 5% (or about 5%).
  • alloys may be fully described by their micro structural features.
  • the micro structure of embodiments of the alloys provides advantageous material properties.
  • the hardness of embodiments of the disclosed alloys can remain relatively low. Hardness was measured used Vickers hardness, specifically HV0.3. The abrasion resistance was measured using ASTM G65 Procedure A. PTA welding was used to compare the alloy of the disclosure with 431 SS using the following parameters resulting in weld beads about 3mm thick and 28 mm wide:
  • the hardness of the disclosed alloys is 450 (or about 450) Vickers or lower. In some embodiments, the hardness is 400 (or about 400) Vickers or lower. In some embodiments, the hardness is 350 (or about 350) Vickers or lower. This can include any type of coating, such as a PTA coating. As mentioned, lower hardness can benefit machinability of the coating.
  • the alloy can have an ASTM G65 volume loss of 200 (or about 200) mm 3 or less. In some embodiments, the alloy can have an ASTM G65 volume loss of 150 (or about 150) mm 3 or less. In some embodiments, the alloy can have an ASTM G65 volume loss of 100 (or about 100) mm 3 or less. This can include any type of coating, such as a PTA coating.
  • the alloy it is also advantageous for the alloy to be weldable crack free under PTA, laser, and EHLA processes, though the particular process does not limit the disclosure.
  • the alloy of the disclosure alloy has demonstrated the capability to weld a crack free overlay under PTA and laser conditions.
  • hard phases such as borides, carbides, borocarbides, oxides, and nitrides can improve the wear resistance of an alloy. There are practical limits to the fraction of hard phases where excessively high values may lead to the alloy cracking after deposition or in service, especially when exposed to cyclical and rapid changes in temperature. Hard phases in this disclosure can be calculated as the sum of all borides, carbides, borocarbides, oxides, and nitrides as measured using quantitative metallography techniques on arc melted samples of the alloys.
  • the alloy may contain amounts of primary carbides in the matrix.
  • a primary carbide volume fraction of 5 (or about 5) vol. % can be embedded in a matrix primarily composed of ferrite.
  • a primary carbide volume fraction of 7.5 (or about 7.5) vol. % can be embedded in a matrix primarily composed of ferrite.
  • a primary carbide volume fraction of 10 (or about 10) vol. % can be embedded in a matrix primarily composed of ferrite.
  • the alloy may contain borides in the micro structure.
  • the volume fraction of hard phase is measured as the sum of all borides [301] [302] as 23%.
  • the volume fraction of hard phases is measured as the borides [401] and carbides [402] as 14%.
  • the volume fraction of all hard phases can be between 5 and 35% (or about 5 and about 35%). In some embodiments of this disclosure, the volume fraction of all hard phases can be between 5 and 25% (or about 5 and about 25%). In some embodiments of this disclosure, the volume fraction of all hard phases can be between 7 and 25% (or about 7 and about 25%). In some embodiments of this disclosure, the volume fraction of all hard phases can be between 8 and 15% (or about 8 and about 15%). In some embodiments of this disclosure, the volume fraction of all hard phases can be between 10 and 25% (or about 10 and about 25%).
  • the PREN of the matrix phase is a strong predictor of corrosion performance of the alloy.
  • PREN is calculated as [Cr + 3.3 * (Mo + 0.5 * W) + 16 * N] where elemental values are in weight percent. Elemental weight percent is measured using energy- dispersive X-ray spectroscopy (EDS) in a scanning electron microscope (SEM).
  • EDS energy- dispersive X-ray spectroscopy
  • the alloys described in this disclosure can be deposited as a coating intended to provide corrosion resistance.
  • corrosive media such as high chloride content water
  • excessive coating porosity may allow corrosive media to penetrate to the substrate. If this penetration occurs, corrosion of the substrate is likely leading to surface discoloration, reduced overlay performance, and/or disbanding of the coating from the substrate.
  • the coating formed from alloys described can have a porosity less than 3% (or about 3%). In some embodiments of this disclosure, the coating formed from alloys described can have a porosity less than 2% (about 2%). In some embodiments of this disclosure, the coating formed from alloys described can have a porosity less than 1.5% (or about 1.5). In some embodiments of this disclosure, the coating formed from alloys described can have a porosity less than 1% (or about 1%).
  • FCC austenite there can be 0 vol.% (or about 0 vol.%) FCC austenite present.
  • the maximum volume fraction of FCC austenite is less than 5 vol.% (or less than about 5 vol.%). In some embodiments the maximum volume fraction of FCC austenite is less than 10 vol.% (or less than about 10 vol.%). In some embodiments the maximum volume fraction of FCC austenite is less than 15 vol.% (or less than about 15 vol.%).
  • the volume fraction of borides can be between 2% and 25% (or about 2% and about 25%). In some embodiments the volume fraction of borides can be between 2% and 10% (or about 2% and about 10%). In some embodiments the volume fraction of borides can be between 2% and 6% (or about 2% and about 6%). In some embodiments the volume fraction of borides can be between 8% and 24% (or about 8% and about 24%). In some embodiments the volume fraction of borides can be between 8% and 16% (or about 8% and about 16%). In some embodiments the volume fraction of borides can be between 10% and 22% (or about 10% and about 22%).
  • the volume fraction of MC carbides can be between 1% and 15% (or between about 1% and about 15%). In some embodiments the volume fraction of MC carbides can be between 1% and 6% (or between about 1% and about 6%). In some embodiments the volume fraction of MC carbides can be between 5% and 15% (or between about 5% and about 15%). In some embodiments the volume fraction of MC carbides can be between 7% and 12% (or about 7% and about 12%).
  • the ferrite phase fraction is 50 (or about 50) vol. % or higher. In some embodiments, the ferrite phase fraction is 60 (or about 60) vol. % or higher. In some embodiments, the ferrite phase fraction is 70 (or about 70) vol. % or higher.
  • the alloy matrix can be 100% ferritic. In some embodiments of this disclosure alloy matrix can be greater than 95% ferritic (or greater than about 95%). In some embodiments, the alloy matrix can be greater than 90% ferritic (or greater than about 90%). In some embodiments, the alloy matrix can be greater than 80% ferritic (or greater than about 80%).
  • the matrix can include, in weight percent, greater than 13% chromium (or greater than about 13%). In some embodiments, the matrix can include, in weight percent, greater than 15% chromium (or greater than about 15%). In some embodiments, the matrix can include, in weight percent, greater than 17% chromium (or greater than about 17%). In some embodiments, the matrix can include, in weight percent, greater than 18% chromium (or greater than about 18%). In some embodiments, the matrix can include, in weight percent, greater than 20% chromium (or greater than about 20%).
  • the alloy can include, in volume percent, less than 25% (or less than about 25%) intermetallic phases. In some embodiments, the alloy can include, in volume percent, less than 20% (or less than about 20%) intermetallic phases. In some embodiments, the alloy can include, in volume percent, less than 15% (or less than about 15%) intermetallic phases. In some embodiments, the alloy can include, in volume percent, less than 10% (or less than about 10%) intermetallic phases. In some embodiments, the alloy can include, in volume percent, less than 8% (or less than about 8%) intermetallic phases.
  • the alloy of the disclosure was deposited by the conventional laser cladding process using the parameters in Table 7.
  • the coating that was deposited was then cross sectioned, mounted and polished for EDS chemistry analysis. 5 measurements taken by the EDS on the matrix of the coating were used to determine the average content of Cr and Mo. The average amount of Cr and Mo in the matrix of the coating are included in Table 9.
  • the Microhardness of the coating was measured using a Vickers hardness measurement with 300gf.
  • the hardness of the alloy was 283 HV300 after taking the average of 10 measurements across the sample.
  • the alloy of the disclosure was deposited by conventional laser cladding process to produce a coating that was approximately 25mm x 75mm and 3mm thick.
  • the coating was subjected to ASTM G65A testing, which resulted in a volume loss of 92.3 mm 3 .
  • the coating was cross sectioned, mounted and polished for Microhardness testing.
  • the Microhardness of the coating was done using Vickers Hardness with a force of 300g.
  • the hardness of the alloy was 270 HV300 after taking advantage of 10 measurements across the sample.
  • a coating of 420 stainless steel was deposited by conventional laser cladding.
  • the ASTM G65A abrasion resistance of the coating was 136.9 mm 3
  • the Microhardness of the coating was measured to be 570 HV300 after an average of ten measurements.
  • alloys described in this patent can be used in a variety of applications and industries. Some non-limiting examples of applications of use include:
  • 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 teeth and hardfacing for ground engaging tools and teeth, shrouds and adapters, wear plate and rock boxes including for buckets and dumptruck liners, heel blocks and hardfacing for heel blocks on mining shovels, grader blades and hardfacing for grader blades, stacker reclaimers, sizer crushers, jaw crushers, ripper teeth, cutting edges, general wear packages for mining components and other comminution components.
  • Downstream oil and gas applications include the following components and coatings for the following components: Downhole casing and downhole casing, drill pipe and coatings for drill pipe including hardbanding, mud management components, mud motors, fracking pump sleeves, fracking impellers, fracking blender pumps, stop collars, drill bits and drill bit components, directional drilling equipment and coatings for directional drilling equipment including stabilizers and centralizers, blow out preventers and coatings for blow out preventers and blow out preventer components including the shear rams, oil country tubular goods and coatings for oil country tubular goods, sucker rods and couplings, lift plungers, neyfor rotors, artificial lift casing, and ESP pump housing and impellers, flowlines and subsea flowlines.
  • Upstream oil and gas applications include the following components and coatings for the following components: Process vessels and coating for process vessels including steam generation equipment, amine vessels, distillation towers, cyclones, catalytic crackers, general refinery piping, corrosion under insulation protection, sulfur recovery units, convection hoods, sour stripper lines, scrubbers, hydrocarbon drums, and other refinery equipment and vessels.
  • Pulp and paper applications include the following components and coatings for the following components: Rolls used in paper machines including yankee dryers, through air dryers, and other dryers, calendar rolls, machine rolls, press rolls, winding rolls, digesters, pulp mixers, pulpers, pumps, boilers, shredders, tissue machines, roll and bale handling machines, fiber guidance systems such as deflector blades, doctor blades, evaporators, pulp mills, head boxes, wire parts, press parts, M.G. cylinders, pope reels, winders, vacuum pumps, deflakers, and other pulp and paper equipment,
  • Power generation applications include the following components and coatings for the following components: boiler tubes, precipitators, fireboxes, turbines, generators, cooling towers, condensers, chutes and troughs, augers, bag houses, ducts, ID fans, coal piping, and other power generation components.
  • Agriculture applications include the following components and coatings for the following components: chutes, base cutter blades, sugar cane harvesting knives, hammers, troughs, primary fan blades, secondary fan blades, augers, components common to mining applications, and other agricultural applications.
  • Construction applications include the following components and coatings for the following components: cement chutes, cement piping, bag houses, mixing equipment and other construction applications
  • Machine element applications include the following components and coatings for the following components: Shaft journals, hydraulic cylinders, paper rolls, gear boxes, drive rollers, impellers, rebuilding of engine decks, propeller shafts and other shafts, general reclamation and dimensional restoration applications including the restoration of cast iron and specifically grey cast iron and ductile iron parts and other machine element applications
  • Steel applications include the following components and coatings for the following components: cold rolling mills, hot rolling mills, wire rod mills, galvanizing lines, continue pickling lines, continuous casting rolls and other steel mill rolls, and other steel applications.
  • Automotive applications include coatings for valves and valve seats, cylinders and other components of the internal combustion engine, brake disks and pads.
  • the alloys described in this patent can be produced and or deposited in a variety of techniques effectively. Some non-limiting examples of processes include:
  • Thermal spray process including those using a wire feedstock such as twin wire arc, spray, high velocity arc spray, combustion spray and those using a powder feedstock such as high velocity oxygen fuel, high velocity air spray, plasma spray, detonation gun spray, and cold spray.
  • Wire feedstock can be in the form of a metal core wire, solid wire, or flux core wire.
  • Powder feedstock can be either a single homogenous alloy or a combination of multiple alloy powder which result in the desired chemistry when melted together.
  • Welding processes including those using a wire feedstock including but not limited to metal inert gas (MIG) welding, tungsten inert gas (TIG) welding, arc welding, submerged arc welding, open arc welding, bulk welding, laser cladding, and those using a powder feedstock including but not limited to laser cladding, ultra-high speed lasers cladding (EHLA), and plasma transferred arc welding.
  • Wire feedstock can be in the form of a metal core wire, solid wire, or flux core wire.
  • Powder feedstock can be either a single homogenous alloy or a combination of multiple alloy powder which result in the desired chemistry when melted together.
  • Casting processes including processes typical to producing cast iron including but not limited to sand casting, permanent mold casting, chill casting, investment casting, lost foam casting, die casting, centrifugal casting, glass casting, slip casting and process typical to producing wrought steel products including continuous casting processes.
  • Post processing techniques including but not limited to rolling, forging, surface treatments such as carburizing, nitriding, carbonitriding, heat treatments including but not limited to austenitizing, normalizing, annealing, stress relieving, tempering, aging, quenching, cryogenic treatments, flame hardening, induction hardening, differential hardening, case hardening, decarburization, machining, grinding, cold working, work hardening, and welding.
  • 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. Additionally, all values of tables within the disclosure are understood to either be the stated values or, alternatively, about the stated value.

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JP2021576786A JP7572384B2 (ja) 2019-07-09 2020-07-07 耐摩耗性と耐食性のために設計された鉄ベースの合金
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