Nickel based thermal spray powder and coating, and method for making the same

Patent metadata

Field	Value
Publication number	US-10240238-B2
Application number	US-201113576563-A
Country	US
Kind code	B2
Filing date	Feb 1, 2011
Priority date	Feb 1, 2010
Publication date	Mar 26, 2019
Grant date	Mar 26, 2019

Abstract

Provided in one embodiment includes a multi-fully alloyed powder that provides a wear-resistant and corrosion-resistant coating on a substrate when applied by a thermal spraying process. The coating exhibits desirable hardness, toughness, and bonding characteristics in a highly dense coating that is suitable for a wide range of temperatures. The embodiment provides a method of forming a coating, the method comprising: providing a substrate; and disposing onto the substrate a coating, comprising: a powder-containing composition comprising an alloy, the alloy comprising a solid solution comprising nickel, and a first component comprising at least one transition metal element and at least one nonmetal element.

First claim

What is claimed:

1. A coating comprising:
an alloy, the alloy comprising a solid solution and a first component, wherein:
the solid solution comprises nickel and chromium,
the first component comprises a binary compound, a ternary compound, or both comprising at least one transition metal element and at least one nonmetal element; and
the alloy is represented by the formula:
(Ni x Cr y ) a (M b N c )

wherein:
M represents the transition metal element in the first component;
N represents the nonmetal element in the first component;
a, b, and c each is greater than 0 and independently represents a weight percentage;
x and y each is greater than 0 and independently represents a weight percentage of the Ni-containing solid solution;
a is from 85 to 95, b is from 0.1 to 10, c is from 5 to 10, a ratio of x to y is between 0.5 to 1.9, and y is 33-35;

wherein the alloy comprises:
48 to 54 wt. % Ni,
33 to 35 wt. % Cr,
3.3 to 3.5 wt. % Si,
4 to 4.5 wt. % B,
about 1 wt. % C,
1-2 wt. % Ti,
and a balance of Fe; and

wherein the coating is substantially amorphous.

2. The coating of claim 1 , wherein the nonmetal element further includes at least one of F, Cl, Br, I, At, O, S, Se, Te, Po, N, P, As, Sb, Bi, Ge, Sn, or Pb.

3. The coating of claim 1 , wherein the transition metal element further includes at least one of Sc, Y, La, Ac, Zr, Hf, V, Nb, Ta, Cr, Mo, W, Mn, Tc, Re, Ru, Os, Co, Rh, Ir, Ni, Pd, Pt, Cu, Ag, Au, Zn, Cd, or Hg, or combinations thereof.

4. The coating of claim 1 , wherein the first component comprises at least one of (i) a boride or (ii) a carbide.

5. The coating of claim 1 , further comprising a second component comprising at least one transition metal element and at least one nonmetal element.

6. The coating of claim 1 wherein the coating is fully amorphous.

Assignees

• Croopnick Gerald A
• Crucible Intellectual Prop Llc

Inventors

• Croopnick Gerald A

Classifications

• Y10T428/24997

  Of metal-containing material · CPC title

• C23C4/10

  Oxides, borides, carbides, nitrides or silicides; Mixtures thereof · CPC title

• C23C24/04 Primary

  Impact or kinetic deposition of particles · CPC title

• C23C4/067

  containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic · CPC title

• Y10T428/31678

  Of metal · CPC title