Fully readable thermal spray coating

Patent metadata

Field	Value
Publication number	US-11279996-B2
Application number	US-201715465954-A
Country	US
Kind code	B2
Filing date	Mar 22, 2017
Priority date	Mar 22, 2016
Publication date	Mar 22, 2022
Grant date	Mar 22, 2022

Abstract

Embodiments of an iron-based coating configured to be thermally sprayed are disclosed. The iron-based coatings can be fully readable, thus allowing for thickness measurements to be performed on the coating with standard magnetic measuring equipment. Further, the iron-based coating can have advantageous properties, such as high hardness, high wear resistance, and high adhesion strength.

First claim

What is claimed is:

1. A thermal spray wire comprising:
a powder core surrounded by a sheath, wherein the core and the sheath have a combined iron-based composition comprising, in wt. %:
C: 4.76 to 5;
Cr: 11.9 to 19;
Ni: 17 to 19;
V: greater than 0 and less than or equal to 2;
Al: greater than 0 and less than or equal to 2;
Mn: greater than 0 and less than or equal to 1.5;
Si: greater than 0 and less than or equal to 0.5; and
Fe: balance,

wherein upon melting and solidifying, the thermal spray wire forms an alloy including a total volume fraction of magnetic phases at 500° C. of below 30%.

2. The thermal spray wire of claim 1 , wherein upon melting and solidifying, the thermal spray wire forms the alloy further comprising:
an FCC-BCC transition temperature at or below 950K; and
one or more hard phases selected from the group consisting of carbides, borides and aluminides, wherein the hard phases are present at a hard phase fraction sum of 20 mol % or greater.

3. The thermal spray wire of claim 1 , wherein the combined composition comprises, in weight percentages:
Mn: 0.93 to 1.13 and Si: 0.28 to 0.34.

4. The thermal spray wire of claim 1 , wherein the combined composition comprises, in weight percentages:
Mn: 0.90 to 1.10 and Si: 0.28 to 0.34.

5. The thermal spray wire of claim 1 , wherein the combined composition comprises, in weight percentages:
Cr: 11.97 to 14.63, Mn: 0.90 to 1.10 and Si: 0.21 to 0.25.

6. The thermal spray wire of claim 1 , wherein the combined composition comprises, in weight percentage: V: 1.2 to 2.

7. The thermal spray wire of claim 1 , wherein the combined composition comprises inevitable impurities.

8. A thermal spray wire comprising:
a powder core surrounded by a sheath, wherein the core and the sheath have a combined iron-based composition, in wt. %:
C: 4.75 to 5;
Cr: 17 to 19;
Ni: greater than 15 and less than or equal to 19;
V: 1.25 to 2.75;
Al: 0.75 to 2.75;
Mn: 0.25 to 2.25;
Si: 0.1 to 0.9; and
Fe: balance,

wherein upon melting and solidifying, the thermal spray wire forms an alloy including a total volume fraction of magnetic phases at 500° C. of below 30%.

9. The thermal spray wire of claim 8 , wherein the thermal spray wire is further configured to form the alloy comprising:
an FCC-BCC transition temperature at or below 950K; and
one or more hard phases selected from the group consisting of carbides, borides and aluminides, wherein the hard phases are present at a hard phase fraction sum of 20 mol % or greater.

10. The thermal spray wire of claim 8 , wherein the combined composition comprises, in weight percentages:
Mn: 0.93 to 1.13, Ni: 15.48 to 18.92, Si: 0.28 to 0.34, V: 1.71 to 2.09 and Al: 1.73 to 2.11.

11. The thermal spray wire of claim 8 , wherein the combined composition comprises, in weight percentages:
Mn: 0.90 to 1.10, Ni: 15.3 to 18.7, Si: 0.28 to 0.34, V: 1.71 to 2.09 and Al: 1.71 to 2.09.

12. The thermal spray wire of claim 8 , wherein the combined composition comprises, in weight percentages:
Mn: 0.90 to 1.10 and Si: 0.21 to 0.25.

13. The thermal spray wire of claim 8 , wherein the combined composition comprises, in wt. %: V: 1.25 to 2.

Assignees

• Oerlikon Metco Us Inc

Inventors

• Cheney Justin Lee
• Mody Zubin
• Jiang David

Classifications

• C23C24/04 Primary

  Impact or kinetic deposition of particles · CPC title

• C22C38/12

  containing tungsten, tantalum, molybdenum, vanadium, or niobium · CPC title

• C22C38/002

  containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60 · CPC title

• C23C4/16 Primary

  Wires; Tubes · CPC title

• C22C38/08

  containing nickel {(C22C38/105 takes precedence)} · CPC title