Corrosion and wear resistant nickel based alloys

Patent metadata

Field	Value
Publication number	US-11939646-B2
Application number	US-201917288186-A
Country	US
Kind code	B2
Filing date	Oct 25, 2019
Priority date	Oct 26, 2018
Publication date	Mar 26, 2024
Grant date	Mar 26, 2024

Abstract

Disclosed herein are embodiments of nickel-based alloys. The nickel-based alloys can be used as feedstock for PTA and laser cladding hardfacing processes, and can be manufactured into cored wires used to form hardfacing layers. The nickel-based alloys can have high corrosion resistance and large numbers of hard phases such as isolated hypereutectic hard phases.

First claim

What is claimed is:

1. A hardfacing layer formed from a feedstock material, comprising:
Ni; and
a corrosion resistant matrix which is characterized by having, under thermodynamic equilibrium conditions:
hard phases of 1,000 Vickers hardness or greater totaling 5 mol. % or greater; and
a matrix proximity of 80% or greater when compared to a known corrosion resistant nickel alloy;

wherein the feedstock material comprises a blend of Monel 400 and at least one of WC and Cr 3 C 2 .

2. The hardfacing layer of claim 1 , wherein the known corrosion resistant nickel alloy is represented by the formula Ni: BAL, and X >20 wt. %, wherein X represents at least one of Cu, Cr, or Mo.

3. The hardfacing layer of claim 1 , wherein the corrosion resistant matrix is a nickel matrix comprising 20 wt. % or greater of a combined total of chromium and molybdenum.

4. The hardfacing layer of claim 1 , wherein, under thermodynamic equilibrium conditions, the corrosion resistant matrix is characterized by having isolated hypereutectic hard phases totaling to 50 mol. % or more of a total hard phase fraction.

5. The hardfacing layer of claim 1 , wherein the feedstock material comprises, by wt. %:
Ni; and
Cr: about 7 to about 14.5.

6. The hardfacing layer of claim 1 , wherein, under thermodynamic equilibrium conditions, the corrosion resistant matrix is characterized by having:
hard phases totaling 50 mol. % or greater; and
a liquidus temperature of 1550 K or lower.

7. The hardfacing layer of claim 1 , wherein the feedstock material is selected from the group consisting of, by wt. %:
75-85% WC+15-25% Monel 400;
65-75% WC+25-35% Monel 400;
60-75% WC+25-40% Monel 400;
75-85% Cr 3 C 2 +15-25% Monel 400;
65-75% Cr 3 C 2 +25-35% Monel 400;
60-75% Cr 3 C 2 +25-40% Monel 400;
75-85% WC/Cr 3 C 2 +15-25% Monel 400;
65-75% WC/Cr 3 C 2 +25-35% Monel 400; and
60-75% WC/Cr 3 C 2 +25-40% Monel 400.

8. The hardfacing layer of claim 1 , wherein the corrosion resistant matrix comprises a WC/Cr 3 C 2 ratio of 0.25 to 5 by volume.

9. The hardfacing layer of claim 1 , wherein the hardfacing layer comprises:
an ASTM G65A abrasion loss of less than 250 mm 3 ; and
two cracks or fewer per square inch when forming the hardfacing layer from a PTA or laser cladding process.

10. The hardfacing layer of claim 1 , wherein the hardfacing layer comprises an impermeable HVOF coating which exhibits a corrosion rate of 1 mpy or less in a 28% CaCl 2 ) electrolyte, pH=9.5 environment.

11. The hardfacing layer of claim 1 , wherein the hardfacing layer comprises:
a hardness of 650 Vickers or greater; and
an adhesion of 9,000 psi or greater when forming the hardfacing layer from a HVOF thermal spray process.

12. The hardfacing layer of claim 1 , wherein the hardfacing layer is applied onto a hydraulic cylinder, a tension riser, a mud motor rotor, or an oilfield component application.

13. The hardfacing layer of claim 1 , wherein the hardfacing layer comprises:
a hardness of 750 Vickers or greater; and
a porosity of 2 volume % or less when forming the hardfacing layer from a HVOF thermal spray process.

14. The hardfacing layer of claim 1 , wherein the feedstock material is selected from the group consisting of a powder, a wire, and combinations thereof.

15. The hardfacing layer of claim 1 , wherein the hardfacing layer is formed from the feedstock material by a weld overlay process or a thermal spray process.

16. A hardfacing layer formed from a feedstock material, the feedstock material comprising, by wt. %:
Ni;
C: about 0.84-about 1.56;
Cr: about 14-about 26;
Mo: about 8.4-about 15.6;
Nb: about 4.2-about 7.8; and
Ti: about 0.35-about 0.65.

17. The hardfacing layer of claim 16 , wherein the hardfacing layer comprises a corrosion resistant matrix which is characterized by having, under thermodynamic equilibrium conditions:
hard phases of 1,000 Vickers hardness or greater totaling 5 mol. % or greater; and
a matrix proximity of 80% or greater when compared to a known corrosion resistant nickel alloy.

18. The hardfacing layer of claim 16 , wherein the hardfacing layer has a corrosion rate of below 0.1 mpy in a 3.5% sodium chloride solution for 16 hours according to G-59/G-61.

19. A hardfacing layer formed from a feedstock material, comprising:
Ni; and
a corrosion resistant matrix which is characterized by having, under thermodynamic equilibrium conditions:
hard phases of 1,000 Vickers hardness or greater totaling 5 mol. % or greater; and
a matrix proximity of 80% or greater when compared to a known corrosion resistant nickel alloy;

wherein the corrosion resistant matrix comprises a WC/Cr 3 C 2 ratio of 0.25 to 5 by volume.

20. A hardfacing layer formed from a feedstock material, comprising:
Ni;
a corrosion resistant matrix which is characterized by having, under thermodynamic equilibrium conditions:
hard phases of 1,000 Vickers hardness or greater totaling 5 mol. % or greater; and
a matrix proximity of 80% or greater when compared to a known corrosion resistant nickel alloy; and

an impermeable HVOF coating which exhibits a corrosion rate of 1 mpy or less in a 28% CaCl 2 ) electrolyte, pH=9.5 environment.

Assignees

• Oerlikon Metco Us Inc

Inventors

• Vecchio James
• Cheney Justin Lee
• Bracci Jonathon
• Fiala Petr

Classifications

• C23C4/06

  Metallic material · CPC title

• C22C19/056 Primary

  with the maximum Cr content being at least 10% but less than 20% · CPC title

• C22C19/05 Primary

  with chromium · CPC title