Erosive wear and corrosion resistant coatings including metal carbide, metal boride, metal nitride, and corresponding methods

Patent metadata

Field	Value
Publication number	US-12104259-B2
Application number	US-201917262374-A
Country	US
Kind code	B2
Filing date	Jul 23, 2019
Priority date	Jul 24, 2018
Publication date	Oct 1, 2024
Grant date	Oct 1, 2024

Abstract

A method of coating an alloy substrate includes providing an alloy substrate that includes less than 0.3 wt. % of diffusible elements; introducing one or more diffusible elements into the alloy substrate to thereby form a diffusible-element-containing alloy substrate; and introducing the diffusible-element-containing alloy substrate to a material reactive with the one or more diffusible elements.

First claim

What is claimed is:

1. A method of coating an alloy substrate, the method comprising steps of:
providing an alloy substrate that includes about 0 wt. % diffusible elements, wherein the diffusible elements of which the alloy substrate includes about 0 wt. % is selected from the group consisting of carbon, nitrogen, boron, oxygen, and combinations thereof, wherein the step of providing the alloy substrate consists of only the step of providing the alloy substrate;
introducing one or more diffusible elements into the alloy substrate that includes about 0 wt. % diffusible elements to thereby form a diffusible-element-containing alloy substrate having a diffusible-element layer, wherein the one or more diffusible elements include carbon; and
introducing, after completion of the step of introducing the one or more diffusible elements into the alloy substrate that includes the about 0 wt. % diffusible elements to thereby form the diffusible-element-containing alloy substrate, the diffusible-element-containing alloy substrate to a material reactive with the one or more diffusible elements of the diffusible-element layer, wherein the material reactive with the one or more diffusible elements is selected from vanadium, aluminum, niobium, tantalum, and combinations thereof,
wherein the step of introducing the diffusible-element-containing alloy substrate to the material reactive with the one or more diffusible elements includes subjecting the diffusible-element-containing alloy substrate to an environment where the one or more diffusible elements will at least partially diffuse from the diffusible-element layer to thereby react with the material reactive with the one or more diffusible elements to form a coating layer including a reaction product thereof, to thereby form a coated alloy substrate, and
wherein the coating layer is a distinct layer from the diffusible-element-containing alloy substrate.

2. The method of claim 1 , wherein the step of introducing one or more diffusible elements into the alloy substrate occurs at a temperature of from about 750° C. to about 950° C.

3. The method of claim 1 , wherein the step of introducing the diffusible-element-containing alloy substrate to a material reactive with the one or more diffusible elements occurs at a temperature of from about 550° C. to about 650° C.

4. The method of claim 1 , wherein the coating layer has a thickness of from 3 μm to 10 μm.

5. The method of claim 1 , wherein the one or more diffusible elements further include nitrogen, boron, oxygen, or combinations thereof.

6. The method of claim 1 , wherein the step of introducing one or more diffusible elements into the alloy substrate occurs in a salt bath.

7. The method of claim 1 , wherein the step of introducing one or more diffusible elements into the alloy substrate occurs by packing the alloy substrate with a composition containing the one or more diffusible elements.

8. The method of claim 1 , wherein the step of introducing the diffusible-element-containing alloy substrate to a material reactive with the one or more diffusible elements occurs in a salt bath.

9. The method of claim 1 , wherein the step of introducing the diffusible-element-containing alloy substrate to a material reactive with the one or more diffusible elements occurs in a fluidized bed.

10. The method of claim 1 , wherein the coating layer has a hardness of from about 1500 HV to about 2500 HV.

11. The method of claim 1 , wherein the coating layer has a hardness of from about 1700 HV to about 2300 HV.

12. The method of claim 1 , wherein the alloy substrate is made of an alloy selected from the group consisting of stainless steel, nickel-based alloys, austenitic nickel-chromium-based superalloys, titanium-based alloys, nickel-titanium alloys, cobalt alloys, titanium aluminide alloys, and tungsten alloys.

13. The method of claim 1 , wherein the alloy substrate is made of Type 410 stainless steel.

14. The method of claim 1 , wherein the coating layer has a thickness of from 2.5 μm to 5 μm.

15. The method of claim 1 , wherein the coating layer includes about 98 wt. % of the reaction product.

16. The method of claim 1 , wherein the coating layer includes about 100 wt. % of the reaction product.

17. The method of claim 1 , wherein the material reactive with the one or more diffusible elements includes vanadium.

Assignees

• Doll Gary L
• Strahin Brandon L
• Univ Akron

Inventors

• Doll Gary L
• Strahin Brandon L

Classifications

• C09D1/00

  Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances · CPC title

• F16C2223/30

  Coating surfaces · CPC title

• C23C8/40 Primary

  using liquids, e.g. salt baths, liquid suspensions · CPC title

• C23C12/00 Primary

  Solid state diffusion of at least one non-metal element other than silicon and at least one metal element or silicon into metallic material surfaces · CPC title