Reduced carbides ferrous alloys

Patent metadata

Field	Value
Publication number	US-12378647-B2
Application number	US-202318399370-A
Country	US
Kind code	B2
Filing date	Dec 28, 2023
Priority date	Mar 29, 2018
Publication date	Aug 5, 2025
Grant date	Aug 5, 2025

Abstract

Disclosed herein are embodiments of wear resistant alloys, such as ferrous alloys, that can have reduced carbide contents. In some embodiments, the alloys may have no carbides. In some, the alloy may have boride phases, such as phases having high Mo+W content and/or high Fe+Cr content. There can be reduced hardphases levels out of the specifically disclosed boride phases in some embodiments. In some embodiments, hypereutectic chromium borides can have limited incorporation into the disclosed alloys.

First claim

What is claimed is:

1. A feedstock material, comprising:
Fe;
B: about 7.5 wt. % to about 8.8 wt. %;
C: about 0.1 wt. % to about 1.0 wt. %;
Cr: about 18 wt. % to about 26 wt. %; and
Mo: about 17 wt. % to about 25 wt. %;
wherein the feedstock material is configured to form a coating on a substrate, the coating comprising:
a martensitic matrix,
a first type of borides comprising one or both of M 2 B and M 3 B 2 , wherein M comprises one or both of Mo and W,
a second type of borides comprising one or both of Cr 2 B and (Fe,Cr) 2 B, and
one or more other phases other than a martensite and the first and second types of borides and having a hardness greater than 1000 HV, wherein the one or more other phases is present in the coating in an amount less than about 10 mole %.

2. The feedstock material of claim 1 , wherein the coating comprises less than about 10 mole % of hypereutectic hard phases.

3. The feedstock material of claim 1 , wherein the coating comprises between about 5 and 50 mole % of a combined amount of the first type of borides, the second type of borides, and the one or more other phases.

4. The feedstock material of claim 1 , wherein the coating comprises less than about 1 mole % of primary carbides.

5. The feedstock material of claim 1 , wherein the feedstock material comprises a powder.

6. The feedstock material of claim 1 , wherein the feedstock material comprises a wire.

7. The feedstock material of claim 6 , wherein the wire comprises a flux core wire or a metal core wire.

8. The feedstock material of claim 1 , wherein the coating comprises between about 5 and 50 mole % of the first type of borides.

9. The feedstock material of claim 1 , wherein the coating comprises between about 5 and 50 mole % of the second type of borides.

10. The feedstock material of claim 1 , wherein the one or more other phases comprise one or both of M 23 (C,B) 6 and M 7 C 3 .

11. A method of forming a hardfacing coating onto a substrate, the method comprising:
providing a feedstock material, wherein the feedstock material comprises:
Fe;
B: about 7.5 wt. % to about 8.8 wt. %;
C: about 0.1 wt. % to about 1.0 wt. %;
Cr: about 18 wt. % to about 26 wt. %; and
Mo: about 17 wt. % to about 25 wt. %; and

applying the feedstock material to the substrate to form the coating, wherein the coating comprises:
a martensitic matrix,
a first type of borides comprising one or both of M 2 B and M 3 B 2 , wherein M comprises one or both of Mo and W,
a second type of borides comprising one or both of Cr 2 B and (Fe,Cr) 2 B, and
one or more other phases other than a martensite and the first and second types of borides and having a hardness greater than 1000 HV, wherein the one or more other phases is present in the coating in an amount less than about 10 mole %.

12. The method of claim 11 , wherein the feedstock material comprises a powder.

13. The method of claim 11 , wherein the feedstock material comprises a wire.

14. The method of claim 13 , wherein the wire comprises a flux core wire or a metal core wire.

15. The method of claim 11 , wherein applying the feedstock to the substrate comprises thermal spraying the feedstock material to the substrate.

16. The method of claim 11 , wherein applying the feedstock to the substrate comprises bulk welding the feedstock material to the substrate.

17. A feedstock material, comprising:
Fe;
B: about 7.5 wt. % to about 8.8 wt. %;
C: about 0.1 wt. % to about 1.0 wt. %;
Cr: about 18 wt. % to about 26 wt. %; and
Mo: about 17 wt. % to about 25 wt. %;
wherein the feedstock material is configured to form an alloy, the alloy comprising:
a martensitic matrix,
a first type of borides comprising one or both of Mo and W, wherein the first type of borides make up between about 5 and about 50 volume % of the alloy,
a second type of borides comprising one or both of Fe and Cr, wherein the second type of borides make up between about 5 and about 50 volume % of the alloy, and
one or more other phases other than a martensite and the first and second types of borides and having a hardness greater than 1000 HV, wherein the one or more other phases is present in the alloy in an amount less than about 10 volume %.

18. The feedstock material of claim 17 , wherein the alloy comprises between 15 and 55 volume % of a combined volume of the first type of borides, the second type of borides, and the one or more other phases.

19. The feedstock material of claim 17 , wherein the alloy comprises less than about 20 volume % of hypereutectic hard phases.

20. The feedstock material of claim 17 , wherein the feedstock material comprises a powder.

Assignees

• Oerlikon Metco Us Inc

Inventors

• Eibl Cameron

Classifications

• B22F1/16

  Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10) · CPC title

• B23K26/342

  Build-up welding · CPC title

• C22C29/14

  based on borides · CPC title

• C23C4/12

  characterised by the method of spraying · CPC title

• C23C4/10

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