Iron-based alloys designed for wear and corrosion resistance

Patent metadata

Field	Value
Publication number	US-12569942-B2
Application number	US-202017625319-A
Country	US
Kind code	B2
Filing date	Jul 7, 2020
Priority date	Jul 9, 2019
Publication date	Mar 10, 2026
Grant date	Mar 10, 2026

Abstract

Disclosed herein are embodiments of alloys configured to form a coating with two contrasting physical behaviors: 1) reduced hardness with the end result of an easily machinable coating and 2) high abrasion resistance. Generally low hardness will result in low abrasion resistance. However, embodiments of the alloys described herein are able to maintain a low hardness while exhibiting higher abrasion resistance.

First claim

What is claimed is:

1 . A cladding feedstock comprising Fe and, in wt. %:
Cr: 16 to 26; Ti: 0.4 to 2.4; Mo: 0.8 to 3.6; Nb: 4 to 6; Nb+Ti+V: 4.4 to 12; and C: 0.6 to 1.2; wherein the feedstock is characterized by having, under thermodynamic equilibrium conditions, a total ferrite phase mole fraction of 50 mol. % or higher at all temperatures below the solidus and above 500 K.

2 . The feedstock of claim 1 , wherein the feedstock comprises, in wt. %: Nb+Ti+V: 4.4 to 10.

3 . The feedstock of claim 1 , wherein the feedstock comprises Fe and, in wt. %:
Cr: 18 to 25; Ti: 0.45 to 2.2; Mo: 0.9 to 3.3; Nb: 4.5 to 5.5; and C: 0.7 to 1.1.

4 . The feedstock of claim 1 , wherein the feedstock further comprises, in wt. %:
B: 0.3 to 0.5.

5 . The feedstock of claim 1 , wherein the total ferrite phase mole fraction is 60 mol. % or higher at all temperatures below the solidus and above 500 K.

6 . The feedstock of claim 1 , wherein the feedstock is characterized by having, under thermodynamic equilibrium conditions, a primary carbide formation temperature between 1750 K and 2100 K.

7 . The feedstock of claim 1 , wherein the feedstock is characterized by having, under thermodynamic equilibrium conditions, a total primary carbide mole fraction of 5 mol. % or higher at 1300 K.

8 . The feedstock of claim 1 , wherein the feedstock is a powder or wherein the feedstock is one or more wires.

9 . The feedstock of claim 1 , comprising, under thermodynamic equilibrium conditions:
a ferrite matrix comprising at least 12 wt. % Cr; and a mole fraction of hard phases precipitating from liquid greater than 5%.

10 . The feedstock of claim 9 , wherein the hard phases comprise at least one of carbides and borides.

11 . A coating formed from the feedstock of claim 1 .

12 . The coating of claim 11 , comprising:
a ferrite matrix; and a plurality of primary carbides, wherein the primary carbides are embedded in the ferrite matrix.

13 . The coating of claim 12 , wherein the plurality of primary carbides comprise at least one of Nb, Ti, and V.

14 . The coating of claim 12 , wherein the plurality of primary carbides comprise an isolated and spherical morphology.

15 . The coating of claim 11 , wherein the coating has a total primary carbide volume fraction of at least 5 vol. %.

16 . The coating of claim 11 , wherein the coating has a Cr content of the ferrite matrix of at least 12 wt. %.

17 . The coating of claim 11 , wherein the coating has a hardness of 450 HV 0.3 or lower.

18 . The coating of claim 11 , wherein the coating has an ASTM G65 Procedure A volume loss of 200 mm 3 or less.

19 . The coating of claim 11 , wherein the coating is configured to be formed through a deposition process.

20 . A method of applying the feedstock of claim 1 as a coating.

Assignees

• Oerlikon Metco Us Inc

Inventors

• Vecchio James Nathaniel
• Cheney Justin Lee
• Eibl Cameron

Classifications

• C22C38/32

  with boron · CPC title

• C22C38/28

  with titanium or zirconium · CPC title

• C22C38/26 Primary

  with niobium or tantalum · CPC title

• C22C38/22

  with molybdenum or tungsten · CPC title

• C23C4/134

  Plasma spraying · CPC title