Abrasion-resistant weld overlay

Patent metadata

Field	Value
Publication number	US-2016355922-A1
Application number	US-201615243313-A
Country	US
Kind code	A1
Filing date	Aug 22, 2016
Priority date	Aug 12, 2005
Publication date	Dec 8, 2016
Grant date	—

Abstract

A material blend for deposition of an abrasion-resistant overlay onto a metal substrate comprising a first metal particle component, a second metal particle component, and a carbide particle component and a method for the application thereof, wherein the overlay process conditions and the homogeneity of tungsten carbide distribution in the overlay are improved.

First claim

1 . A material blend for deposition of an abrasion-resistant overlay onto a metal substrate, the blend comprising:
a first powder metal component comprising first powder alloy selected from the group consisting of Ni alloy, Fe alloy, Co alloy and mixtures thereof; a second powder metal component comprising second alloy powder including one or more elements selected from the group consisting of Al, Ti, Y, V, Nb, Ta, Zr, Hf and rare earth elements; and a tungsten carbide particle component, wherein the tungsten carbide particle component is present in an amount of 50 to 80 weight percent of the material blend.

2 . The material blend of claim 1 , wherein the first powder metal is Ni alloy.

3 . The material blend of claim 2 , wherein the Ni alloy comprises Cr.

4 . The material blend of claim 2 , wherein Ni is present in the alloy in an amount of at least 75 weight percent.

5 . The material blend of claim 1 , wherein the first powder metal component is present in an amount of 15 to 35 weight percent of the material blend.

6 . The material blend of claim 3 , wherein the Ni—Cr alloy further comprises at least one of Si, B and C.

7 . The material blend of claim 1 , wherein at least 80 weight percent of the second powder alloy is Ni, Fe or Co.

8 . The material blend of claim 7 , wherein at least 80 weight percent of the second powder alloy is Ni.

9 . The material blend of claim 7 , wherein the second powder alloy includes Al.

10 . The material blend of claim 1 , wherein the second powder metal component is present in an amount of 3 to 20 weight percent of the material blend.

11 . A method of enhancing abrasion-resistance of a metal substrate comprising:
depositing an abrasion-resistant overlay onto a surface of a metal substrate by plasma transfer arc welding deposition of molten material formed from a material blend comprising: a first powder metal component comprising first powder alloy selected from the group consisting of Ni alloy, Fe alloy, Co alloy and mixtures thereof; a second powder metal component comprising second alloy powder including one or more elements selected from the group consisting of Al, Ti, Y, V, Nb, Ta, Zr, Hf and rare earth elements and a tungsten carbide particle component, wherein the tungsten carbide particle component is present in an amount of 50 to 80 weight percent of the material blend, wherein the plasma transfer arc welding deposition is performed by establishing a plasma arc between an electrode and the metal substrate by ionizing a gas, feeding powder through a nozzle into said plasma arc and melting said plasma arc for molten deposition on the meal substrate.

12 . The method of claim 11 , wherein the first powder alloy is Ni alloy.

13 . The method of claim 12 , wherein the Ni alloy comprises Cr.

14 . The method of claim 12 , wherein Ni is present in the alloy in an amount of at least 75 weight percent.

15 . The method of claim 11 , wherein the first powder metal component is present in an amount of 15 to 35 weight percent of the material blend.

16 . The method of claim 13 , wherein the Ni—Cr alloy further comprises at least one of Si, B and C.

17 . The method of claim 11 , wherein at least 80 weight percent of the second powder alloy is Ni, Fe or Co.

18 . The material blend of claim 17 , wherein the second powder alloy includes Al.

19 . The method of claim 11 , wherein the second powder metal component is present in an amount of 3 to 20 weight percent of the material blend.

20 . The method of claim 11 , wherein the tungsten carbide component is substantially uniformly distributed in the abrasion-resistant overlay.

Assignees

• Kennametal Inc

Inventors

• Swingley Thomas
• Luer Kevin
• Webber Rodrick
• Wu James B C

Classifications

• B23K2103/08

  Non-ferrous metals or alloys · CPC title

• C23C4/06

  Metallic material · CPC title

• C23C4/134 Primary

  Plasma spraying · CPC title

• C22C19/007

  with a light metal (alkali metal Li, Na, K, Rb, Cs; earth alkali metal Be, Mg, Ca, Sr, Ba, Al Ga, Ge, Ti) or B, Si, Zr, Hf, Sc, Y, lanthanides, actinides, as the next major constituent · CPC title

• C23C4/131

  Wire arc spraying · CPC title