Spallation-resistant multilayer thermal spray metal coatings

Patent metadata

Field	Value
Publication number	US-9556506-B2
Application number	US-201314082276-A
Country	US
Kind code	B2
Filing date	Nov 18, 2013
Priority date	Jun 10, 2009
Publication date	Jan 31, 2017
Grant date	Jan 31, 2017

Abstract

A multilayer, wear- and corrosion-resistant coating on a metal substrate comprising a first metal coating layer comprising a composite carbide material; a second metal coating layer over the first metal coating layer comprising at least about 50 wt % of a metal selected from the group consisting of Co, Ni, and Fe; and a surface metal coating layer comprising a cemented carbide material having a third-layer carbide material and a third-layer Co-based or Ni-based binder material.

First claim

What is claimed is:

1. A multilayer, wear- and corrosion-resistant coating on a metal substrate comprising:
a first metal coating layer having a thickness between about 5 and about 50 microns and comprising a composite carbide material comprising a first-layer composite carbide material and a first-layer Co-based or Ni-based binder material;
a second metal coating layer over the first metal coating layer comprising at least about 50 wt % of a metal selected from the group consisting of Co, Ni, and Fe; and
a surface metal coating layer over the second metal coating layer wherein the surface metal coating layer comprises a cemented carbide material having a third-layer composite carbide material and a third-layer Co-based or Ni-based binder material.

2. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the first metal coating layer has a thickness of no more than about 50 microns and the first-layer composite carbide material comprises between about 75 and about 88 wt % first-layer carbide material and between about 12 and about 25 wt % first-layer Co-based or Ni-based binder material.

3. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the second-layer coating material is a Co-based material having at least about 60 wt % Co.

4. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the first, second, and third layers have a combined thickness of between about 55 and about 600 microns.

5. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the first-layer composite carbide material comprises about 83 wt % carbide material WC or WC/W 2 C and about 17 wt % Co.

6. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the second layer coating material comprises between about 0.1 and about 1.4 wt % C, between 0 and about 10 wt % Mo, between 0 and about 10 wt % W, between about 20 and 35 wt % Cr, and balance Co and incidental impurities.

7. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the second layer has a thickness between about 50 and about 200 microns.

8. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the third-layer composite carbide material comprises between about 65 and about 92 wt % third-layer carbide material Cr 3 C 2 , WC or WC/W 2 C and between about 8 wt % and about 35 wt third-layer Co-based or Ni-based binder material.

9. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the third-layer composite carbide material comprises between about 75 and about 92 wt % third-layer carbide material, and between about 3 and about 8 wt % Cr and between about 5 and about 22 wt % Co constituting the third-layer binder material.

10. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the third-layer composite carbide material comprises about 86 wt % carbide material WC or WC/W 2 C, about 10 wt % Co, and about 4 wt % Cr.

11. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the third coating layer has a thickness between about 25 microns and about 250 microns.

12. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the third coating layer has a thickness between about 40 microns and about 100 microns.

13. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the first-layer composite carbide material comprises between about 75 and about 88 wt % first-layer carbide material and between about 12 and about 25 wt % first-layer Co-based binder material;
the second layer coating material comprises between about 0.1 and about 1.4 wt % C, between 0 and about 10 wt % Mo, between 0 and about 10 wt % W, between about 20 and 35 wt % Cr, and balance Co and incidental impurities; and
the third-layer composite carbide material comprises between about 75 and about 92 wt % third-layer carbide material, and between about 3 and about 8 wt % Cr and between about 5 and about 22 wt % Co constituting the third-layer binder material.

14. The multilayer wear- and corrosion-resistant coating of claim 13 wherein:
the second layer has a thickness between about 50 and about 200 microns;
the third coating layer has a thickness between about 40 microns and about 100 microns; and
the first, second, and third layers have a combined thickness of between about 55 and about 600 microns.

15. The multilayer, wear- and corrosion-resistant coating on a metal substrate of claim 1 wherein:
the first-layer composite carbide material comprises between about 75 and about 88 wt % first-layer carbide material and between about 12 and about 25 wt first-layer Co-based or Ni-based binder material; and the second metal coating layer over the first metal coating layer comprises at least about 60 wt % Co.

16. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the second layer coating material consists of between about 0.1 and about 1.4 wt % C, between 0 and about 10 wt % Mo, between 0 and about 10 wt % W, between about 20 and 35 wt % Cr, and balance Co and incidental impurities.

17. The multilayer wear- and corrosion-resistant coating of claim 1 wherein:
the first-layer composite carbide material consists essentially of between about 75 and about 88 wt % first-layer carbide material and between about 12 and about 25 wt % first-layer Co-based binder material;
the second layer coating material consists essentially of between about 0.1 and about 1.4 wt % C, between 0 and about 10 wt % Mo, between 0 and about 10 wt % W, between about 20 and 35 wt % Cr, and balance Co and incidental impurities;
the third-layer composite carbide material consists essentially of between about 75 and about 92 wt % third-layer carbide material, and between about 3 and about 8 wt % Cr and between about 5 and about 22 wt % Co constituting the third-layer binder material;
the first layer has a thickness between about 5 and about 50 microns;
the second layer has a thickness between about 50 and about 200 microns; and
the third coating layer has a thickness between about 40 microns and about 100 microns.

Assignees

• Kennametal Inc

Inventors

• Lee David A
• De Villiers-Lovelock Heidi Lynette
• Dewet Danie Jacobus
• Wu James B C

Classifications

• C23C4/067 Primary

  containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic · CPC title

• C23C4/065 Primary

  Chemistry & Metallurgy · mapped topic

• C23C4/06

  Metallic material · CPC title

• Y10T428/12056

  Entirely inorganic · CPC title

• C23C4/02 Primary

  Pretreatment of the material to be coated, e.g. for coating on selected surface areas · CPC title