Composite wear pad and methods of making the same

Patent metadata

Field	Value
Publication number	US-9849532-B2
Application number	US-201414303205-A
Country	US
Kind code	B2
Filing date	Jun 12, 2014
Priority date	Jun 12, 2014
Publication date	Dec 26, 2017
Grant date	Dec 26, 2017

Abstract

A composite wear pad includes a substrate that is selected from the group of iron based alloys, steel, nickel based alloys, and cobalt based alloys. A hard particle-matrix alloy layer is bonded at a surface to the substrate. The hard particle-matrix alloy layer has a plurality of hard particles dispersed in a matrix alloy. The hard particle-matrix alloy layer has a thickness ranging between greater than about 13 millimeters and about 20 millimeters.

First claim

What is claimed is:

1. A composite wear pad comprising:
a substrate being selected from the group consisting of iron based alloys, steel, nickel based alloys, and cobalt based alloys, the substrate comprising a surface for engaging an article;
a hard particle-matrix alloy layer bonded metallurgically to the substrate, the hard particle-matrix alloy layer comprising a plurality of hard particles dispersed uniformly in a nickel-based matrix alloy; and
the hard particle-matrix alloy layer of the composite wear pad having a thickness ranging between greater than about 13 millimeters and about 20 millimeters, wherein the hard particle-matrix alloy layer is void-free.

2. The composite wear pad according to claim 1 wherein the hard particles comprise one or more of the following hard particles: metal carbides, metal nitrides, metal carbonitrides, metal borides, metal silicides, cemented carbides, cast carbides, ceramics or mixtures thereof.

3. The composite wear pad according to claim 1 wherein the hard particles are selected from the following hard particles: tungsten carbide, cemented tungsten carbide, cast carbide, spherical cast carbide, crushed binderless carbide, crushed cemented tungsten carbide, cermet, and/or all mixtures thereof.

4. The composite wear pad according to claim 1 wherein the hard particle-matrix alloy layer comprises the hard particles in an amount between about 30 volume percent and about 80 volume percent of the hard particle-matrix alloy layer, and the matrix alloy is present in an amount between about 20 volume percent and about 70 volume percent of the hard particle-matrix alloy layer.

5. The composite wear pad according to claim 1 further comprising a diffusion zone between the hard particle-matrix alloy layer and the substrate, the diffusion zone having a thickness ranging between 1 micrometers and 2000 micrometers.

6. The composite wear pad according to claim 1 having an arcuate convex shape.

7. The composite wear pad according to claim 1 wherein the substrate comprises drilled or tapped holes, chamfers, channels, post or threaded posts.

8. The composite wear pad according to claim 1 , wherein the article comprises a base plate.

9. The composite wear pad of claim 1 , wherein the article is an inner diameter of a tube.

10. The composite wear pad of claim 1 , wherein the article is an oil sands sifting screen.

11. The composite wear pad of claim 1 , wherein the article is a cheek plate.

12. The composite wear pad of claim 1 , wherein the hard particle-matrix alloy layer exhibits an adjusted volume loss less than 0.02 cm 3 according to ASTM G65 Standard Method for Measuring Abrasion Using the Dry Sand/Rubber Wheel, Procedure A.

13. The composite wear pad of claim 1 , wherein the hard particle-matrix alloy layer exhibits an adjusted volume loss less than 0.008 cm 3 according to ASTM G65 Standard Method for Measuring Abrasion Using the Dry Sand/Rubber Wheel, Procedure A.

14. The composite wear pad of claim 1 , wherein the hard particle-matrix alloy layer exhibits an erosion rate of less than 0.05 mm 3 /g at a particle impingement angle of 90 degrees according to ASTM G76-07 Standard Test Method for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets.

15. The composite wear pad of claim 1 , wherein the matrix alloy is nickel based alloy of composition 13-17 weight percent chromium, 3-4.5 weight percent boron, 0-1 weight percent carbon and the balance nickel.

16. The composite wear pad of claim 1 , wherein the matrix alloy is nickel based alloy of composition 12-16 weight percent chromium, 8-12 weight percent phosphorus, 0-1 weight percent carbon and the balance nickel.

17. The composite wear pad of claim 1 , wherein the matrix alloy is nickel based alloy of composition 23-27 weight percent chromium, 8-12 weight percent phosphorus, 0-1 weight percent carbon and the balance nickel.

18. The composite wear pad of claim 1 , wherein the matrix alloy is nickel based alloy of composition 17-21 weight percent chromium, 9-11 weight percent silicon, 0-1 weight percent carbon and the balance nickel.

19. The composite wear pad of claim 1 , wherein the matrix alloy is nickel based alloy of composition 20-24 weight percent chromium, 5-8 weight percent silicon, 3-6 weight percent phosphorus and the balance nickel.

20. The composite wear pad of claim 1 , wherein the matrix alloy is nickel based alloy of composition 15-19 weight percent chromium, 7-11 weight percent a combination of silicon and boron and the balance nickel.

Assignees

• Zheng Qingjun
• Vasinko Robert J
• Liu Yixiong
• Kennametal Inc

Inventors

• Zheng Qingjun
• Vasinko Robert J
• Liu Yixiong

Classifications

• C22C1/1036

  starting from a melt · CPC title

• B23K35/0233 Primary

  Sheets or foils (B23K35/0244 takes precedence) · CPC title

• C22C32/0047

  with carbides, nitrides, borides or silicides as the main non-metallic constituents · CPC title

• C22C33/0228

  comprising other non-metallic compounds or more than 5% of graphite · CPC title

• B23K1/19

  taking account of the properties of the materials to be soldered · CPC title