Wear Resistant Alloy Powders and Coatings

Abstract

This invention relates to alloys and wear resistant alloy powders useful for deposition through thermal spray devices. The alloys comprise from about 20 to 65 weight percent chromium, about 20 to 65 weight percent molybdenum, about 0.5 to 3 weight percent carbon, and about 10 to 45 weight percent nickel. The wear resistant alloy powders are useful for forming coatings having the same composition.

1 . An alloy comprising from about 20 to 65 weight percent chromium, about 20 to 65 weight percent molybdenum, about 0.5 to 3 weight percent carbon, and about 10 to 45 weight percent nickel. 
     
     
         2 . The alloy of  claim 1  comprising about 10 to 45 weight percent nickel plus cobalt. 
     
     
         3 . The alloy of  claim 1  comprising about 0.5 to 3 weight percent carbon plus boron, silicon and/or manganese. 
     
     
         4 . The alloy of  claim 1  further comprising precipitated carbides and optionally nitrides of chromium and molybdenum interspersed throughout. 
     
     
         5 . The alloy of  claim 4  in which the volume fraction of the precipitated carbides and optionally nitrides dispersed throughout the alloy is 0.25 or greater. 
     
     
         6 . The alloy of  claim 4  in which the size of the precipitated carbides and optionally nitrides is between 0.5 or less and 20 micrometers in its largest dimensions. 
     
     
         7 . A wear resistant powder useful for deposition through thermal spray devices, the powder comprising an alloy of about 20 to 65 weight percent chromium, about 20 to 65 weight percent molybdenum, about 0.5 to 3 weight percent carbon, and about 10 to 45 weight percent nickel. 
     
     
         8 . The wear resistant powder of  claim 7  in which the alloy further comprises about 10 to 45 weight percent nickel plus cobalt. 
     
     
         9 . The wear resistant powder of  claim 7  in which the alloy further comprises about 0.5 to 3 weight percent carbon plus boron, silicon and/or manganese. 
     
     
         10 . The wear resistant powder of  claim 7  in which the alloy further comprises precipitated carbides and optionally nitrides of chromium and molybdenum interspersed throughout. 
     
     
         11 . The wear resistant powder of  claim 10  in which the volume fraction of the precipitated carbides and optionally nitrides dispersed throughout the alloy is 0.25 or greater. 
     
     
         12 . The wear resistant powder of  claim 10  in which the size of the precipitated carbides and optionally nitrides is between 0.5 or less and 20 micrometers in its largest dimensions.