Thermal spray coatings for reduced hexavalent and leachable chromuim byproducts

Abstract

A target material for thermal spraying may include chromium and at least one of about 0.5-12% by weight of aluminum and about 2-15% by weight of manganese.

1 . A target material for thermal spraying, comprising:
 chromium; and   at least one of about 0.5-12% by weight of aluminum and about 2-15% by weight of manganese.   
   
   
       2 . The target material of  claim 1 , wherein the target material includes manganese. 
   
   
       3 . The target material of  claim 2 , wherein the target material includes manganese between about 5-7% by weight. 
   
   
       4 . The target material of  claim 1 , wherein the target material includes aluminum. 
   
   
       5 . The target material of  claim 4 , wherein the target material includes aluminum between about 9-11% by weight. 
   
   
       6 . The target material of  claim 1 , further including up to about 80% by weight of chromium carbide and up to about 20% by weight of nickel chromium. 
   
   
       7 . The target material of  claim 1 , further including about 9-12% by weight of carbon, about 15-20% by weight of nickel, and less than about 0.5% by weight of iron. 
   
   
       8 . The target material of  claim 1 , further including a iron containing material. 
   
   
       9 . The target material of  claim 8 , wherein the iron containing material includes about 20-80% by weight of chromium, about 10-75% by weight of iron, about 0.5-30% by weight of nickel, and about 5-10% by weight of carbon. 
   
   
       10 . The target material of  claim 1 , further including less than about 0.4% by weight of carbon, about 12-14% by weight of chromium, less than or equal to about 1% by weight of silicon, and less than or equal to about 0.15% by weight of phosphorous and sulfur. 
   
   
       11 . A method of applying a coating on a surface using thermal spraying, comprising:
 delivering a target material that includes chromium to a thermal spraying machine, the target material also including at least one of about 0.5-12% by weight of aluminum and about 2-15% by weight of manganese; and   directing particles of the target material to the surface to form the coating.   
   
   
       12 . The method of  claim 11 , further including forming a shell of one or more of an oxide of aluminum and a chromium oxide manganese oxide spinel over a surface of the particles as the particles are directed from the thermal spraying machine to the surface. 
   
   
       13 . The method of  claim 11 , wherein delivering the target material includes delivering a target material that includes about 0.5-12% by weight of aluminum. 
   
   
       14 . The method of  claim 13 , wherein delivering the target material includes delivering a target material that includes about 9-11% by weight of aluminum. 
   
   
       15 . The method of  claim 11 , wherein delivering the target material includes delivering a target material that includes about 2-15% by weight of manganese. 
   
   
       16 . The method of  claim 15 , wherein delivering the target material includes delivering a target material that includes about 5-7% by weight of manganese. 
   
   
       17 . A method of reducing the formation of hexavalent chromium compounds during thermal spraying of a surface, comprising:
 directing particles of a target material from a thermal spraying machine to the surface, the target material including chromium and at least one of about 0.5-12% by weight of aluminum and about 2-15% by weight of manganese; and   forming a shell of at least one of an oxide of aluminum and a chromium oxide manganese oxide spinel over a core of the particles as the particles travel from the thermal spraying machine to the surface.   
   
   
       18 . The method of  claim 17 , wherein the target material includes at least one of about 9-11% by weight of aluminum and about 5-7% by weight of manganese. 
   
   
       19 . The method of  claim 17 , wherein the target material is a chromium replacement coating material. 
   
   
       20 . The method of  claim 17 , wherein the target material includes a stainless steel alloy.