US2014116575A1PendingUtilityA1

Compositions and methods for determining alloys for thermal spray, weld overlay, thermal spray post processing applications, and castings

Assignee: SCOPERTA INCPriority: Sep 17, 2009Filed: Oct 18, 2013Published: May 1, 2014

Est. expirySep 17, 2029(~3.2 yrs left)· nominal 20-yr term from priority

Inventors:Justin Lee Cheney John Hamilton Madok

C23C 4/06B23K 35/3053C22C 38/22C22C 45/008C22C 29/08C23C 30/00C23C 4/073B23K 35/3093C23C 30/005B23K 35/308C21D 2211/005C22C 29/067C22C 38/32C22C 45/02C22C 38/28C22C 38/24C22C 38/26

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Claims

Abstract

Disclosed herein are iron-based alloys having a microstructure comprising a fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferritic matrix comprises <10 μm Nb and W carbide precipitates. Also disclosed are methods of welding comprising forming a crack free hardbanding weld overlay coating with such an iron-based alloy. Also disclosed are methods of designing an alloy capable of forming a crack free hardbanding weld overlay, the methods comprising the steps of determining an amorphous forming epicenter composition, determining a variant composition having a predetermined change in constituent elements from the amorphous forming epicenter composition, and forming and analyzing an alloy having the variant composition.

Claims

exact text as granted — not AI-modified

1 . An iron-based alloy having a microstructure comprising a fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferritic matrix comprises &lt;10 μm Nb and W carbide precipitates. 
     
     
         2 . The alloy of  claim 1 , given by the chemical formula (In weight percent): Fe 65.3-79.95 Cr 3-7 Ni 0-6 Mn 0-6 Nb 3.5-7 V 0-2.8 C 0.5-1.5 B 0.6-1.75 W 7.5-15.45 Si 0-1.0 Ti 0-1.0 Ti 0-1 Al 0-4 . 
     
     
         3 . The alloy of  claim 2 , given by the chemical formula (In weight percent):
 Fe 65.3-79.95 Cr 5 Ni 0-6 Mn 0-6 Nb 3.5-6 V 0-2 C 0.8-1.5 B 0.8-1.4 W 8.5-13.5 Si 0.15 Ti 0.25-1 Al 0-4 .   
     
     
         4 . The alloy of  claim 2 , given by the chemical formula (In weight percent): Fe 67.3-77.05 Cr 3-7 Ni 0-3 Mn 0-2 Nb 3.5-7 C 0.5-1.4 B 0.6-1.75 W 9.5-15.45 Si 0-0.5 Ti 0-0.5 . 
     
     
         5 . The alloy of  claim 4 , given by the chemical formulas (in weight percent):
 Fe 74.35 Cr 5 Nb 4 V 2 C 0.8 B 1 WE 12.45 Si 0.15 Ti 0.25 .   
     
     
         6 . The alloy of  claim 2 , given by the chemical formula (In weight percent): Fe 67.3-77.05 Cr 3-7 Ni 0-3 Mn 0-6 Nb 4-7 C 0.5-1.4 B 0.6-1.75 W 9.5-15.45 Si 0-0.5 Ti 0-0.5 . 
     
     
         7 . The alloy of  claim 2 , given by the chemical formula (In weight percent): Fe bal Cr 4.8-5.0 Mn &lt;1.0 Nb 0.4-4.2 C 1.0-1.1 V 1.95-2.05 B 1.15-1.25 W 12.4-12.5 Si &lt;1.0 Ti 0.2-0.3 . 
     
     
         8 . The alloy of  claim 2 , given by the chemical formula (In weight percent):
 Fe bal Cr 4.8-5.2 Mn &lt;1.1 Nb 0.4.0-4.4 C 1.0-1.1 V 0.40-2.8 B 0.8-1.25 W 7.5-9.2 Si &lt;1.0 Ti 0.2-0.3 .   
     
     
         9 . The alloy of  claim 2 , given by the chemical formula (In weight percent):
 Fe bal Cr 5.1 Mn 1.1 Nb 4.3 C 1.1 V 2.7 B 0.8 W 7.6 Si 0.5 Ti 0.2 .   
     
     
         10 . A method of welding, comprising forming a crack free hardbanding weld overlay coating with an iron-based alloy having a microstructure comprising a fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferritic matrix comprises &lt;10.1μm Nb and W carbide precipitates. 
     
     
         11 . The method of  claim 10 , wherein the alloy is given by the chemical formula (In weight percent): Fe 65.3-79.95 Cr 3-7 Ni 0-6 Mn 0-6 Nb 3.5-7 V 0-2.8 C 0.5-1.5 B 0.6-1.75 W 7.5-15.45 Si 0-1.0 Ti 0-1 Al 0-4 . 
     
     
         12 . The method of  claim 11 , wherein the alloy is given by the chemical formula (In weight percent): Fe 67.3-77.05 Cr 3-7 Ni 0-3 Mn 0-2 Nb 3.5-7 C 0.5-1.4 B 0.6-1.75 W 9.5-15.45 Si 0-0.5 Ti 0-0.5 . 
     
     
         13 . The method of  claim 11 , wherein the alloy is given by the chemical formula (In weight percent): Fe 67.3-77.05 Cr 3-7 Ni 0-3 Mn 0-2 Nb 3.5-7 C 0.5-1.4 B 0.6-1.75 W 9.5-15.45 Si 0-0.5 Ti 0-0.5 . 
     
     
         14 . The method of  claim 13 , wherein the alloy is given by the chemical formulas (in weight percent): Fe 74.35 Cr 5 Nb 4 V 2 C 0.8 B 1 W 12.45 Si 0.15 Ti 0.25 . 
     
     
         15 . The method of  claim 11 , wherein the alloy is given by the chemical formula (In weight percent): Fe 67.3-77.05 Cr 3-7 Ni 0-3 Mn 0-6 Nb 4-7 C 0.5-1.4 B 0.6-1.75 W 9.5-15.45 Si 0-0.5 Ti 0-0.5 . 
     
     
         16 . The method of  claim 11 , wherein the alloy is given by the chemical formula (In weight percent): Fe bal Cr 4.8-5.0 Mn &lt;1.0 Nb 0.4.0-4.2 C 1.0-1.1 V 1.95-2.05 B 1.15-1.25 W 12.4-12.5 Si &lt;1.0 Ti 0.2-0.3 . 
     
     
         17 . The method of  claim 11 , wherein the alloy is given by the chemical formula (In weight percent): Fe bal Cr 4.8-5.2 Mn &lt;1.1 Nb 0.4.0-4.4 C 1.0-1.1 V 0.4-2.8 B 0.8-1.25 W 7.5-9.2 Si &lt;1.0 Ti 0.2-0.3 . 
     
     
         18 . The method of  claim 11 , wherein the alloy is given by the chemical formula (In weight percent): Fe bal Cr 5.1 Mn 1.1 Nb 4.3 C 1.1 V 2.7 B 0.8 W 7.6 Si 0.5 Ti 0.2 . 
     
     
         19 - 29 . (canceled)

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