Ni-cr-al chromium carbide powder

Pending Publication Date: 2022-08-18
SULZER METCO (US) INC
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The patent describes a thermal spray feedstock that includes a specific combination of elements. The feedstock is made up of about 15-30% Ni, about 7-25% Al, about 4-5% Cr, and about 15-30% Cr7C3 carbides. The feedstock can also include other carbides, such as Cr2C, Cr5C, and Cr6C. The feedstock has a specific matrix structure that includes a gamma phase and a beta phase, with the beta phase being about 0.1-0.7 gamma / beta ratio. The feedstock can also be characterized by its weight percentage of aluminum content in a single phase FCC_A1 matrix at 1500K. The thermal spray feedstock is useful for coating materials in various applications.

Problems solved by technology

Manufacturing methods like this are costly and time consuming.
In addition, the resultant powders produced from these processes are prone to decarburization and oxidation during the thermal spray process which can alter the chemistry of the applied coating in negative ways.

Method used

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  • Ni-cr-al chromium carbide powder
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  • Ni-cr-al chromium carbide powder

Examples

Experimental program
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example 1

[0128]This example demonstrates how the single-phase FCC_A1 temperature range can be advantageous for designing an alloy with a single-phase matrix. As shown in FIG. 4, note that alloy X1 has a single-phase FCC_A1 range of 0K and alloy X3 has a single-phase FCC_A1 range of 725K. After both alloys were manufactured, a significant difference between the two can be observed. The matrix of alloy X1, with the single-phase range of 0K, is multi-phase [401]. In contrast, the matrix of alloy X3, with the single-phase range of 725K, is single phase [402]. Thus, it can be appreciated that the single-phase FCC_A1 range provides a useful measure of the matrix phase and stability.

example 2

[0129]The second example demonstrates an alloy that was successfully gas atomized into a powder and HVOF sprayed to form a coating. The alloy P105-X3 was gas atomized using argon gas and sieved to a particle size range of −53+20 μm. The resultant atomized powder chemistry was measured and listed in Table VI. The powder was then sprayed through a WokaJet 400 HVOF gun to form a coating. Table VII lists the HVOF spray parameters used to form the coating. Finally, the coating was analyzed, and the results are listed in Table VIII. The alloy P105-X3 meets all the thermodynamic, microstructural and performance criteria of this disclosure.

TABLE VIChemical Analysis Results for GasAtomized P105-X3 Powder (wt. %)AlCCrNiNitrogenOxygenT.A.O2.144.2852.51Bal.0.010.02

TABLE VIIHVOF Spray Parameters for WokaJet 400Oxygen Flow950l / minNitrogen Flow344l / minFuel Flow24.3l / hrFuel TypeKerosenePowder Feed Rate29.3g / minSpray Distance300mmSurface Speed80m / minCoating Thickness320μmApplication Rate16μ / passDepo...

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Abstract

Disclosed herein are improved chromium carbide alloy which possess improved properties as related to previous developments. The utilization of aluminum in the alloy can enhance the high temperature oxidation resistance. Embodiments of alloys were designed to simultaneously possess 1) a low liquidus temperature which enables easy atomization on an industrial scale, and 2) a microstructure of a gamma matrix and Cr7C3 carbide precipitates which enables high temperature stability and retention of advantageous properties at high temperatures.

Description

INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS[0001]This application claims from the benefit of U.S. application Ser. No. 62 / 868135, filed Jun. 28, 2019, and entitled “NI—CR—AL CHROMIUM CARBIDE POWDER”, and U.S. application Ser. No. 62 / 969,474, filed Feb. 3, 2020, and entitled “NI—CR—AL CHROMIUM CARBIDE POWDER”, the entirety of each of which is incorporated by reference herein.BACKGROUNDField[0002]The embodiments of this disclosure generally relate to nickel-based alloys containing chromium carbides which serve as effective feedstock.Description of the Related Art[0003]Many commercially available nickel-based chromium carbide powders for thermal spray applications are produced via agglomerating and sintering or mechanical cladding processes. These manufacturing processes involve mechanical blending of individual constituents. For example, chromium carbide powder can be blended with a nickel-chromium alloy powder, sintered together and spheroidized to form a new powder of in...

Claims

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Application Information

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IPC IPC(8): C23C4/10C22C29/02
CPCC23C4/10C22C29/02B22F3/115C22C1/045C22C1/0433B22F7/04C23C4/06C23C30/00C22C19/05C22C30/00C22C27/06
InventorBRACCI, JONATHON HUNTERCHENEY, JUSTIN LEE
OwnerSULZER METCO (US) INC