Composite welding wires and related clad articles

Abstract

Welding wire, comprising: a hard particle component dispersed in a nickel-based alloy matrix or cobalt-based alloy matrix, wherein the hard particle component comprises tungsten carbide particles having an average size of less than 45 µm and the nickel-based alloy matrix or cobalt-based alloy matrix comprises at least one metal carbide forming element.

Description

TECHNICAL FIELDThe present application relates to welding wires and associated plating articles, and more particularly to welding wires comprising hard particles dispersed in alloy matrix.GENERAL STATE OF THE ARTPlatings are frequently applied to articles or components that are subject to harsh environments or operating conditions in an effort to extend the useful life of the articles or components. Composite claddings can be applied to metallic substrates by a variety of techniques including build-up welding, thermal spraying, laser cladding, infrared cladding, or induction cladding. Conventional build-up welding processes employ hard build-up welding rods of various compositions. One type of carbide hard-build welding rod is, for example, a tubular rod consisting of a steel pipe and metal carbide particles positioned within the pipe, with or without organic binder. Another type of welding wire consists of metal carbide particles partially compacted in a matrix alloy. Each of these rod designs has structural problems that result in deposition of platings that have poorer properties and performance. Tubular rods, for example, often have loose powder in the tube and a heterogeneous grain size distribution. This produces platings with non-uniform structure and wear properties. The partially compacted rods are weak and easily fracture during shipping and handling. Partially densified rods also have a cross-linked porosity (such as packed powder in a tubular rod) that may be oxidized and / or absorb moisture from the environment, which may result in weld defects.US 2011 / 0315668 A1 describes a welding wire with a nickel- or cobalt-based alloy basic structure, in which a hard particle component, for example tungsten carbide, is dispersed.DE 21 2013 000 163 U1 discloses a welding wire with tungsten carbide particles, which can be dispersively embedded in a base filler material made of nickel. Furthermore, the tungsten carbide particles may have a nominal diameter of 20 to 200 μm.CN 101462206 A discloses a welding wire which contains a hard phase composed of tungsten carbide, titanium carbide or a mixture thereof and one or two elements from the group consisting of iron, nickel and cobalt.US 2010 / 0230173 A1 discloses a carbide composite material comprising a continuous ductile phase and at least one discrete carbide region surrounded by the ductile phase.SUMMARYIn view of these deficiencies, novel welding wire compositions for making platings having desirable microstructure and / or improved corrosion resistance are described herein. Briefly, a welding wire comprises a hard particle component dispersed in a nickel-based alloy or cobalt-based alloy framework, wherein the hard particle component comprises tungsten carbide particles having an average size of less than 45 μm and the nickel-based alloy or cobalt-based alloy framework comprises at least one metal carbide forming element. In some embodiments, the tungsten carbide particles are present in the welding wire in an amount of at least 40 weight percent.In another aspect, clad composites are described herein. In some embodiments, a composite article comprises a metallic substrate and a plating adhered to the substrate, wherein the plating comprises a hard particle component dispersed in a nickel-based alloy or cobalt-based alloy base, and the hard particle component comprises tungsten carbide particles having an average size of less than 45 μm. The nickel-based alloy or cobalt-based alloy primitives comprise at least one metal carbide forming element. As further described herein, the plating may be adhered to the substrate via a build-up welding process.In another aspect, methods for plating metallic substrates are provided. A method of plating a metallic substrate, in some embodiments, includes providing a welding wire comprising a hard particle component dispersed in a nickel-based alloy or cobalt-based alloy base, wherein the hard particle component comprises tungsten carbide particles having an average size of less than 45 μm, and the nickel-based alloy or cobalt-based alloy base. In some embodiments, the nickel-based alloy or cobalt-based alloy comprises at least one metal carbide forming element. The plating is deposited on the metallic substrate from the welding wire.These and other embodiments will be further described in the following detailed description.BRIEF DESCRIPTION OF THE DRAWINGSFIG. 1 provides surface roughness values of eroded platings having a structure and composition described herein relative to previous platings formed from welding wires that use coarse tungsten carbide particles, in accordance with some embodiments.DETAILED DESCRIPTIONEmbodiments described herein may be more readily understood by reference to the following detailed description and examples, and their foregoing and following descriptions. Elements, devices, and methods described herein, however, are not limited to the specific embodiments depicted in the detailed description and examples. It should be appreciated that these embodiments merely illustrate the principles of the present invention. Numerous modifications and adaptations will readily occur to those skilled in the art without departing from the spirit and scope of the invention.I. Welding Wires and Composite ArticlesA welding wire, in one aspect, comprises a hard particle component dispersed in a nickel-based alloy or cobalt-based alloy framework, wherein the hard particle component comprises tungsten carbide particles having an average size of less than 45 μm and the nickel-based alloy or cobalt-based alloy framework comprises at least one metal carbide forming element.In some embodiments, metal carbide forming elements of the nickel-based alloy or cobalt-based alloy framework are selected from the group consisting of chromium, molybdenum, titanium, silicon, boron, and various mixtures thereof. Metal carbide forming elements may be present in the alloy microstructure in any desired amount, including amounts sufficient to improve wear and / or corrosion resistance properties of platings deposited to form the welding wire. Metal carbide forming elements, such as boron and / or silicon, may also be present in amounts sufficient to improve liquid phase sintering and / or wetting of the hard particles during manufacture of the welding wire. For example, a metal carbide forming element may be present in the alloy microstructure in an amount of less than about 10 weight percent or less than about 5 weight percent. In some embodiments, a mixture of metal carbide forming elements is present in the alloy microstructure in an amount of less than about 10 weight percent or less than about 5 weight percent. Alternatively, addition of metal carbide forming elements in the alloy microstructure may exceed 10 weight percent. In such embodiments, each individual metal carbide forming element included in the addition may be present in the alloy microstructure in an amount of less than 10 weight percent or less than 5 weight percent. The weight percent of metal carbide forming elements is determined over the entire alloy microstructure composition and is not limited to any local region of the alloy microstructure. In some embodiments, the nickel-based alloy microstructure or cobalt-based alloy microstructure has a liquidus temperature of less than 1200° C. or less than 1100° C.The nickel-based alloy microstructure of the welding wire may have a composition selected from Table I in some embodiments. Table I - Nickel-based alloy matrix Table I - Nickel-based alloy matrixChromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium0-30Molybdenum molybdenum0-28Tungsten Tungsten Tungsten Tungsten Tungsten0-15Niobium0-6Tantalum Tantalum Tantalum0-6Titanium Titanium0-6Iron iron is iron0-30Cobalt Cobalt Cobalt Cobalt Cobalt Cobalt0-15Copper Copper0-50Carbon0-2Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese0-2Silicon Silicon0-10Phosphorus0-10Sulfur0-0,1Aluminum0-1Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron0-5NickelRemainder: Remainder:A nickel-based alloy microstructure may comprise, for example, 1 to 10 wt % chromium, 0 to 5 wt % molybdenum, 0 to 10 wt % titanium, 0 to 5 wt % silicon, 0 to 3 wt % boron, 0 to 15 wt % tungsten, 0 to 2 wt % carbon and the balance nickel. The cobalt-based alloy of the welding wire may further have a composition selected from Table II in some embodiments. Table II - Cobalt-Based Alloy Matrix Table II - Cobalt-Based Alloy MatrixChromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium Chromium0-30Tungsten Tungsten Tungsten Tungsten Tungsten0-15Molybdenum molybdenum0-20Nickel0-20Iron iron is iron0-25Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese Manganese0-2Silicon Silicon0-5Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium Vanadium0-5Carbon0-4Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron Boron0-5Copper Copper0-5Cobalt Cobalt Cobalt Cobalt Cobalt CobaltRemainder: Remainder:In some embodiments, a cobalt-based alloy microstructure comprises, for example, 3 to 10 wt % chromium, 0 to 5 wt % molybdenum, 0 to 10 wt % titanium, 0 to 5 wt % silicon, 0 to 3 wt % boron, 0 to 15 wt % tungsten, 0 to 2 wt % carbon, and the balance cobalt.As described herein, welding wires comprise a hard particle component dispersed in the nickel-based alloy or cobalt-based alloy matrix. The hard particle component comprises tungsten carbide particles having an average size of less than 45 μm. In some embodiments, tungsten carbide particles of the hard particle component have an average size selected from Table III. Table III - Average tungsten carbide particle size (μm) Table III - Average tungsten carbide particle size (μm)≤ 4010-4315-4020-43Tungsten carbide particles of the hard particle component include macrocrystalline tungsten carbide, cast tungsten carbide, polycrystalline tungsten carbide containing metallic binder in an amount greater than 3 weight percent, cemented carbide, and / or mixtures thereof. Sintered tungsten carbide particles used in the hard particle component can comprise any desired amount of metallic binder. The metallic binder content of tungsten carbide sintered particles can be selected according to several considerations including the desired hardness and wear resistance of the particles. In some embodiments, sintered tungsten carbide particles comprise 3 to 20 weight percent metallic binder. The metallic binder of cemented carbide particles may comprise cobalt, nickel, iron or various alloys thereof.Tungsten carbide particles may be present in the welding wire at any desired amount. For example, tungsten carbide particles may be present in an amount of at least 40 weight percent of the welding wire. In some embodiments, tungsten carbide particles are present in the welding wire in an amount of 40 to 80 weight percent or 50 to 70 weight percent. In some embodiments, the majority of tungsten carbide particles in the welding wire are macrocrystalline tungsten carbide particles. At least 60 percent of the tungsten carbide particles in the welding wire can be, for example, macrocrystalline tungsten carbide. In some embodiments, 70 to 100 percent of the tungsten carbide particles in the welding wire are macrocrystalline tungsten carbide.In addition to tungsten carbide particles, the hard particle component may also comprise particles of metal carbides, metal nitrides, metal carbonitrides, metal borides, metal silicides, intermetallic compounds or other ceramics or mixtures thereof. In some embodiments, metallic elements of hard particles include aluminum, boron, silicon, and / or one or more metallic elements selected from Groups IVB, VB, and VIB of the Periodic Table. Groups of the Periodic Table described herein are identified according to the CAS designation. In some embodiments, hard particles include, for example, carbides of titanium, chromium, molybdenum, zirconium, hafnium, tantalum, niobium, rhenium, vanadium, boron, or silicon, or mixtures thereof. Hard particles in some embodiments include nitrides of aluminum, boron, silicon, titanium, zirconium, hafnium, tantalum, or niobium including cubic boron nitride or mixtures thereof. In some embodiments, hard particles additionally include borides such as titanium diboride, B 4 C or tantalum borides or silicides such as MoSi 2 or Al 2 O 3- SiN. Hard particles may include crushed carbide, crushed nitride, crushed boride, crushed silicide, or mixtures thereof. Hard particles may have any desired size in addition to tungsten carbide. In some embodiments, these hard particles have an average size of 10 μm to 100 μm or greater. In other embodiments, these hard particles have an average size of less than 45 μm. The hard particles may, for example, have a size selected from Table III herein.Particles of the hard component may be uniformly or substantially uniformly dispersed in the alloy matrix of the welding wire. Furthermore, welding wires described herein may have any dimensions suitable for the application of plating via build-up welding techniques. In some embodiments, welding wires have a circular or ellipsoidal cross-section.In another aspect, composite articles are described herein. In some embodiments, a composite article includes a metallic substrate and a plating adhered to the substrate, wherein the plating includes a hard particle component dispersed in a nickel-based alloy or cobalt-based alloy microstructure, the hard particle component includes tungsten carbide particles having an average size of less than 45 μm, and the nickel-based alloy or cobalt-based alloy microstructure includes at least one metal carbide forming element.The plating may be adhered to the metal substrate by a build-up welding process using a welding wire or wires having the composition and properties described herein. Accordingly, the plating may have some of the compositional properties described in this Section I. The plating may comprise, for example, any nickel-based alloy or cobalt-based alloy base. Tungsten carbide particles dispersed in the alloy framework may additionally have compositions described in this Section I and average particle sizes selected from Table III.Claddings of composite articles may also have desirable wear properties. In some embodiments, a plating has an erosion rate of less than 0.07 mm 3 or less than 0.05 mm 3 per gram of erodible media according to ASTM G76 - Standard Test Method for Conducting Erosion Tests by Solid Particle Impingement Using Gas Jets. Welding wire-formed platings as described herein may also have an adjusted volume loss of less than 30 mm 3 according to ASTM G65 - Standard Test Method for Measuring Abrasion Using the Dry Sand / Rubber Wheel Apparatus, Procedure A.The platings may be adhered to any desired metallic substrate. Suitable metallic substrates include, but are not limited to, steels, iron-based alloys, nickel-based alloys, and cobalt-based alloys. Steels include, in some embodiments, carbon steels, alloy steels, tool steels or stainless steels. In one embodiment, a steel substrate has, for example, a carbon content greater than 0.3 weight percent. Further, in some embodiments, nickel-based alloy substrates are commercially available under the trade designations INCONEL ®, HASTELLOY ® and / or BALCO ® and cobalt-based alloy substrates are commercially available under the trade designations STELLIT® HAYNES® and / or TRIBALOY®.Metallic substrates may have various geometries. In some embodiments, a substrate has a cylindrical geometry, wherein the inner diameter (ID) surface, the outer diameter (AD) surface, or both may be plated. In some embodiments, metallic substrates include, for example, antiwear agents, granulating plates, bearings, extruder barrels, extruder screws, flow control components, piping, or pipes. Plated substrates are used in some embodiments in oil wells and / or gas wells, in petrochemicals, power generation, the food and animal feed industry, as well as in general industrial applications involving wear, abrasion, corrosion and / or high temperatures.In some embodiments, claddings of composite articles described herein have a worn or eroded surface. Erodible areas of a plating described herein may occur by mechanical working or grinding of the plating after deposition and / or by exposing the plating to one or more erodible environments, such as when the plating article is used in its normal manner. An eroded surface of the plating has a surface roughness (R a) of less than 10 μm or less than 5 μm in some embodiments. In some embodiments, an eroded surface of the plating has a surface roughness of 0.5 μm to 5 μm. In particular, in some embodiments described herein, platings may have the foregoing surface roughness values at any time during the lifetime of the plating. For example, a plating may have a surface roughness of 0.5 μm to 10 μm with less than 50 percent of the plating remaining on the metallic substrate. The ability to maintain desirable surface roughness values over the life of the plating can be at least partially associated with the fine tungsten carbide particle size of the welding wire transferred to the deposited plating.FIG. 1 provides surface roughness values of eroded platings having a structure and composition described herein relative to previous platings formed from welding wires using coarse tungsten carbide particles. As illustrated in FIG. 1, eroded surfaces of platings described herein are substantially smoother with a roughness generally less than 5 μm.Method for plating metallic substratesIn another aspect, methods for plating metallic substrates are provided. A method of plating a metallic substrate, in some embodiments, includes providing a welding wire that includes a hard particle component dispersed in a nickel-based alloy or cobalt-based alloy base, wherein the hard particle component includes tungsten carbide particles having an average size of less than 45 μm, and the nickel-based alloy or cobalt-based alloy base includes at least one metal carbide forming element. The plating is deposited on the metallic substrate from the welding wire. Welding wires and associated platings of methods described herein may have any composition and / or properties described in Section I above.A welding wire may be provided by blending or mixing the hard particle component with nickel-based powder alloy or cobalt-based powder alloy. Composition parameters of the mixture may be consistent with the desired composition parameters of the welding wire, including weight percent and average size of the tungsten carbide particles. The hard particle powder alloy mixture is combined with the organic binder to produce a sheet containing the mixture. The organic binder and the hard particle powder alloy mixture may be mechanically worked or processed to trap the particulate mixture in the organic binder. For example, in one embodiment, the hard particle powder alloy mixture is combined with 3 to 15 vol % PTFE and mechanically worked to fibrillate the PTFE and trap the particulate mixture. The mechanical processing may include rolling, ball milling, stretching, stretching, spreading, or combinations thereof. In some embodiments, the sheet comprising the hard particle powder alloy mixture is subjected to cold isostatic pressing. The resulting sheet can have a low modulus of elasticity and a high green strength. In some embodiments, a sheet comprising organic binder and the hard particle powder alloy mixture is made according to the disclosure of one or more of U.S. Pat. Nos. 3,743,556 A, 3,864,124 A, 3,916,506 A, 4,194,040 A, and 5,352,526 A, each of which is incorporated herein by reference in its entirety.The sheet is then rolled and cut to the desired length and thickness. The rod-shaped plate is then subjected to liquid phase sintering to provide the welding wire. Sintering temperatures and times will depend on the specific composition of the nickel-based powder alloy or the cobalt-based powder alloy. For several powder alloys described herein, sintering temperatures may generally range from 950° C. to 1300° C. for a sintering period of 20 minutes to 2 hours to achieve full or substantially full densification of the welding wire. In some embodiments, the welding wire has less than 2 vol % porosity or less than 1 vol % porosity. The hard particle component and the powder alloy may alternatively be separated into individual plates. The individual plates can be formed as described above. Once the sheets are formed, they can be stacked, rolled and cut to the desired length. Then, liquid phase sintering is performed to finish the production of the welding wire.In other embodiments, a welding wire described herein may be made by mixing the powder alloy and the hard particle component and filling the resulting mixture into a mold having the desired shape and size of the welding wires. The mixture is then sintered and compacted in the mold. In some embodiments, the powder alloy and the hard particle component may be layered within the mold such that the powder alloy infiltrates a hard particle layer during the sintering process.Welding wires described herein find application in a variety of build-up welding techniques for plating metallic substrates. Welding wires can be used, for example, with inert gas welding, CO 2- welding, metal noble gas welding (MIG / TIG), submerged arc welding and / or plasma powder build-up welding (PTA).Various embodiments of the invention have been described for achieving the various objects of the invention. It should be appreciated that these embodiments merely illustrate the principles of the present invention. Numerous modifications and adaptations thereof will readily occur to those skilled in the art without departing from the spirit and scope of the invention.

Claims

A welding wire comprising: a hard particle component dispersed in a nickel-based alloy or cobalt-based alloy framework, wherein the hard particle component comprises tungsten carbide particles having an average size of less than 45 μm and the nickel-based alloy or cobalt-based alloy framework comprises at least one metal carbide forming element.The welding wire of claim 1, wherein the at least one metal carbide forming element is selected from the group consisting of chromium, molybdenum, titanium, silicon, and boron.The welding wire of claim 2, wherein the at least one metal carbide forming element is present in the nickel-based alloy or cobalt-based alloy framework in an amount less than 10 weight percent.The welding wire of claim 2 or 3, wherein the at least one metal carbide forming element is present in the nickel-based alloy or cobalt-based alloy framework in an amount of less than 5 weight percent.The welding wire of any preceding claim, wherein the tungsten carbide particles comprise macrocrystalline tungsten carbide, cast tungsten carbide, cemented carbide, or mixtures thereof.The welding wire of claim 5, wherein the cemented carbide particles comprise metallic binders in an amount of 3 to 20 weight percent.The welding wire according to any one of the preceding claims, wherein the hard particle component further comprises particles selected from the group of metal carbides, metal nitrides and metal carbonitrides.The welding wire of claim 7, wherein the particles of metal carbides, metal nitrides and metal carbonitrides have an average size of less than 45 μm.The welding wire of any preceding claim, wherein the hard particle component is present in the welding wire in an amount of at least 40 weight percent.The welding wire of any preceding claim, wherein the tungsten carbide particles are present in the welding wire in an amount of from 40 weight percent to 80 weight percent.The welding wire of any preceding claim, wherein at least 60 percent of the tungsten carbide particles is macrocrystalline tungsten carbide.The welding wire according to any one of the preceding claims, wherein a part of the tungsten carbide particles has a size of 20 μm to 40 μm.A method of plating a metallic substrate, comprising: providing a welding wire comprising a hard particle component dispersed in a nickel-based alloy or cobalt-based alloy base, wherein the hard particle component comprises tungsten carbide particles having an average size of less than 45 μm and the nickel-based alloy or cobalt-based alloy base comprises at least one metal carbide forming element; and depositing the plating on the metallic substrate from the welding wire.The method of claim 13, wherein at least 60 percent of the tungsten carbide particles is macrocrystalline tungsten carbide.The method of claim 13 or 14, wherein the at least one metal carbide forming element is selected from the group consisting of chromium, molybdenum, titanium, silicon, and boron.The method of any one of claims 13 to 15, wherein the tungsten carbide particles comprise macrocrystalline tungsten carbide, cast tungsten carbide, cemented carbide, or mixtures thereof.The method of any one of claims 13 to 16, wherein the tungsten carbide particles are present in the welding wire in an amount of 40 weight percent to 80 weight percent.The method of claim 17, wherein a portion of the tungsten carbide particles has a size of 20 μm to 40 μm.The method of any one of claims 13 to 18, wherein the plating has an erosion rate of less than 0.07 mm 3 per gram of erodible media according to ASTM G76.The method of any one of claims 13 to 19, wherein the plating has an adjusted volume loss of less than 30 mm 3 according to ASTM G65 procedure A.The method of any of claims 13 to 20, further comprising erodibleally a surface of the plating, wherein the erodible surface has a roughness (Ra) of less than 10 μm.Method according to claim 21, wherein the eroded surface has a roughness (R a) of less than 5 μm.

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