Low-friction, high-temperature cobalt-free coating system for gate valves, ball valves, stems, and seats

Abstract

A manufacturing method for a device involves the thermal spraying of tungsten carbide onto raw materials that do not contain cobalt but do contain nickel, copper, or a nickel-copper alloy. This method improves the hardness of the base coating, as well as its anti-corrosion and anti-fouling properties, for high-load applications in seawater and brackish water environments. Furthermore, a cobalt-free material reduces material costs and decreases the overall demand for cobalt. Providing a silicon-doped DLC top layer significantly reduces the brittleness of the top layer and common DLC failures, such as "eggshell" in high-stress applications. Therefore, high-hardness, low-friction applications can be adapted for high-tension environments.

Description

The terms of this disclosure generally refer to cobalt-free alloys that can serve as effective raw materials for hardfacing processes, such as load-bearing surfaces. Specifically, the terms of this description refer to cobalt-free alloys that can serve as effective raw materials for hardfacing load-bearing surfaces on gate valves, ball valves, stems, and seats. BACKGROUND OF THE INVENTION Abrasive and erosive wear is a major concern for operators in applications involving wear of the medium against a surface. Applications experiencing severe wear often utilize high-hardness materials to resist material failure due to the risk of wear. Materials used to protect components from wear due to pressure applied by opposing surfaces may include carbides and / or borides as hard precipitates, which resist abrasion and increase the material's hardness. These materials are often applied as a coating, known as hardfacing, through various welding processes, or molded directly onto a part. For example, tungsten carbide with a cobalt matrix can be applied by thermal spraying, followed by a top layer of diamond-like coating (DLC) applied by chemical vapor deposition (CVD). Another concern for operators is corrosion. Applications that experience severe corrosion typically use stainless steel or soft nickel-based materials with high chromium content. In these types of applications, cracks in the coating may be unacceptable, as cracks can lead to corrosion of the underlying base material. BRIEF DESCRIPTION OF THE INVENTION Example modalities of current disclosure include tungsten carbide or other carbides, in some embodiments, in a cobalt-free matrix such as, for example, a nickel matrix, a copper matrix, or a nickel-copper matrix. Such matrices, when used to form a basecoat, improve the corrosion resistance and antifouling properties of the basecoat. Such cobalt-free materials have lower material costs than cobalt and reduce supply concerns due, at least in part, to the fact that a large portion of the world's cobalt supply comes from conflict zones. Therefore, there is a need to replace the cobalt matrix with another matrix that does not present the cost drawbacks and environmental concerns associated with cobalt matrices. For example, nickel, copper, or nickel-copper alloys improve the corrosion resistance and antifouling properties of the base layer. It is common to use either a wear-resistant or a corrosion-resistant material, as few alloys satisfy both requirements. However, existing materials may not provide the necessary service life, or they may require the addition of carbides to increase wear resistance, which can cause cracking. Polymer coatings have been used on general load-bearing sliding surfaces, including ball valves. Some polymer-type coatings have also been used on gate valves, but they generally suffer from insufficient load-bearing capacity and ductility, especially at elevated temperatures. A thermoplastic polymer coating tends to slip or deform, or even permanently deform, under high contact stress and elevated temperatures. A thermoset polymer coating does not soften with temperature as a thermoplastic does, but it generally suffers from poor ductility and a propensity for increased adhesion, especially at elevated temperatures. These properties generally result in cracking of the coating and removal of the coating from its mating surface. Plasma-assisted CVD (PA-CVD) of a top layer using a silicon dopant reduces internal stresses in the top layer while maintaining normal hardness and low friction properties. Gate valves are used when straight-line fluid flow and minimal flow restriction are required. When the valve is fully open, the gate is inserted into the opposite end of the valve cavity. The gate has an opening for flow through the valve that is the same size as the pipe in which the valve is installed. The valve provides an unobstructed passage that, when fully open, is best suited for main fluid supply lines and pump lines, and is often used in oil and gas production, where pressures can range from 5,000 psi to 30,000 psi. Gate valves may have a coating on the outer surface of the gate and valve seats to reduce friction, as well as to reduce corrosion and improve wear resistance.Some earlier versions have used hard coatings, such as tungsten carbide, on the surface of the gate and valve seats. Other earlier versions have used a vapor deposition process, or chemical vapor deposition, to coat the outer surface of the gate and valve seats. Corrosion- and wear-resistant coatings can be prepared based on a feed material, wherein the feed material is configured to form a matrix that has specific physicochemical properties under thermodynamic equilibrium conditions. Example embodiments include an apparatus for controlling well fluids, the apparatus including a gate valve having a body, the body having a cavity and a flow passage that crosses or intersects with the cavity; a seat ring mounted on the body at the intersection of the flow passage and the cavity, the seat ring having a mating face formed of a steel alloy; a gate in the cavity having a mating face formed of a steel alloy that slides to engage with the face of the seat ring as it moves between the open and closed positions; a hardened outer layer forming the mating face of the seat ring, the hardened layer comprising tungsten carbide in a cobalt-free matrix; and a diamond-like carbon friction-resistant ce / Qnn / Lznz / E / Yii coating on the hardened outer layer;where the hardened outer layer is made of a cobalt-free raw material. Example embodiments include a method of manufacturing a valve, the method comprising thermally sputtering tungsten carbide in a cobalt matrix onto a selected load-bearing surface of a valve component to produce a hardened layer on the load-bearing surface; applying a low-friction coating of a diamond-like carbon layer to the hardened layer; and assembling the component into the valve with the diamond-like carbon layer in sliding engagement with a valve mating surface; wherein the load-bearing surface comprises a mating face of a valve seat ring, and the mating surface comprises a face of a valve gate that moves linearly across the mating face of the seat ring. Example embodiments include a method of manufacturing a valve, the method comprising thermally spraying tungsten carbide in a cobalt-free matrix onto the surface of a valve component to deposit a hardened layer; applying a diamond-like carbon layer to the hardened layer on the surface of the valve component using a vapor deposition process; and assembling the valve component into the valve with the diamond-like carbon layer in sliding coupling with a steel alloy surface of the valve; wherein the valve component comprises a seat ring and the steel alloy surface comprises a mating face of a gate that moves linearly through the diamond-like carbon layer on the seat ring.In example modalities, thermal sputtering comprises the thermal sputtering of tungsten carbide in a matrix that includes at least one nickel and one copper. This document describes modalities of a raw material that include, in % by weight, Ni and C: 0.5 - 2, Cr: 10 - 30, Mo: 5.81 - 18.2, Nb + Ti: 2.38 -10, Ni: Remainder. In example configurations, the feed material or raw material may also include, in % by weight, C: 0.8-1.6, Cr: 14-26, and Mo: 8-16. In example configurations, the feed material may also include, in % by weight, C: 0.84-1.56, Cr: 14-26, Mo: 8.4-15.6, and Nb + Ti: 4.2-8.5. In example configurations, the feed material may also include, in % by weight, C: 8.4-1.56, Cr: 14-26, Mo: 8.4-15.6, Nb: 4.2-7.8, and Ti: 0.35-0.65. In example modalities, the feed material may also include, in % by weight, C: 1.08-1.32, Cr: 13-22, Mo: 10.8-13.2 and Nb: 5.4-6.6. In other example modalities, the raw material may also include, in % by weight, C: 1.2, Cr: 20, Mo: 12, Nb: 6 and Ti: 0.5, Ni: Remainder. In some example embodiments, the feed material or raw material is a powder. In other example embodiments, the feed material is a wire. In still other example embodiments, the feed material is a combination of wire and powder. In additional example embodiments, the feed material may be or include other forms of material suitable for thermal spraying, such as, for example, material prepared by an agglomeration and sintering process. Also described herein are embodiments of a hard coating layer formed from the feed material as described herein. ce / Qnn / Lznz / E / Yii In example embodiments, the hardfacing layer may include a nickel matrix comprising hard phases with a Vickers hardness of 1,000 or greater totaling 5 mol% or more of nickel, 20 wt% or more of a combined total of chromium and molybdenum, isolated hypereutectic hard phases totaling 50 mol% or more of a total hard phase fraction, a WC / Cr3C2 ratio of 0.33 to 3, an ASTM G65A abrasion loss of less than 250 mm3, and a Vickers hardness of 650 or greater. In other example embodiments, the hardfacing layer may have a Vickers hardness of 750 or greater. In additional example embodiments, the hardfacing layer may exhibit two or fewer cracks per square inch (2.54 cm2), have a bond strength of 9,000 psi or greater, and have a porosity of 2% by volume or less. In other example configurations, the hard coating layer may have a porosity of 0.5% by volume or less.In additional embodiments, the hard coating layer may have a corrosion rate of 1 mpy (milliinches per year) or less in an approximately 28% CaCl electrolyte at an ambient pH of 9.5. In other example embodiments, the hard coating layer may have a corrosion rate of 0.4 mpy or less in an approximately 28% CaCl electrolyte at an ambient pH of 9.5. In other example embodiments, the hard coating layer may have a corrosion rate of less than 0.1 mpy in a 3.5% sodium chloride solution for 16 hours in accordance with G-59 / G-61. In still other example embodiments, the hard coating layer may have a corrosion rate of less than 0.08 mpy in a 3.5% sodium chloride solution for 16 hours in accordance with G-59 / G-61. In example embodiments, the nickel matrix may have a matrix proximity of 80% or more compared to a corrosion-resistant alloy defined by Ni: BAL, X > 20 wt%, where X represents at least one of Cu, Cr, or Mo. In example embodiments, the corrosion-resistant alloy is selected from the group consisting of Inconel 625, Inconel 622, Hastelloy C276, Hastelloy X, and Monel 400, where Monel is a nickel-copper alloy with high tensile strength and corrosion resistance. In example modalities, the hard coating layer can be applied over a hydraulic cylinder, a tension lift, a mud motor rotor, or an oilfield component application. Also described in this document are example modalities of a feed material or raw material that includes nickel, wherein the feed material is configured to form a corrosion-resistant matrix characterized by having, under thermodynamic equilibrium conditions, hard phases of Vickers hardness of 1,000 or higher, totaling 5 mol% or more, and a matrix proximity of 80% or more compared to a known corrosion-resistant nickel alloy. In example forms, the known corrosion-resistant nickel alloy may be represented by the formula Ni: BAL X > 20% by weight, where X represents at least one of Cu, Cr, or Mo. In example embodiments, the corrosion-resistant matrix may be a nickel matrix that includes 20 wt% or more of a combined total of chromium and molybdenum. In example embodiments, under thermodynamic equilibrium conditions, the corrosion-resistant matrix may be characterized by having isolated hypereutectic hard phases ce / Qnn / Lznz / E / Yii that total 50 mol% or more of a total hard phase fraction. In example modalities, the known corrosion-resistant nickel alloy can be selected from the group consisting of Inconel 625, Inconel 622, Hastelloy C276, Hastelloy X, and Monel 400. In example configurations, the feed material may include, in % by weight, C: 0.84-1.56, Cr: 14-26, Mo: 8.4-15.6, Nb: 4.2-7.8 and Ti: 0.35-0.65, Ni: Remainder. In example configurations, the feed material may also include B: 2.5 to 5.7, and Cu: 9.8 to 23. In example configurations, the feed material may also include Cr: 7 to 14.5. In example modalities, under thermodynamic equilibrium conditions, the corrosion-resistant matrix can be characterized by having hard phases totaling 50% by moles or more, and a liquid temperature of 1550 K or less. In example modalities, the feed material may include a mixture of Monel and at least one of WC or Cr3C2. In example modalities, the raw material or feed material is selected from the group consisting of, by weight, 75-85% WC + 15-25% Monel, 65-75% WC + 25-35% Monel, 60-75% WC + 25-40% Monel, 75-85% Cr3C2 + 15-25% Monel, 65-75% Cr3C2 + 25-35% Monel, 60-75% Cr3C2 + 25-40% Monel, 75-85% WC / Cr3C2 + 15-25% Monel, 65-75% WC / Cr3C2 + 25-35% Monel, and 60-75% WC / Cr3C2 + 25-40% Monel. In example modalities, a WC / Cr3C2 ratio of the corrosion-resistant matrix can be from 0.2 to 5 by volume. In example configurations, the hard coating layer may include an ASTM G65A abrasion loss of less than 250 mm³ and two or fewer cracks per square inch (2.54 cm²) when the hard coating layer is formed from a laser or plasma transfer arc (PTA) coating process. In example configurations, the hard coating layer may include a high-velocity oxygen fuel (HVOF) impermeable coating that exhibits a corrosion rate of 1 mpy or less in an approximately 28% CaCl₂ electrolyte at an ambient pH of 9.5. In example configurations, the hard coating layer may also include a Vickers hardness of 650 or more, and an adhesion of 9,000 psi or more when the hard coating layer is formed from an HVOF thermal spray process. In example modalities, the hardening layer may include a Vickers hardness of 750 or more, and a porosity of 2% by volume or less, preferably 0.5% or less when the hardening layer is formed from an HVOF thermal spray process. BRIEF DESCRIPTION OF THE FIGURES The present disclosure is further described in the detailed description below, with reference to the plurality of figures indicated, as modalities of examples of the present disclosure, in which similar characters represent similar elements in the various views of the figures. ce / Qnn / Lznz / E / Yii FIG.1 is a cross-sectional view of a gate valve having a lining on at least one of the interfaces between the gate and the seats, according to example modalities. FIG. 2 illustrates a phase mole fraction versus temperature diagram of the P82-X6 alloy showing the mole fraction of phases present in an alloy at different temperatures, according to example modalities. FIG. 3 illustrates a phase mole fraction versus temperature diagram of the P76-X23 alloy showing the mole fraction of phases present in an alloy at different temperatures, according to example modalities. FIG.4 shows an SEM image of an example modality of a P82-X6 alloy with hard phases, hypereutectic hard phases and a matrix. FIG.5 shows an optical microscopy image of P82-X6 laser welded from gas atomized powder according to example 1, parameter set 1. FIG.6 shows SEM images of the gas atomized powder 501 and the resulting coating 502 of the P76-X24 alloy according to example 2. FIG.7 shows an SEM image of an HVOF coating deposited from agglomerated and sintered WC / Cr3C2 powder + a Ni alloy according to example 3, specifically a mixture of 80 wt% WC / CrsCz (50 / 50 wt%) mixed with 20 wt% Monel, according to example modalities. DETAILED DESCRIPTION OF THE INVENTION Through one or more of its various aspects, it is intended that specific modalities and / or characteristics, or subcomponents of this disclosure, highlight one or more of the advantages as specifically described above and indicated below. The modalities of this disclosure include, but are not limited to, hardbanding materials, alloys or powder compositions used to manufacture such hardbanding materials, methods for forming hardbanding materials, and components or substrates that incorporate or protect such hardbanding materials. Figure 1 is a cross-sectional view of a gate valve having a liner at at least one of the interfaces between the gate and the seats, according to example embodiments. In Figure 1, the gate valve 11 has a body 13 and a flow passage 15 extending transversely through the body 13. The valve 11 also has a gate 17 with an orifice 19 passing through it. The gate 17 is shown in Figure 1 in the open position. The gate valve 11 illustrated in Figure 1 is a non-rising stem type valve, but alternatively it may be a rising stem type valve. Also shown in Figure 1 are ring-shaped valve seats 21, which have orifices 23 that intersect with the flow passage 15 of the valve.Gate valve 11 is shown as a split gate type having two separate plates, but gate valve 11 can alternatively be of the single-plate type. ce / Qnn / Lznz / E / Yii When gate 17 is in the open position, orifice 19 of gate 17 registers with flow passage 15 of valve 11, thus allowing flow through the valve. When the gate is closed, orifice 19 no longer registers with flow passage 15. Gate 17 has a mating face 25 on each side that interacts with seats 21. When gate 17 is closed, the pressure in flow passages 15 creates a substantial load on one of the faces 25 that is against one of the seats 21. Movement of gate 17 to or from the closed position causes one of the faces 25 to slide against one of the seats 21 while exerting contact forces, if one of the flow passages 15 is under high pressure. The gate valve 11 is shown in FIG. 1 is a direct-acting gate valve, which means that gate 17 moves down to close gate valve 11.Alternatively, gate valve 11 can be a reverse-acting gate valve by repositioning the location of the gate opening. The gate valve slab or gate 17 may be made of corrosion-resistant steel alloys, such as one of the following: high-quality low-alloy steel; stainless steel; nickel-copper alloy steel; and Monel alloys. The seats 21 may be formed from the same types of material. Example modalities of a method for applying a top layer to the surface of faces 25 and / or seats 21 include a plasma-assisted CVD (PA) process that uses a silicon dopant to reduce internal stresses in the top layer while maintaining normal hardness and low-friction properties. This reduces the incidence of cracking in the top layer due to mechanical and thermal stresses. In example modalities, nickel- and / or copper-based alloys as described herein can serve as effective raw materials for PTA processes, laser hardfacing processes, including high-speed laser hardfacing, and / or thermal spray processing, including HVOF thermal spraying, although disclosure is not as limited. Example modalities include the fabrication of nickel- and / or copper-based alloys into core wires for hardfacing processes, and methods for welding nickel- and / or copper-based wires and powders using wire-fed lasers and short-wave lasers. The term alloy can encompass the chemical composition of a powder used to form a metallic component and the powder itself. The term alloy can also encompass the chemical composition of a molten mass used to form a casting component and the molten mass itself. The term alloy can encompass the composition of the metallic component formed by heating, sintering, and / or deposition of the powder. The term alloy can also encompass the composition of the metallic component after cooling. In example modalities, the term alloy can encompass the chemical composition of the powder described below and the powder itself. The term alloy can encompass the raw material used to form the metallic component.The term alloy may encompass the wire, the wire including a powder, the combined composition of a combination of wires, the composition of the metallic component formed by heating and / or powder deposition or other methodology, and the metallic component. ce / Qnn / Lznz / E / Yii In example modalities, alloys manufactured as solid or core wire (a sheath containing a powder), for welding or for use as a raw material for another process, may be described by specific chemical processes in this document. For example, the wires may be used for thermal spraying. Furthermore, the compositions described below may be of a single wire or a combination of multiple wires (such as 2, 3, 4, or 5 wires). In some example applications, the alloys can be applied via a thermal spraying process to form a thermal spray coating, such as HVOF alloys. In other example applications, the alloys can be applied as a weld layer. In other example applications, the alloys can be applied either as a thermal spray or as a weld layer, for example, serving a dual purpose. Replacing the cobalt matrix in tungsten carbides with nickel, copper, or nickel-copper alloys can be achieved through a modified sintering process to produce high-quality thermal spray powders. Furthermore, Rapid Alloy Development software can be used to tailor the matrix formulation to specific coating requirements. Additionally, doping the DLC top layer with silicon significantly reduces internal stresses in the top layer. In most high-stress applications, high internal stresses in DLC lead to top layer cracking and reduced performance. Example embodiments include a method for producing load-bearing components of steel and nickel, copper, or nickel-copper alloy valves, such as gates, balls, seats, and valve body stems, with a thermally sprayed tungsten carbide nickel, copper, or nickel-copper alloy matrix base coating in a thickness range from 0.005 in. (0.0127 cm) to 0.025 in. (0.0635 cm). A silicon-doped DLC downstream finish material is also used. A non-limiting DLC ​​thickness is up to 30 microns (10.6 meters) to create a monolithic, high-temperature, lower-stress coating to reduce sliding friction and improve corrosion and antifouling properties in seawater or brackish water environments. Metal alloy compositions: In example modalities, a manufactured item, such as a raw material composition as described in this document, may include Ni and in weight percent (% wt): B: 0.4; C: 0-9.1; Cr: 0-60.9; Cu: 0-31; Fe: 0-4.14; Mn: 0-1.08; Mo: 0-10.5; Nb: 0-27; Si: 0-1; Ti: 0-24; and W: 0-12. In example modalities, a manufactured item, such as a raw material composition as described in this document, may include Ni and in weight percent (% wt): C: 0.5-2; Cr: 10-30; Mo: 5-20; and Nb + Ti: 2-10. In example modalities, a manufactured item, such as a raw material composition as described in this document, may include Ni and in weight percent (% wt): C: 0.8-1.6; Cr: 14-26; Mo: 8-16; and Nb + Ti: 2-10. In example modalities, a manufactured item, such as a raw material composition as described in this document, may include Ni and in weight percent (% wt): C: 0.84-1.56; Cr: 14-26; Mo: 8.4-15.6; and Nb + Ti: 4.2-8.5. ce / Qnn / Lznz / E / Yii In example modalities, a manufactured item, such as a raw material composition as described in this document, may include Ni and in weight percent (% wt): C: 0.84 - 1.56; Cr: 14 - 26; Mo: 8.4 - 15.6; Nb: 4.2 - 7.8; and Ti: 0.35 - 0.65. In example modalities, a manufactured item, such as a raw material composition as described herein, may include Ni and in weight percent (% wt): C: 1.08-1.32; Cr: 18-22; Mo: 10.8-13.2; and Nb: 5.4-6. In example modalities, a manufactured item, such as a raw material composition as described herein, may include Ni, and in weight percent (% wt): C: 0.5-2; Cr: 10-30; Mo: 5.81-18.2; and Nb + Ti: 2.38-10. In example modalities, a manufactured item, such as a raw material composition as described herein, may include one of the following, in weight percent (% wt): C: 0.5, Cr: 24.8, Mo: 9.8, Ni: BAL; C: 0.35-0.65, Cr: 17.3-32.3, Mo: 6.8-12.7, Ni: BAL; C: 0.45-0.55, Cr: 22.3-27.3, Mo: 8.8-10.8, Ni: BAL; C: approximately 0.8, Cr: approximately 25, Mo: approximately 14, Ni: BAL; C: 0.56-1.04, Cr: 17.5-32.5, Mo: 9.8-18.2, Ni: BAL; C: 0.7-0.9, Cr: 22.5-27.5, Mo: 12.6-15.4, Ni: BAL; C: approximately 1.2, Cr: approximately 24, Mo: approximately 14, Ni: BAL; C: 0.84-1.56, Cr: 16.8-31.2, Mo: 9.8-18.2, Ni: BAL; C: 1.08-1.32, Cr: 21.6-26.4, Mo: 12.6-15.4, Ni: BAL; C: approximately 1.2, Cr: approximately 20, Mo: approximately 12, Nb: approximately 6, Ti: approximately 0.5, Ni: BAL; C: 0.84 -1.56, Cr: 14 -26, Mo: 8.4 -15.6, Nb: 4.2 -7.8, Ti: 0.35 -0.65, Ni: BAL; C: 1.08 -1.32, Cr: 18 -22, Mo: 10.8 -13.2, Nb: 5.4 -6.6, Ti: 0.45-0.55, Ni: BAL; C: approximately 1.6, Cr: approximately 18, Mo: approximately 14, Nb: approximately 6, Ni: BAL; C: 1.12-2.08, Cr: 12.6-23.4, Mo: 9.8-18.2, Nb: 4.2-7.8, Ni: BAL; C: 1.44-1.76, Cr: 16.2-19.8, Mo: 12.6-15.4, Nb: 5.4-6.6, Ni: BAL. In example modalities, a manufactured item, such as a raw material composition as described herein, may include Ni and in weight percent (% wt): C: approximately 1.4, Cr: approximately 16, Fe: approximately 1.0, Mo: approximately 10, Nb: approximately 5, Ti: approximately 3.8; B: approximately 3.5, Cu: approximately 14; B: 2.45-4.55, Cu: 9.8-18.2; B: 3.15-3.85, Cu: 12.6-15.4; B: approximately 4.0, Cr: approximately 10, Cu: approximately 16; B: 2.8-5.2, Cr: 7-13, Cu: 11.2-20.8; B: 3.6-4.4, Cr: 9-11, Cu: 14.4-17.6; o C: about 1.2, Cr: about 20, Mo: about 12, Nb: about 6, Ti: about 0.5. In example embodiments, a manufactured article, such as a raw material composition as described herein, may include agglomerated and sintered mixtures of, in weight percent (% wt): 75-85% WC + 15-25% Monel; 65-75% WC + 25-35% Monel; 60-75% WC + 25-40% Monel; 75-85% Cr3C2 + 15-25% Monel; 65-75% Cr3C2 + 25-35% Monel; 60-75% Cr3C2 + 25-40% Monel; 60-85% WC + 15-40% Ni30Cu; 60-85% Cr3C2 + 15-40% Ni30Cu; 75-85% (50 / 50% by volume) of WC / Cr3C2+ 15-25% of Monel; 75-85% (50 / 50% by volume) of WC / Cr3C2+ 25-35% of Monel; 75-85% of WC / Cr3C2+ 15-25% of Monel; 75-85% of WC / Cr3C2+ 25-35% of Monel; or 60-90% hard phase + 10-40% Monel alloy. ce / Qnn / Lznz / E / Yii In the above, the hard phases are one or more of the following: tungsten carbide (WC) and / or chromium carbide (Cr3C2). Monel is a nickel-copper alloy of the target composition Ni BAL 30 wt% Cu with a common chemical tolerance of 20–40 wt% Cu, or more preferably 28–34 wt% Cu with known impurities including, but not limited to, C, Mn, S, Si, and Fe. Monel does not include any carbides, and therefore the example embodiments in the disclosure add carbides, such as tungsten carbides and / or chromium carbides. Tungsten carbide is generally described by the formula W: BAL, 4–8 wt% C. In example embodiments, tungsten carbide may be described by the formula W: BAL, 1.5 wt% C. In example modalities with 60-85% WC + Ni30Cu, the manufactured article may be, in percentage by weight: Ni: 10.5 - 28; Cu: 4.5 - 12; C: 3.66 - 5.2; W: 56.34 - 79.82. Example modalities include 60-85% CrsCz + Ni30Cu, and the manufactured article may be, in weight percent: Ni: 10.5 - 28; Cu: 4.5 - 12; C: 7.92 - 11.2; W: 52.1 - 73.78. Therefore, the above description of the raw material indicates that tungsten carbide, a known alloy with that simple chemical formula, was mechanically mixed with Monel (as described by the simple formula Ni30Cu in the prescribed ratio). During this general process, many particles stick together so that a new agglomerated particle is formed. In each case, the agglomerated particle is included in the proportions described. Table 1 below lists a number of experimental alloys, with their compositions listed in weight percent. In example applications, P76 alloys can be thermally sprayed alloys, and P82 alloys can be weld-overlay alloys (such as PTA or laser). However, the disclosure is not so limited. For example, any of the compositions described herein may be effective for hardfacing processes such as plasma transferred arc (PTA), laser hardfacing processes including high-speed laser hardfacing, and thermal spraying processes such as high-speed oxygen fuel (HVOF) thermal spraying. In example modalities, the compositions described may be the wire / powder, the coating or other metallic component, or both. The alloys described may incorporate the aforementioned elemental constituents up to a total of 100% by weight. In example embodiments, the alloy may include, be limited to, or consist essentially of the aforementioned elements. In example embodiments, the alloy may include 2% by weight or less, 1% by weight or less, 0.5% by weight or less, 0.1% by weight or less, or 0.01% by weight or less of impurities, or any range between any of these values. Impurities may be understood as elements or compositions that may be included in the alloys due to their inclusion in the raw material components or through their introduction during the manufacturing process. Furthermore, the Ni content identified in all compositions described in the preceding paragraphs may be the remainder of the composition, or alternatively, when Ni is provided as the remainder, the remainder of the composition may include Ni and other elements. In example embodiments, the remainder may consist essentially of Ni and may include incidental impurities. Table 1: List of experimental compositions of nickel-based alloys % by weight. ce / Qnn / Lznz / E / Yii Asewss» i H | S | C s Cr Ca = Fe ; M ( Me Nb í δ» s 15 í W j .....$8.....j................í......2......(....253 J...............i...............i...............LJ&S.J.......3.......í...............i................[...............ΐ ................;......2......j......Si......i...............S................j...............J.......3.......i...............j................(...............ΐ RB»X3 ( 55.133 | | 13 I 28.95 ; ; 4.14 ; ; 7.47 i 3.« ( | í í f^&X4 i 4836 | S 23 S 35.4 i j 3.68 i i 634 i 2J2 i | í í 1..^^..1..42,84 J................S.....33(4185 .............MI (..£38.Ji................í...............j L R2-X6 J 62.8 (_______________S_____1.4 :_____.16_____:______________|_____1_______i______________]_____10_____¿______5______i_______________. 5 _____ΐ_______________i ___________,,,L.A_____________L.^ P82-X8 ( 58.51 ( 1.9 ( « S ! ϊ ; i 18( 5 ( 1 43 í 1 R&X9 i 62 S 1 2 ¡ IS S S 1 ; 18 5 : S ! PS&XW r βββ i 13 í « 1 SI; i 18 6 : 84 ! 2 ! « ( S 1 ; i 18.....i.....14 >8 _______________I______i______|___________________I_____i_______;___________________X______i______1____________________[_______________( P78-X1 i 47.8 (_______________[ 23(28 j 24; :_________ (i_______________(________________( 1 __________(_______________1 P73X2 j SM и i 13 f 22 26 S · ; ; ; : ¡7M3 i 53 8 i S 1.2 1 ; i í ( 1^-6 1_______________ 25 : 28.4 j______________ pjq................................... PTSFXO ( 65 ¡ ( Ϊ ( ( 25 ( .....¡_______________T1ΓΤ P75ΧΪΠ64 :}.......................................™........................... 1^5 { i 23t ; 28 X........... i 2......t PM-XM 1 5234 ( | 4 | ( ( 1» | *......4 Γμτι'Τ ..... ImStíi 5Ϊ38 [ Γ οΓ Γ 2672 T ΓρΜΧΪβ Τ 1 Γ~342 t Γ2338Π í M66 1 1 0 1 343 s 19,14 j ΍tO2΍. j 82 j______2______S_______________L.............S_____10 ;______________ Γρτ&^Τ'ίβ'ίf2.5 i f.............; ίδ T ™3^~t...............) ; 3.96 í í í í ;Π Π Π Η N Η Η N Π ; í í í í í í \ \ \ ííwí^íí»; : ; í í í^íís>í i í ;; í í í í ;;;;;; í : : í ; í > í í í 1 ífe? í ifiür í 'ittít í í í < ·: í í í ' ' jC»; i $ i :: i i i P 78-X24 i 70 ( 4 S (10 .....1 4 j Γ............ imx^T'7i't 2 '...............Γ........... i P76-X27 i 7ΐΤχ~ 3.5 Ί >............. ϊ j«jí S 3.5 ' ] ______16 J______________ ΰ ΐ ~22T ' ; 13 ; 13 S — 700 1(1 i I w1 s T ; ........1 1 in 1 17 1. Thermodynamic criteria: En modalities de ejemplo, las aleaciones pueden caracterizante por sus criteria thermodinámicos en equilibrio. En modalities de ejemplo, las aleaciones pueden caracterizante por cumplir algunos de los criteria thermodinámicos descritos. En modalias de ejemplo, las aleaciones pueden caracterizadorse por cumplir todos los criteria thermodinámicos descritos. A primary thermodynamic criterion relates to the total concentration of hard particles in the microstructure. As the mole fraction of hard particles increases, the apparent hardness of the alloy may also increase, and consequently, wear resistance, which can be advantageous for hardfacing applications. For the purposes of this description, hard particles can be defined as phases exhibiting a Vickers hardness of 1000 or greater. The total concentration of hard particles can be defined as the total mole percent of all phases that meet or exceed a Vickers hardness of approximately 1000 and are thermodynamically stable at approximately 1500 K in the alloy. In example configurations, the fraction of hard particles is 3 mol% or more, 4 mol% or more, 5 mol% or more, 8 mol% or more, 10 mol% or more, 12 mol% or more, 15 mol% or more, 20 mol% or more, 30 mol% or more, 40 mol% or more, 50 mol% or more, 60 mol% or more, or any range between any of these values In example configurations, the hard particle fraction can vary depending on the intended alloying process. For instance, for thermal spray alloys, the hard particle fraction can range from 40 to 60 mol%. For alloys intended for laser welding, plasma transfer arc welding, or other wire welding applications, the hard particle phase fraction can range from 15 to 30 mol. A second thermodynamic criterion relates to the amount of hypereutectic hard phases that form in the alloy. A hypereutectic hard phase is a hard phase that begins to form at a temperature above the eutectic point of the alloy. The eutectic point of these alloys is the temperature at which the face-centered cubic (FCC) matrix begins to form. In example modalities, the hypereutectic hard phases total 40 mol% or more, 45 mol% or more, 50 mol% or more, 60 mol% or more, 70 mol% or more, 75 mol% or more, or 80 mol% or more of the total hard phases present in the alloy, or any range between any of these values. A third thermodynamic criterion relates to the corrosion resistance of the alloy. The corrosion resistance of nickel-based alloys can increase with higher weight percentages of chromium and / or molybdenum present in the FCC matrix. This third thermodynamic criterion measures the total weight percent of chromium and molybdenum in the FCC matrix at approximately 1500 K. In example modalities, the total weight percent (% wt) of chromium and molybdenum in the matrix is ​​15 wt% or more, 18 wt% or more, 20 wt% or more, 23 wt% or more, 25 wt% or more, 27 wt% or more, 30 wt% or more, or any interval between any of these values. A fourth thermodynamic criterion relates to the alloy matrix chemistry. In example modalities, it can be beneficial to maintain a matrix chemistry similar to that of a known alloy, such as Monel 400. In example modalities, to maintain a matrix chemistry similar to a known alloy, the matrix chemistry of alloys at 1300K was compared to that of a known alloy. Comparisons of this type are called Matrix Proximity. For example, Monel Cr: 28-34, Ni: BAL. In example modalities, the matrix proximity is 50% or more, 55% or more, 60% or more, 70% or more, 80% or more, 85% or more, or 90% or more of the previous alloy. Matrix proximity can be determined in various ways, such as energy-dispersive X-ray spectroscopy (EDS). ce / Qnn / Lznz / E / Yii The following equation can be used to calculate the similarity or proximity of the modeled alloy matrix to an alloy with known corrosion resistance. A value of 100% means an exact match between the compared elements. ce / Qnn / Lznz / E / Yii rnes the percentage of the nth element in the reference alloy; x is the calculated percentage of the nth element in the modeled alloy matrix; £r is the total percentage of elements compared; m is the number of solute elements used in the comparison. A fifth thermodynamic criterion relates to the alloy's liquid temperature, which can help determine its suitability for the gas atomization manufacturing process. The liquid temperature is the lowest temperature at which the alloy is still 100% liquid. A lower liquid temperature generally corresponds to greater suitability for the gas atomization process. In example configurations, the alloy's liquid temperature might be 1850 K or lower. In example configurations, the alloy's liquid temperature might be 1600 K or lower. In example configurations, the alloy's liquid temperature might be 1450 K or lower. The thermodynamic behavior of the P82-X6 alloy is shown in Figure 2. The diagram shows a material precipitating a hypereutectic FCC carbide 101 in a nickel matrix 103, which is greater than 5% at 1500 K. The number 101 represents the fraction of FCC carbide as a function of temperature, forming an isolated hypereutectic phase. The number 102 specifies the total hard phase content at 1300 K, which includes the FCC carbide in addition to the M6C carbide. Therefore, the hypereutectic hard phases constitute more than 50% of the total hard phases in the alloy. The number 103 specifies the alloy matrix, which is an FCC_L12 nickel matrix. The matrix proximity of alloy 103 is greater than 60% compared to Inconel 625. MeC-type carbide also precipitates at a lower temperature to form a total carbide content of approximately 15 mol% at 1300 K (12.6% FCC carbide, 2.4% M6C carbide). The FCC carbide represents the isolated carbides in the alloy and constitutes the majority (>50%) of the total carbides in the alloy. The arrow specifically points to the point where the FCC_L12 matrix composition is extracted for insertion into the matrix proximity equation. As shown in this example, the volume fraction of all hard phases exceeds 5 mol%, with over 50% of the carbide fraction forming as a hypereutectic phase known to form an isolated morphology with the remaining FCC_L12 matrix phase possessing over 60% proximity to Inconel 625. In this calculation, although not shown in FIG. 2, the matrix composition is 18 wt% Cr, 1 wt% Fe, 9 wt% Mo, and 1 wt% Ti, the remainder being nickel. It can be seen that the matrix chemistry of P82-X6 is completely different from the overall chemistry of P82-X6. P82-X6 is designed to have corrosion performance similar to Inconel 625, and the matrix similarity to Inconel 625 is 87%. The thermodynamic behavior of the P76-X23 alloy is shown in Figure 3. The diagram represents a material precipitating a eutectic NhB 203 in a nickel 201 matrix. The number 201 indicates the liquid temperature of the alloy, which is below 1850 K according to a preferred embodiment. The number 202 represents the mole fraction of the hard phases in the alloy, in this case nickel boride (NhB), which exceeds 5 mol% at 1200 K. The number 203 represents the matrix phase fraction, in which case the matrix chemistry is extracted at 1200 K and the matrix proximity is greater than 60% with Monel. The liquid temperature of the alloy is 1400 K, making the material very suitable for gas atomization. NhB is that hard phase in this example and is present at a mole fraction of 66% at 1300 K. The matrix chemistry is 33% by weight Cu, the remainder is nickel.It can be seen that the matrix chemistry of P76-X23 is completely different from the general chemistry of P76-X23. P76-X23 is designed to have corrosion performance similar to Monel 400, and the matrix similarity of P76-X23 to Monel 400 is 100%. Microstructural criteria In example configurations, alloys can be described by their microstructural criteria. In example configurations, alloys can be characterized by meeting some of the described microstructural criteria. In example configurations, alloys can be characterized by meeting all of the described microstructural criteria. A first microstructural criterion relates to the measured total volume fraction of hard particles. For the purposes of this description, hard particles can be defined as phases exhibiting a Vickers hardness of 1000 or greater. The total concentration of hard particles can be defined as the total mole percent of all phases that meet or exceed a Vickers hardness of 1000 and are thermodynamically stable at 1500 K in the alloy. In example embodiments, an alloy possesses at least 3% by volume, at least 4% by volume, at least 5% by volume, at least 8% by volume, at least 10% by volume, at least 12% by volume, at least 15% by volume of hard particles, at least 20% by volume of hard particles, at least 30% by volume of hard particles, at least 40% by volume of hard particles, at least 50% by volume of hard particles, or any interval between any of these values. In example configurations, the hard particle fraction can be varied according to the intended process of the alloy. For example, for thermal spray alloys, the hard particle fraction can be between 40 and 60% by volume. For alloys intended for welding by laser, plasma transfer arc, or other wire welding applications, the hard particle phase fraction can be between 15 and 30% by volume. A second microstructural criterion relates to the fraction of isolated hypereutectic hard phases in an alloy. Isolated, as used herein, includes modalities in which the particular isolated phase (such as spherical or partially spherical particles) remains disconnected from other hard phases. For example, an isolated phase may be 100% enclosed by the matrix phase. This can be contrasted with rod-shaped phases that can form long needles that act as low-toughness “bridges,” allowing cracks to propagate through the microstructure. To reduce the susceptibility of an alloy to cracking, it can be beneficial to form isolated hypereutectic phases instead of continuous grain boundary phases. In example embodiments, the isolated hypereutectic hard phases total 40% by volume or more, 45% by volume or more, 50% by volume or more, 60% by volume or more, 70% by volume or more, 75% by volume or more, or 80% by volume or more of the total hard phase fraction present in the alloy, or any range between any of these values. A third microstructural criterion relates to the alloy's increased corrosion resistance. To enhance corrosion resistance in nickel-based alloys, a high total weight percent of chromium and molybdenum in the matrix can be beneficial. For example, the total chromium and molybdenum content in the matrix, as measured by EDS, might be 15% or more, 18% or more, 20% or more, 23% or more, 25% or more, 27% or more, 30% or more, or any range between these values. A fourth microstructural criterion relates to the matrix similarity of an alloy compared to that of a known alloy, such as Monel. An energy-dispersive X-ray spectrometer (EDS) was used to measure the alloy's matrix chemistry. In example modalities, the matrix similarity is 50% or more, 55% or more, 60% or more, 70% or more, 80% or more, 85% or more, 90% or more of the known alloy, or any range between these values. Figure 4 shows an SEM image of a microstructure for P82-X6 produced by PTA welding. In this case, the alloy was created as a powder mixture for experimental purposes. Number 301 highlights isolated niobium carbide precipitates, which have a volume fraction at 1500 K greater than 5%; number 302 highlights hypereutectic hard phases, which constitute more than 50% of the total hard phases in the alloy; and number 303 highlights the matrix, which has a matrix proximity greater than 60% compared to Inconel 625. The carbide precipitates form a combination of isolated (larger size) and eutectic (smaller size) morphologies, both of which contribute to the total hard phase content. In this example, the isolated morphology hard phases constitute more than 50% by volume of the total carbide fraction. Performance criteria In example modalities, a hard coating layer is produced by a weld overlay process that includes, but is not limited to, a PTA coating or a laser coating. In example applications, an alloy may have several advantageous performance characteristics. For instance, it may be advantageous for an alloy to have one or more of the following: 1) high abrasion resistance, 2) minimal or no cracking when welded using a laser cladding process or other welding method, and 3) high corrosion resistance. The abrasion resistance of hardfacing alloys can be quantified using the ASTM G65A dry sand abrasion test. The material's crack resistance can be quantified using a dye penetration test on the alloy. The alloy's corrosion resistance can be quantified using the ASTM G48, G59, and G61 tests. All listed ASTM tests are incorporated herein in their entirety for reference. In example configurations, a hard coating layer may have an ASTM G65A abrasion loss of less than 250 mm³, less than 100 mm³, less than 30 mm³, or less than 20 mm³. In example configurations, the hard coating layer may exhibit 5 cracks per square inch, 4 cracks per square inch, 3 cracks per square inch, 2 cracks per square inch, 1 crack per square inch, 0 cracks per square inch of coating, or any range in between. In example configurations, a crack is a line on a surface along which it has split without breaking into separate pieces. In example embodiments, the hardfacing layer may have a corrosion resistance of 50% or more, 55% or more, 60% or more, 70% or more, 80% or more, 85% or more, 90% or more, 95% or more, 98% or more, 99% or more, 99.5% or more than a known alloy, or any interval between any of these values. In example embodiments, the alloy may have a corrosion rate of 1 mpy or less in an approximately 28% CaCl₂ electrolyte, ambient pH 9.5. In example embodiments, the alloy may have a corrosion rate of 0.6 mpy or less in an approximately 28% CaCb electrolyte, ambient pH 9.5. In example configurations, the alloy may have a corrosion rate of 0.4 mpy or less in an electrolyte of approximately 28% CaCl₂, ambient pH = 9.5. In example configurations, the alloy may have a corrosion resistance in a 3% sodium chloride solution.5% for 16 hours according to G-59 / G-61 of less than 0.1 mpy. In example embodiments, the alloy may have a corrosion resistance in a 3.5% sodium chloride solution for 16 hours according to G-59 / G-61 of less than 0.08 mpy. In example modalities, a hard coating layer is produced by a thermal spraying process that includes, but is not limited to, high-velocity oxygen fuel (HVOF) thermal spraying. In example configurations, the Vickers hardness of the coating may be 650 or higher. In example configurations, the Vickers hardness of the thermal spraying process may be 700 or higher. In example configurations, the Vickers hardness of the thermal spraying process may be 900 or higher. In example configurations, the adhesion of the thermal spray coating may be 7,500 psi or higher. In example configurations, the adhesion of the thermal spray coating may be 8,500 psi or higher. In example configurations, the adhesion of the thermal spray coating may be 9,500 psi or higher. Examples Example 1: PTA welding of P82-X6 The P82-X6 alloy was gas-atomized into a powder with a particle size distribution of 53–150 pm suitable for PTA and / or laser coating. The alloy was laser-coated using two sets of parameters: 1) a laser power of 1.8 kW and a flow rate of 20 L / min, and 2) a laser power of 2.2 kW and a flow rate of 14 L / min. In both cases, the coating showed isolated fine precipitates of niobium / titanium carbide in a nickel matrix, as shown in Figure 5. The Vickers hardness at 300 grams of force of the laser coatings was 435 ce / Qnn / Lznz / E / Yii and 348 for parameter sets 1 and 2, respectively. The ASTM G65 tests showed 1.58 g lost (209 mm3) and 1.65 g lost (200 mm3) for parameter sets 1 and 2, respectively. Example 2: HVOF spraying of P76-X23 and P76-X24 The P76-X23 and P76-X24 alloys were gas-atomized into powders with a particle size distribution of 15–45 pm, as suitable for HVOF thermal spray processing. Both powders form an extremely fine-scale morphology, in which a nickel matrix phase and a nickel boride phase appear to be present, as predicted by computational modeling, but are very difficult to distinguish and measure quantitatively. As shown in Figure 6, where 501 is the gas-atomized powder and 502 is the resulting powder coating, in addition to the Ni matrix and boride phase 504 (e.g., the nickel / nickel boride eutectic structure of the gas-atomized powder), the P76-X24 alloy also forms chromium boride precipitates 503, as predicted by the model, as isolated fine particles.Number 505 highlights a region of eutectic structure consisting primarily of nickel / nickel boride in the sprayed HVOF coating, and number 506 highlights a region containing many chromium boride precipitates in the coating. Both alloys were sprayed with HVOF to a coating thickness of 200–300 µm, forming dense coatings. The 300-gram-force Vickers hardness of the coatings was 693 and 726 for P76-X23 and P76-X24, respectively. Adhesion tests for P76-X23 resulted in glue failure up to 9,999 psi, while P76-X24 showed 75% adhesion and 25% glue failure in two tests reaching 9,576 and 9,999 psi. The ASTM G65A test (converted from an ASTM G65B test) showed a loss of 87 mm3 for P76-X24. The ASTM G65A test uses 6,000 revolutions, while procedure B uses 2,000 revolutions and is generally used for thin coatings such as thermal spray coatings.P76-X24 was tested in an approximately 28% CaCl₂ electrolyte at pH 9.5, resulting in a measured corrosion rate of 0.4 mpy. In comparison, cracked hard chromium exhibits a rate of 1.06 mpy in a similar environment. Hard Cr is used as a relevant coating for a variety of applications requiring resistance to both corrosion and abrasion. In example configurations, the alloy in the form of an HVOF coating produces a corrosion rate of 1 mpy or less in an approximately 28% CaCl₂ electrolyte at ambient pH 9.5. In example configurations, the alloy in the form of an HVOF coating can produce a corrosion rate of 0.6 mpy or less in an approximately 28% CaCl₂ electrolyte at ambient pH 9.5. In example configurations, the alloy in the form of an HVOF coating can produce a corrosion rate of 0.4 mpy or less in an approximately 28% CaCl electrolyte, ambient pH = 9.5. In example modalities, the HVOF coating alloy produces a non-permeable coating as per the ECP (electrochemical potential) test. Example 3: HVOF spraying of a WC / Cr3C2 and Ni alloy matrix mixture. A mixture of 80 wt% WC / Cr3C2 (50 / 50 wt%) blended with 20 wt% Monel was agglomerated and sintered at 15–45 pm as suitable for thermal spray processing. The HVOF coating, as shown in Figure 7, had a Vickers hardness of 946 g / cm³, forming a dense layer with a porosity of 0.43%. The ce / Qnn / Lznz / E / Yii coating HVOF produced an ASTM G65A mass loss of approximately 12 mm3. FIG.7 illustrates an SEM image of an agglomerated and sintered powder of a WC / CrsC2 + Ni alloy, for example 3, specifically a mixture of 80 wt% WC / CrsC2 (50 / 50 wt%) mixed with 20 wt% Monel. Example 4: Welding studies of P82-X13, 14, 15, 18, 19 compared to Inconel 625 A welding study was conducted evaluating several alloys with varying carbide contents and morphologies against Inconel 625. All alloys in the study were designed to form a matrix similar to Inconel 625, quantified by matrix proximity, with 100% equivalent to a matrix exactly like the bulk composition of Inconel 625. All alloys were laser-welded in three overlapping layers to test crack resistance. Similarly, two-layer welds of each alloy were produced using plasma transfer arc welding to test cracking and other properties. Table 2: Comparison of all ce / Qnn / Lznz / E / Yii microstructures Alloy Name Hard Phase GB Hard Phase Iso Matrix Proximity Inconel 625 0% 0% 100% P82-X13 10.50% 0% 100% P82-X14 20.10% 0% 99% P82-X15 30.40% 0% 84% P82-X18 9.90% 8.10% 98% P82-X19 20.00% 8.00% 98% P82-X18 exemplifies this disclosure, yielding favorable results in this study. P82-X18 is significantly harder than Inconel 625 in both PTA and laser processes. Despite the increased hardness, no cracks were observed in the laser-coated or PTA-coated samples. P82-X18 exhibits improved abrasion resistance compared to Inconel 625 in both processes. The overall trend toward increased hardness holds true for all tested alloys, as shown in Table 3 below. However, increased hardness does not always translate into greater abrasion resistance. P82-X13, P82-X14, and P82-X15 all exhibited higher wear rates than Inconel 625 despite being harder and containing carbides. This result demonstrates the advantageous carbide morphology discovered in relation to the total carbide fraction and alloy hardness. The P82-X18 alloy meets the thermodynamic, microstructural, and performance criteria of the example configurations described herein. P82-X18 is predicted to form 8.1 mol% isolated carbides and 8-12% isolated carbides in the studied and industry-relevant welding processes. The alloy is also predicted to form 9.9 mol% grain boundary hard phases, and in fact, it forms 10 vol% or less grain boundary hard phases. The isolated carbide content exceeds 40% of the total carbide content in the alloy. This high proportion of isolated carbide fraction provides greater wear resistance than would be expected from the total carbide fraction alone. Table 3: Comparison of microhardness values ​​of the test alloy HVi Hardness Inco 625 X13 X14 X15 X18 X19 Ingot 217 252 303 311 333 360 PPTAW 236 309 342 376 375 394 LASER 282 338 370 424 389 438 Table 4: Comparison of Abrasion Performance, ASTM G65 A mm3 lost, of ce / Qnn / Lznz / E / Yii Test Alloys PTAW LASER Inco 625 232 X13 259 256 X14 256 267 The matrix composition of P82-X18 was measured using EDS, which yielded Cr: 19-20 wt%, Mo: 10-12 wt%, Ni: remainder. Therefore, the matrix composition is quite similar to and somewhat overlaps with a typical manufacturing range for Inconel 625, which is: Cr: 20-23 wt%, Mo: 8-10 wt%, Nb + Ta: 3.15-4.15 wt%, Ni: remainder. P82-X18 was tested in the G-48 ferric chloride immersion test for 24 hours and, like Inconel 625, showed no corrosion. P82-X18 was tested against corrosion in a 3.5% sodium chloride solution for 16 hours in accordance with ASTM G-59 / G-61, and a corrosion rate of 0.075 - 0.078 mpy (thousandths of an inch per year) was measured. In example configurations, the measured corrosion rate of the material in a 3.5% sodium chloride solution for 16 hours according to G-59 / G-61 is less than 0.1 mpy. In example configurations, the measured corrosion rate of the material in a 3.5% sodium chloride solution for 16 hours according to G-59 / G-61 is less than 0.08 mpy. In example configurations, the alloys described in this document, for instance, P82-X18, can be used in place of nickel or other common materials as the metallic component in metal matrix carbide (MMC) composites. Common examples of MMC types include 60 wt% WC, 40 wt% Ni. Using P82-X18 in this example would produce an MMC of the type: 60 wt% WC, 40 wt% P82-X18. A variety of carbide ratios and carbide types can be used. Example 5: P82-X18 HVOF Spray Study P82-X18 was thermally sprayed using the hydrogen-fed HVOF process. The resulting coating had an adhesion strength of 10,000 psi, a Vickers 700 HV300 hardness, and an ASTM G65B mass loss of 0.856 (volume loss 10.46 g / mm3). Example 6: HVOF spray study of 30% Ni-Cu sintered and agglomerated materials Two powders were manufactured by agglomeration and sintering according to the following formulas: 1) 65-75% WC / Cr3C2 + 25-35% of a Ni-Cu alloy, and 2) 65-75% CrsCz + 25-35% of a Ni-Cu alloy. To clarify the first mixture, 65-75% of the total volume fraction of the agglomerated and sintered particle is carbide, with the remainder being the Ni-Cu metal alloy. The carbide content of the particle itself consists of a combination of both WC and Cr3C2 carbide types. In example formulations, the WC / Cr3C2 ratio is 0 to 100 by volume. In example formulations, the WC / Cr3C2 ratio is 0.33 to 3 by volume. In example modalities, the WC / CrsC2 ratio is 0.25 to 5 by volume. In example modalities, the WC / CrsCz ratio is 0.67 to 1.5.The composition of the Ni-Cu alloy is Cu: 20-40% by weight, preferably Cu: 25-35% by weight, still preferably: Cu: 28-34% by weight, the remainder being nickel with other common impurities below 3% by weight each. Both powders were sprayed using the HVOF process to form coatings, which were then tested. The coatings produced from powder 1 and powder 2 demonstrated corrosion rates of 0.15 mpy and 0.694 mpy, respectively, in approximately 28% CaCl₂ electrolyte solution at pH 9.5. The coatings produced from powder 1 and powder 2 were impermeable, as measured by the ECP test. The coatings produced from powder 1 and powder 2 showed abrasion volume losses on ASTM G65A of 11.3 mm³ and 16.2 mm³, respectively. The coatings produced from powder 1 and powder 2 showed microhardness values ​​of 816 HV300 and 677 HV300, respectively. The coatings produced from both powders had bond strengths exceeding 12,500 psi. Applications The alloys described herein can be used in a variety of applications and industries. Some non-limiting examples of applications include, in addition to the gate valves mentioned above: surface and open-pit mining, marine, energy, oil and gas, and glass manufacturing. Open-pit or surface mining applications include the following components and coatings for the following components: Wear-resistant sleeves and / or wear-resistant hard linings for slurry or slurry pipes, slurry pump components, including pump casings or impellers or hard linings for slurry pump components, ore feed channel components, including hopper blocks or hard linings for hopper blocks, separation screens including, but not limited to, rotary breaker screens, banana screens and shaker screens, linings for autogenous and semi-autogenous mills, ground or cutting engagement tools and hard linings for ground or cutting engagement tools, wear plates for buckets and linings for dump trucks or CE / QNN / LZNZ / E / YII self-dump trucks.Heel end filler blocks and hard lining for heel end filler blocks in mining shovels, grader blades and hard lining for grader blades, reclaimer stackers, calibrating crushers, general wear packs for mining components and other crushing components. From the preceding description, it will be seen that inventive nickel-based, copper-based, or nickel-copper-based hardfacing alloys and methods of use are described. While several components, techniques, and aspects have been described with a certain degree of particularity, it is clear that many changes can be made to the specific designs, constructions, and methodologies described herein without departing from the spirit and scope of this disclosure. The following publications are incorporated herein by reference in their entirety: United States Patent 8,146,889; PCT Application PCT / EP2018 / 071248; WO2013 / 129939; and US 2004 / 0118455. Certain features described herein in the context of separate implementations may also be implemented in combination in a single implementation. Conversely, several features described in the context of a single implementation may also be implemented in multiple separate implementations or in any suitable subcombination. Furthermore, although features may be described above as acting in certain combinations, one or more features of a claimed combination may, in some cases, be removed from the combination, and the combination may be claimed as any subcombination or variation of any subcombination. Furthermore, although the methods may be represented in the figures or described in the specification in a particular order, these methods need not be performed in the specific order shown or in sequential order, and it is not necessary to perform all the methods to achieve the desired results. Other methods not represented or described in the example methods and processes may be incorporated. For example, one or more additional methods may be performed before, after, simultaneously with, or between any of the described methods. Moreover, the methods may be rearranged or reordered in other implementations. Furthermore, the separation of various system components in the implementations described above should not be interpreted as requiring such separation in all implementations, and it should be understood that the described components and systems can generally be integrated into a single product or packaged into multiple products.In addition, other implementations are within the scope of this disclosure. Conditional language, such as may, could, might, or could, unless specifically stated otherwise or understood differently within the context in which it is used, is generally intended to convey that certain modalities include or do not include certain features, elements, and / or stages or steps. Therefore, such conditional language is not generally intended to imply that the features, elements, and / or stages or steps are required in any way for one or more modalities. Conjunctive language such as the phrase "at least one of X, Y, and Z," or "at least one of X, Y, and Z," unless specifically stated otherwise, is generally understood within the context used to convey that an element, term, etc., can be either X, Y, or Z. Therefore, such conjunctive language is not generally intended to imply that certain modalities require the presence of at least one of X, at least one of Y, and at least one of Z. The grade language used in this document, such as the terms approximately, around, generally, and substantially, as used herein, represents a value, quantity, or characteristic close to the stated value, quantity, or characteristic that still performs a desired function or achieves a desired result. For example, the terms approximately, around, generally, and substantially may refer to an amount that is within less than or equal to 10% of, within less than or equal to 5% of, within less than or equal to 1% of, within less than or equal to 0.1% of, and within less than or equal to 0.01% of the stated amount. If the stated amount is 0 (e.g., none, has none), the ranges mentioned above may be specific ranges and not within a particular percentage of the value. For example, within less than or equal to 10% w / v, within less than or equal to 5% w / v, within less than or equal to 1% w / v., within less than or equal to 0.1% weight / vol., and within less than or equal to 0.01% weight / vol. of the stated amount. The disclosure herein of any feature, aspect, method, property, characteristic, quality, attribute, element, or similar detail in relation to various modalities may be used in all other modalities set forth herein. Furthermore, it shall be acknowledged that any method described herein may be practiced using any device suitable for performing the enumerated steps. Although several forms and variations thereof have been described in detail, other modifications and methods of use thereof will be obvious to those skilled in the art. It should therefore be understood that various applications, modifications, materials, and substitutions of equivalents may be made without departing from the unique and inventive description hereof or the scope of the claims. In one modality, the hard coating layer is formed from the feed material or raw material. In one embodiment, the feed material is a cobalt-free feed material. In one embodiment, the cobalt-free feed material comprises, in % by weight: Ni: Remainder; C: about 0.8 - about 1.6; Cr: about 14 - about 26; and Mo: about 8 - about 16. In one embodiment, the cobalt-free feed material comprises, in wt.%: Ni: Remainder; C: about 0.84 - about 1.56; Cr: about 14 - about 26; Mo: about 8.4 - about 15.6; and Nb + Ti: about 4.2 - about 8.5. In one embodiment, the cobalt-free feed material comprises, in % by weight: Ni: Remainder; C: about 1.2; Cr: about 20; Mo: about 12; Nb: about 6; and Ti: about 0.5. In one form, the cobalt-free feed material is a powder. In one embodiment, the cobalt-free feed material is a wire. ce / Qnn / Lznz / E / Yii In one form, the cobalt-free raw material or feed is a combination of wire and powder. In one embodiment, the feed material comprises nickel; wherein the feed material is configured to form a corrosion-resistant matrix characterized by having, under thermodynamic equilibrium conditions: hard phases of Vickers hardness 1,000 or higher totaling 5 mol% or more; and a matrix proximity of 80% or more compared to a known corrosion-resistant nickel alloy. In one embodiment, the known corrosion-resistant nickel alloy is represented by the formula Ni: BAL X > 20% by weight, where X represents at least one of Cu, Cr, or Mo. In one form, the cobalt-free feed material is a powder. In one modality, the powder is prepared by an atomization process. In one modality, the powder is prepared by an agglomeration and sintering process. In one embodiment, the corrosion-resistant matrix is ​​a nickel matrix comprising 20% ​​by weight or more of a combined total of chromium and molybdenum. In one modality, under thermodynamic equilibrium conditions, the corrosion-resistant matrix is ​​characterized by having isolated hypereutectic hard phases that total 50% by moles or more of a total hard phase fraction. In one embodiment, the known corrosion-resistant nickel comprises Monel 400. In one embodiment, the cobalt-free feed material comprises: Ni: Remainder; C: 0.84-1.56; Cr: 14-26; Mo: 8.4-15.6; Nb: 4.2-7.8; and Ti: 0.35-0.65. In one embodiment, the cobalt-free feed material further comprises: Ni: Remainder; B: approximately 2.5 to approximately 5.7; and Cu: from approximately 9.8 to approximately 23. In one embodiment, the cobalt-free feed material further comprises: Cr: approximately 7 to approximately 14.5. In one embodiment, the thermal spray feed material comprises a wire. In one embodiment, the thermal spray feed material comprises a combination of wire and powder. In one embodiment, the invention comprises a method for reducing the brittleness of an upper layer by coating it with a silicon-doped diamond-type coating, wherein the upper layer is hard and exhibits low friction. In one embodiment, the device is a valve and the part of the device is a gate. In one embodiment, the invention comprises a method for manufacturing a valve, the method comprising: thermally spraying tungsten carbide on a cobalt-free raw material onto a surface of a valve component to deposit a hardened layer; applying a diamond-like carbon layer to the hardened layer on the surface of the valve component using a vapor deposition process; and assembling the valve component into the valve with the diamond-like carbon layer in sliding coupling with a steel alloy surface of the valve; wherein the valve component comprises a seat ring and the steel alloy surface comprises a mating face of a gate that moves linearly through the diamond-like carbon layer on the seat ring. In one embodiment, thermal sputtering comprises the thermal sputtering of tungsten carbide into a feedstock that includes at least one of nickel and copper.

Claims

1. An apparatus for controlling well fluids, characterized in that it comprises: a gate valve having a body, the body having a cavity and a flow passage intersecting with the cavity; a seat ring mounted on the body at the intersection of the flow passage and the cavity, the seat ring having a mating face formed of a steel alloy; a gate in the cavity, having a mating face formed of a steel alloy that slides to the face of the seat ring while moving between the open and closed positions; a hardened outer layer formed on the mating face of the seat ring, the hardened layer formed from a cobalt-free feed material or raw material and comprising tungsten carbide in a cobalt-free matrix; and a diamond-like carbon friction-resistant coating on the hardened outer layer.

2. The apparatus according to claim 1, further characterized in that the cobalt-free feed material or raw material comprises, in % by weight: Ni: Remainder C: 0.5-2; Cr: 10-30; Mo: 5.81 - 18.2; Nb + Ti: 2.38- 10.

3. The apparatus according to claim 1, further characterized in that the cobalt-free feed material or raw material comprises, in % by weight: Ni: Remainder C: about 0.84 - about 1.56; Cr: about 14 - about 26; Mo: about 8.4 - about 15.6; Nb: about 4.2 - about 7.8; and Ti: about 0.35 - about 0.

65.

4. The apparatus according to claim 1, further characterized in that the cobalt-free feed material or raw material comprises, in % by weight: Ni: Remainder C: about 1.08 - about 1.32; Cr: about 13 - about 22; Mo: about 10.8 - about 13.2; and Nb: about 5.4 - about 6.

6.

5. The apparatus according to claim 1, further characterized in that the cobalt-free matrix of the hardfacing layer comprises a nickel matrix comprising: hard phases of Vickers hardness of 1,000 or higher totaling 5 mol% or more; 20 wt% or more of a combined total of chromium and molybdenum; ce / Qnn / Lznz / E / Yii isolated hypereutectic hard phases totaling 50 mol% or more of a total hard phase fraction; a WC / Cr3C2 ratio of 0.33 to 3; an ASTM G65A abrasion loss of less than 250 mm3; and a Vickers hardness of 650 or higher.

6. The apparatus according to claim 1, further characterized in that the hard coating layer has a Vickers hardness of 750 or greater.

7. The apparatus according to claim 1, further characterized in that where the hard coating layer has two cracks or less per square inch (2.54 cm2) it has an adhesion or bond strength of 9,000 psi or more and has a porosity of 2% by volume or less.

8. The apparatus according to claim 1, further characterized in that the hard coating layer has a porosity of 0.5% by volume or less.

9. The apparatus according to claim 1, further characterized in that the hard coating layer has a corrosion rate of 1 mpy or less in a 28% CaCb electrolyte, an ambient pH of 9.5, preferably a corrosion rate of 0.4 mpy or less in a 28% CaCb electrolyte, ambient pH of 9.

5.

10. The apparatus according to claim 5, further characterized in that the hard coating layer has a corrosion rate of less than 0.1 mpy in a 3.5% sodium chloride solution for 16 hours according to ASTM G59 / ASTM G61, preferably a corrosion rate of less than 0.08 mpy in a 3.5% sodium chloride solution for 16 hours according to ASTM G59 / ASTM G61.

11. The apparatus according to claim 5, further characterized in that the nickel matrix has a matrix proximity of 80% or more compared to a corrosion-resistant alloy defined by Ni: BAL, X > 20% by weight, wherein X represents at least one of Cu, Cro Mo.

12. The apparatus according to claim 11, wherein the corrosion-resistant alloy comprises Monel 400.

13. The apparatus according to claim 1, further characterized in that the hard coating layer is applied over a hydraulic cylinder, a tension lifter, a mud motor rotor, or an oilfield component application.

14. The apparatus according to claim 1, further characterized in that the cobalt-free matrix forms a corrosion-resistant matrix and, under thermodynamic equilibrium conditions, the corrosion-resistant matrix has: hard phases totaling 50 mol% or more; and a liquid temperature of 1550 K or less.

15. The apparatus according to claim 1, further characterized in that the cobalt-free feed material or raw material comprises a mixture of Monel and at least one of WC or Cr3C2.

16. The apparatus according to claim 1, further characterized in that the cobalt-free feed material or raw material is selected from the group consisting of, by weight: ce / Qnn / Lznz / E / Yii 75-85% WC + 15-25% Monel; 65-75% WC + 25-35% Monel; 60-75% WC + 25-40% Monel; 75-85% Cr3C2 + 15-25% Monel; 65-75% Cr3C2 + 25-35% Monel; 60-75% Cr3C2 + 25-40% Monel; 75-85% WC / Cr3C2 + 15-25% Monel; 65-75% WC / Cr3C2 + 25-35% Monel; and 60-75% WC / Cr3C2 + 25-40% Monel.

17. The apparatus according to claim 14, further characterized in that the WC / Cr3C2 ratio of the corrosion-resistant matrix is ​​0.0.2 to 5 by volume.

18. The apparatus according to claim 1, further characterized in that the hard coating layer comprises: an ASTM G65A abrasion loss of less than 250 mm3; and two cracks or less per square inch when forming the hard coating layer from a PTA or laser coating process.

19. The apparatus according to claim 18, further characterized in that the hard coating layer comprises an impermeable HVOF coating exhibiting a corrosion rate of 1 mpy or less in a 28% CaCI2 electrolyte, at an ambient pH of 9.

5.

20. The apparatus according to claim 19, further characterized in that the hard coating layer further comprises: a Vickers hardness of 650 or greater; and an adhesion of 9,000 psi or more when the hard coating layer is formed from an HVOF thermal spray process.

21. The apparatus according to claim 18, further characterized in that the hard coating layer comprises: a Vickers hardness of 750 or greater; and a porosity of 2% by volume or less, preferably 0.5% or less when the hard coating layer is formed from an HVOF thermal spraying process.

22. A method of manufacturing a device, characterized in that it comprises: thermally spraying tungsten carbide onto a load-bearing surface, selected from a device component, onto a cobalt-free feed material or raw material to produce a hardened layer on the load-bearing surface; applying a low-friction coating of a diamond-like carbon layer to the hardened layer; and assembling the component into the valve with the diamond-like carbon layer in sliding coupling with a coupling surface of the device; ce / Qnn / Lznz / E / Yii wherein the load-bearing surface comprises a mating face of a seat ring of the device, and the mating surface comprises a face of a device part that moves linearly across the mating face of the seat ring.

23. The method according to claim 22, further characterized in that it additionally comprises applying a lubricant to the diamond-type layer.

24. The method according to claim 22, further characterized in that the cobalt-free feed material is at least one of nickel feed material, copper feed material, and nickel-copper feed material.