Bulk Amorphous Alloy Feedstock for Uniform Hardfacing Welds
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Solution Overview
Problem
Traditional tungsten carbide-based hardfacing materials suffer from uneven distribution of hard faces due to density differences, leading to cracks and compromised structural integrity, as tungsten carbide particles settle at the bottom of the weld, leaving the top area devoid of particles and creating undesirable cracks.
Innovation Solution
Development of bulk amorphous metal (BAM) alloys with a density less than tungsten carbide, composed of iron, chromium, manganese, molybdenum, tungsten, silicon, carbon, and boron, which are welded using plasma transfer arc (PTA) techniques to create crack-free coatings with uniform hard faces across the weld.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If tungsten carbide particles are used to improve wear resistance, then wear resistance is improved, but density increases causing particle settling and crack formation
Solution Approach 1:
The patent changes the density parameter of the hardfacing material from tungsten carbide (high density) to bulk amorphous metal alloy (lower density). This parameter change eliminates the density-driven particle settling problem while maintaining wear resistance through the amorphous alloy's inherent properties and uniform hard face distribution.
Solution Approach 2:
The patent uses bulk amorphous metal alloy as a composite material alternative to traditional tungsten carbide particulate composites. The amorphous alloy provides a homogeneous microstructure without discrete particulate phases, eliminating the interface problems and density mismatch issues that cause cracking in composite materials.
2Strength
If tungsten carbide particles are applied to improve wear resistance, then wear resistance is improved, but uniform distribution of hard faces is compromised
Solution Approach 1:
The patent achieves homogeneity by using bulk amorphous metal alloy instead of particulate composites. The amorphous alloy forms a uniform, homogeneous microstructure throughout the weld deposit, ensuring consistent hard face distribution and eliminating the segregation problems inherent in particulate reinforcement systems.
3Strength
If tungsten carbide is used as hardfacing material, then wear resistance is improved, but density causes particles to settle at the bottom of the weld
Solution Approach 1:
The patent changes the density parameter of the hardfacing material from tungsten carbide (high density) to bulk amorphous metal alloy (lower density). This parameter change eliminates the density-driven particle settling problem while maintaining wear resistance through the amorphous alloy's inherent properties and uniform hard face distribution.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The BAM alloys achieve wear resistance comparable to tungsten carbide-based materials while maintaining a lower density, ensuring uniform hard facing and preventing cracks, thus enhancing the structural integrity and wear resistance of welds.
Implementation Method 1
welded using plasma transfer arc (PTA) techniques to create crack-free coatings
Implementation Method 2
the BAM alloys, applied through PTA welding or thermal spraying, refer to iron-based alloys that are fully amorphous that may be welded using PTA to achieve crack-free welds
Data Source
AI summary
Embodiments disclosed herein relate to the production of bulk amorphous metal (BAM) alloys comprising chromium, manganese, molybdenum, tungsten, silicon, carbon, boron, and the balance of iron to replace tungsten carbide-based welded material. The BAM alloy embodied herein can be applied through PTA welding, HVOF, TWAS, flame spraying, plasma spraying, laser, their combinations, and other coating and welding processes. When used as welded material, the density of the embodiment of around 7 grams per CC, which is less dense than the tungsten carbide customarily used, resulting in even hard faces during welding spread uniformly across the weld, therefore creating a harder and more wear-resistant weld.