Coated Bodies With Iron-Based Amorphous Alloy Layers Against Crystallization
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Solution Overview
Problem
Existing coatings made from amorphous alloy powders crystallize during application, leading to poor coating density and susceptibility to corrosion in harsh environments.
Innovation Solution
A coated body with a base member coated by an iron-based amorphous alloy layer, comprising iron, chromium, and molybdenum, with a high amorphous phase fraction, is formed using a spray coating process to maintain amorphous structure and improve durability, corrosion resistance, and friction characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If amorphous alloy powder is sprayed on bodies to fabricate coated bodies, then the application process can be completed, but crystallization occurs after the alloy powder is melted making it difficult to manufacture products utilizing amorphous characteristics
Solution Approach 1:
The patent changes the chemical composition parameters of the alloy by adding specific elements (at least one of B, Si, or C) to suppress crystallization during the spray coating process. This compositional modification allows the material to maintain its amorphous structure through the coating fabrication process, resolving the contradiction between ease of manufacture and structural stability.
Solution Approach 2:
The patent creates a composite amorphous alloy system by combining Fe with Cr, Mo, and at least one of B, Si, or C. This composite material approach enhances the amorphous forming ability and stabilizes the amorphous structure during the coating process, allowing fabrication while maintaining the desired structural characteristics.
2Reliability
If conventional coatings are applied, then coating coverage is achieved, but coating density is poor allowing foreign substances to penetrate in corrosive environments
Solution Approach 1:
The patent modifies the alloy composition parameters by incorporating specific elements (B, Si, or C) that enhance coating density and reduce porosity. This compositional change creates a denser, more reliable coating that resists corrosion and prevents foreign substance penetration in harsh environments.
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 coated body maintains an amorphous structure post-coating, enhancing durability, corrosion resistance, and friction characteristics with high amorphous phase fraction and density, reducing porosity and improving wear resistance.
Implementation Method 1
The coating layer may be formed of powder of the iron-based amorphous alloy through a spray coating process.
Implementation Method 2
the iron-based amorphous alloy has an amorphous structure and includes iron, chromium, and molybdenum as main components
Data Source
AI summary
Provided is a coated body including a base member coated with an iron-based amorphous alloy powder capable of maintaining an amorphous structure even after a coating process, such that the durability, surface hardness, and friction of the base member may be improved. The coated body includes the base member and a coating layer which is formed of an iron-based amorphous alloy and provided on a surface of the base member.