Diffusion-Bonded Carbide Coatings for Corrosion and Erosive Wear

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Solution Overview

Problem

Current corrosion-resistant coatings lack sufficient resistance to erosive wear, while coatings resistant to erosive wear often fail to provide adequate corrosion resistance due to voids or low energy diffusion pathways.

Innovation Solution

A method involving introducing diffusible elements into an alloy substrate, followed by a reactive environment to form a distinct coating layer that offers both corrosion and erosive wear resistance, with specific embodiments detailing temperature ranges, element selection, and processing techniques such as salt baths and fluidized beds.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If a hard coating is formed to provide erosive wear resistance, then erosive wear resistance is improved, but voids and low energy diffusion pathways are created that reduce corrosion resistance

Engineering Contradiction:

Improveerosive wear resistanceVSAvoidcorrosion penetration through voids

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The invention introduces an intermediate layer containing diffusible elements (carbon, nitrogen, boron, or oxygen) between the substrate and the hard coating layer. This intermediary layer acts as a diffusion barrier that prevents corrosive elements from penetrating through voids in the hard coating, while still allowing the hard coating to provide erosive wear resistance

Inventive Principle:

Principle #24Intermediary (Mediator)

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 method achieves a coating layer with hardness ranging from 1500 HV to 2500 HV, providing both sufficient corrosion resistance and erosive wear resistance by forming a metallurgically bonded layer devoid of voids and low energy diffusion channels.

Implementation Method 1

the step of introducing the diffusible-element-containing alloy substrate to a material reactive with the one or more diffusible elements includes subjecting the diffusible-element-containing alloy substrate to an environment where the one or more diffusible elements will at least partially diffuse from the diffusible-element-containing alloy substrate to thereby react with the material reactive with the diffusible element

Methodology Applied

Scientific EffectDiffusion: Diffusion

Implementation Method 2

the one or more diffusible elements will at least partially diffuse from the diffusible-element-containing alloy substrate to thereby react with the material reactive with the diffusible element to form a coating layer including the reaction product

Methodology Applied

Scientific EffectChemical reaction: Chemical Bonding

Data Source

PatentUS12104259B2Erosive wear and corrosion resistant coatings including metal carbide, metal boride, metal nitride, and corresponding methods

Publication Date: 2024.10.01 THE UNIVERSITY OF AKRON

AI summary

A method of coating an alloy substrate includes providing an alloy substrate that includes less than 0.3 wt. % of diffusible elements; introducing one or more diffusible elements into the alloy substrate to thereby form a diffusible-element-containing alloy substrate; and introducing the diffusible-element-containing alloy substrate to a material reactive with the one or more diffusible elements.