Flux-Cored Wire Composition for Low-Porosity Arc Spray Coatings
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Solution Overview
Problem
Twin wire arc spray methods face limitations in forming wear-resistant coatings due to the inevitable formation of pores and oxides within the coating layer, which hampers their application in extreme wear-resistant environments.
Innovation Solution
A flux-cored wire with a stainless steel sheath filled with an alloy powder composition of chromium (13.0-18.0%), boron (1.0-7.0%), carbon (0.5-3.0%), molybdenum (6.0-25.0%), and silicon (1.0% or less), along with manganese (1.0% or less), which forms a coating layer with a carbides and borides fraction of 8 area % or more, an oxides fraction of 9 area % or less, and porosity of 2.5% or less, enhancing wear resistance while suppressing pores and oxides.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If twin wire arc spray is used to form a coating layer, then the coating layer can be formed with sheath and alloy powder uniformly mixed, but pores and oxides are inevitably formed within the coating layer, limiting wear resistance
Solution Approach 1:
The patent applies parameter changes by precisely controlling the chemical composition parameters of the flux alloy powder, specifically setting chromium content at 13.0-18.0%, boron at 1.0-7.0%, carbon at 0.5-3.0%, and molybdenum at 6.0-25.0%. These compositional parameters enable the formation of carbides and borides while suppressing oxide formation, resolving the contradiction between wear resistance and harmful inclusions
Solution Approach 2:
The patent uses composite materials by creating a flux alloy powder containing multiple elements (Cr, B, C, Mo, Si, Mn) that work synergistically. The combination of these elements produces a coating layer with both carbides and borides phases, achieving high wear resistance while the specific composition controls oxide formation, thus resolving the technical contradiction
2Reliability
If chromium content is increased to enhance carbide formation and wear resistance, then wear resistance improves, but oxide formation may increase
Solution Approach 1:
The patent optimizes the chromium content parameter within a specific range (13.0-18.0%) rather than simply increasing it. This controlled parameter change ensures sufficient carbide formation for wear resistance while preventing excessive oxide formation. The balanced composition including boron (1.0-7.0%) and carbon (0.5-3.0%) further controls the carbide/oxide ratio
Solution Approach 2:
The patent applies local quality by creating different phases within the coating layer - carbides and borides in specific regions for wear resistance, while controlling oxide distribution. The flux composition is designed to produce localized carbide and boride formations rather than uniform distribution, achieving high wear resistance with minimal harmful oxides
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 solution effectively enhances the wear resistance of the coating layer by ensuring high carbides and borides formation while minimizing pores and oxides, resulting in improved performance in wear-resistant applications.
Implementation Method 1
utilizing an electric arc generated at an intersection of two wires to melt the wires
Implementation Method 2
spraying the molten wires onto the workpiece to form a coating layer
Data Source
AI summary
According to one aspect of the present disclosure, a flux-cored wire provided can effectively enhance the wear resistance of a coating layer by ensuring the formation of carbides and borides above a certain level within the coating layer when applying twin wire arc spray, while actively suppressing the formation of pores and oxides within the coating layer.