METAL CORED WELDING WIRE, HARDBAND ALLOY AND METHOD

• US 20140131338A1
• Filed: 11/12/2013
• Published: 05/15/2014
• Est. Priority Date: 11/14/2012
• Status: Active Grant

• Current Assignee: Postle Industries, Inc.
• Original Assignee: Postle Industries, Inc.
• Inventors: Postle, Christopher J.
• Granted Patent: US 9,724,786 B2
• Time in Patent Office: Days
• US Class Current: 219/146.23
• CPC Class Codes: B23K 2101/38 Conductors
• CPC Class Codes: B23K 35/0244 Powders, particles or spheres; Preforms made therefrom
• CPC Class Codes: B23K 35/0261 Rods, electrodes, wires
• CPC Class Codes: B23K 35/0266 flux-cored
• CPC Class Codes: B23K 35/3053 Fe as the principal constituent
• CPC Class Codes: B23K 35/308 with Cr as next major constituent
• CPC Class Codes: B23K 35/3086 containing Ni or Mn
• CPC Class Codes: B23K 9/04 Welding for other purposes than joining, e.g. built-up welding
• CPC Class Codes: B23K 9/048 on cylindrical surfaces
• CPC Class Codes: C22C 37/08 with nickel
• CPC Class Codes: C22C 38/18 containing chromium
• CPC Class Codes: C22C 38/36 with more than 1.7% by weight of carbon
• CPC Class Codes: C22C 38/40 with nickel
• CPC Class Codes: C22C 38/58 with more than 1.5% by weight of manganese

Abstract

Various embodiments of a metal cored wires, hardband alloys, and methods are disclosed. In one embodiment of the present invention, a hardbanding wire comprises from about from about 16% to about 30% by weight chromium; from about 4% to about 10% by weight nickel; from about 0.05% to about 0.8% by weight nitrogen; from about 1% to about 4% by weight manganese; from about 1% to about 4% by weight carbon from about 0.5% to about 5% by weight molybdenum; from about 0.25% to about 2% by weight silicon; and the remainder is iron including trace elements. The hardband alloy produced by the metal cored wire meets API magnetic permeability specifications and has improved metal to metal, adhesive wear resistance compared to conventional hardband alloys.

Claims

1. A metal cored wire for forming a hardband alloy onto a surface, the metal wire comprising:

a metal sheath;

a metal-powder core material; and

wherein the metal cored wire comprises, by weight, based on the total weight of the metal cored wire;

from about 16% to about 30% by weight chromium;

from about 4% to about 10% by weight nickel;

from about 0.05% to about 0.8% by weight nitrogen;

from about 1% to about 4% by weight manganese;

from about 0.6% to about 4% by weight carbon;

from about 0.25% to about 2% by weight silicon; and

from about 40% to about 78% by weight iron.

2. The metal cored wire of claim 1, further comprising, by weight, from about 0.5% to about 5% by weight molybdenum.

3. The metal cored wire of claim 1, wherein the hardband alloy formed onto a metal surface has a relative magnetic permeability of less than about 1.01 according to the API Standard.

4. The metal cored wire of claim 1, wherein the hardband alloy formed onto a metal surface has a weight loss of less than 0.5 grams according to ASTM G65 Wear Testing.

5. The metal cored wire of claim 1, wherein the weight of the metal sheath ranges from about 60% to about 80% of the total weight of the metal cored wire, and the weight of the metal-powder core ranges from about 20% to about 40% of the total weight of the metal cored wire.

6. The metal cored wire of claim 1, wherein the metal sheath comprises, by weight, based on the weight of the metal sheath:

from about 16% to about 22% by weight chromium;

from about 7% to about 12% by weight nickel;

from about 0.01% to about 1% by weight manganese;

from about 0.04% to about 0.12% by weight carbon

from about 0.1% to about 1% by weight silicon; and

from about 60% to about 75% by weight iron.

7. The metal cored wire of claim 1, wherein the metal-powder core comprises, by weight, based on the weight of the metal-powder core:

from about 30% to about 50% by weight chromium;

from about 1% to about 5% by weight nickel;

from about 0.1% to about 1% by weight nitrogen;

from about 1% to about 8% by weight manganese;

from about 2% to about 7% by weight carbon

from about 0.25% to about 4% by weight silicon; and

from about 40% to about 60% by weight iron.

8. The metal cored wire of claim 6, wherein the metal-powder core comprises, by weight, based on the weight of the metal-powder core:

from about 30% to about 50% by weight chromium;

from about 1% to about 5% by weight nickel;

from about 0.1% to about 1% by weight nitrogen;

from about 1% to about 8% by weight manganese;

from about 2% to about 7% by weight carbon

from about 0.25% to about 4% by weight silicon; and

from about 40% to about 60% by weight iron.

9. The metal cored wire of claim 8, further comprising, by weight, from about 0.5% to about 5% by weight molybdenum.

10. The metal cored wire of claim 8 wherein the weight of the metal sheath ranges from about 60% to about 80% of the total weight of the metal cored wire, and the weight of the metal-powder core ranges from about 20% to about 40% of the total weight of the metal cored wire.

11. The metal cored wire of claim 8, wherein the hardball alloy formed onto a metal surface has a relative magnetic permeability of less than about 1.01 according to the API Standard.

12. The metal cored wire of claim 11, wherein the hardband alloy formed onto a metal surface has a weight loss of less than 0.5 grams per the ASTM G65 wear testing,

13. The metal cored wire of claim 1, comprising:

a sheath comprising, by weight, based on the total weight of the sheath;

from about 16% to about 20% by weight chromium;

from about 6% to about 10% by weight nickel;

from about 0.03% to about 0.08% by weight manganese;

from about 0.03% to about 0.08% by weight carbon

from about 0.1% to about 0.08% by weight silicon;

from about 68% to about 77% by weight iron;

a metal-powder core comprising, by weight, based on the total weight of the metal-powder core;

from about 32% to about 45% by weight chromium;

from about 2% to about 4% by weight nickel;

from about 0.1% to about 0.8% by weight nitrogen;

from about 3% to about 7% by weight manganese;

from about 2% about 4% by weight carbon

from about 1% to about 3% by weight silicon; and

from about 45% to about 55% by weight iron.

14. A hardband alloy disposed on the surface of an industrial product, the hardband alloy comprising:

from about 16% to about 30% by weight chromium;

from about 4% to about 10% by weight nickel;

from about 0.05% to about 0.8% by weight nitrogen;

from about 1% to about 4% by weight manganese;

from about 0.6% to about 4% by weight carbon;

from about 0.25% to about 2% by weight silicon;

a

from about 49% to about 80% by weight iron.

15. The hardband alloy of claim 14, wherein the hardband ahoy has a relative magnetic permeability of less than about 1.01 according to the API Standard.

16. The hardband alloy of claim 15, wherein the hardband alloy has a weight loss of less than 0.50 grams according to the ASTM G65 wear testing.

17. The hardband alloy of claim 14, wherein the industrial product is non-magnetic and has a relative magnetic permeability of less than about 1.01 according to the API Standard.

18. The hardband alloy of claim 17, wherein the industrial product is a non-magnetic drilling tool.

19. A method for hardbanding an industrial product, the method comprising:

welding a metal cored wire to an industrial product to form a hardband alloy; and

wherein the metal cored wire comprises, by weight based, on the total weight of the metal cored wire;

from about 16% to about 30% by weight chromium;

from about 4% to about 10% by weight nickel;

from about 0.05% to about 0.8% by weight nitrogen;

from about 1% to about 4% by weight manganese;

from about 0.6% to about 4% by weight carbon;

from about 0.25% to about 2% by weight silicon; and

from about 49% to about 80% by weight iron.

20. The method of claim 19, wherein:

the industrial product is non-magnetic and has a relative magnetic permeability of less than about 1.01 according to the API Standard; and

the hardband alloy formed on the industrial product has a weight loss of less than 0.5 grams according to the ASTM G65 wear testing.