Corrosion resistant powder and coating

• US 6,503,290 B1
• Filed: 03/01/2002
• Issued: 01/07/2003
• Est. Priority Date: 03/01/2002
• Status: Active Grant

• Current Assignee: Praxair S.T. Technology, Inc. (Linde Plc)
• Original Assignee: Praxair S.T. Technology, Inc. (Linde Plc)
• Inventors: Jarosinski, William John Crim, Temples, Lewis Benton
• Primary Examiner(s): MAI, NGOCLAN THI
• Application Number:
  US10/087,093
• Time in Patent Office: 312 Days
• Field of Search: 752/52, 427/455
• US Class Current: 75/252
• CPC Class Codes: B22F 2201/10 Inert gases
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 9/082 atomising using a fluid using centrifugal force B22F9/10
• CPC Class Codes: C22C 1/045 Alloys based on refractory metals
• CPC Class Codes: C22C 27/04 Alloys based on tungsten or molybdenum
• CPC Class Codes: C22C 27/06 Alloys based on chromium
• CPC Class Codes: C23C 30/00 Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process C23C26/00, C23C28/00 take precedence
• CPC Class Codes: C23C 4/08 containing only metal elements C23C4/073 takes precedence

Abstract

The invention is a corrosion resistant powder useful for deposition through thermal spray devices. The powder consists essentially of, by weight percent, 30 to 60 tungsten, 27 to 60 chromium, 1.5 to 6 carbon, a total of 10 to 40 cobalt plus nickel and incidental impurities plus melting point suppressants.

Claims

1. A corrosion resistant powder useful for deposition through thermal spray devices, the powder consisting essentially of, by weight percent, about 30 to 60 tungsten, about 27 to 60 chromium, about 1.5 to 6 carbon, a total of about 10 to 40 cobalt plus nickel and incidental impurities plus melting point suppressants.

2. The corrosion resistant powder of claim 1 wherein the powder contains about 10 to 30 cobalt.

3. The corrosion resistant powder of claim 1 wherein the powder contains about 10 to 30 nickel.

4. The corrosion resistant powder of claim 1 wherein the powder has a morphology that lacks carbides having an average cross section width in excess of 10 μ

m.

5. A corrosion resistant powder useful for deposition through thermal spray devices, the powder consisting essentially of, by weight percent, about 30 to 55 tungsten, about 27 to 55 chromium, about 1.5 to 6 carbon, a total of about 10 to 35 cobalt plus nickel and incidental impurities and 0 to 5 melting point suppressants.

6. The corrosion resistant powder of claim 5 wherein the powder contains about 10 to 30 cobalt.

7. The corrosion resistant powder of claim 5 wherein the powder contains about 10 to 30 nickel.

8. The corrosion resistant powder of claim 5 wherein the powder has a morphology that lacks carbides having an average cross section width in excess of 5 μ

m.

9. A corrosion resistant powder useful for deposition through thermal spray devices, the powder consisting essentially of, by weight percent, about 30 to 50 tungsten, about 30 to 50 chromium, about 1.5 to 5 carbon, a total of about 10 to 30 cobalt plus nickel and incidental impurities and 0 to 3 melting point suppressants.

10. The corrosion resistant powder of claim 9 wherein the powder contains about 10 to 30 cobalt.

11. The corrosion resistant powder of claim 9 wherein the powder contains about 10 to 30 nickel.

12. The corrosion resistant powder of claim 9 wherein the powder has a morphology that lacks carbides having an average cross section width in excess of 2 μ

m.

13. The corrosion resistant powder of claim 9 wherein the powder contains about 35 to 45 tungsten, about 30 to 40 chromium, about 3 to 5 carbon, and the total cobalt plus nickel is about 15 to 25.

14. The corrosion resistant powder of claim 9 wherein the powder contains about 30 to 40 tungsten, about 40 to 50 chromium, about 1.5 to 5 carbon, and the total cobalt plus nickel is about 15 to 25.

15. The corrosion resistant powder of claim 9 wherein the powder contains about 30 to 40 tungsten, about 45 to 50 chromium, about 3 to 5 carbon, and the total cobalt plus nickel is about 10 to 15.

16. A corrosion resistant coating having good wear resistance, the coating consisting essentially of, by weight percent, about 30 to 60 tungsten, about 27 to 60 chromium, about 1.5 to 6 carbon, a total of about 10 to 40 cobalt plus nickel and incidental impurities and melting point suppressants.

17. The corrosion resistant coating of claim 16 wherein the coating contains about 30 to 50 tungsten, about 1.5 to 5 carbon and about 30 to 50 chromium.

18. The corrosion resistant coating of claim 16 wherein the coating contains about 35 to 45 tungsten, about 30 to 40 chromium, about 3 to 5 carbon and the total cobalt plus nickel is about 15 to 25.

19. The corrosion resistant coating of claim 16 wherein the coating contains about 30 to 40 tungsten, about 40 to 50 chromium, about 1.5 to 5 carbon and the total cobalt plus nickel is about 15 to 25.

20. The corrosion resistant coating of claim 16 wherein the coating contains about 30 to 40 tungsten, about 45 to 50 chromium, about 3 to 5 carbon and the total cobalt plus nickel is about 10 to 15.