Iron-based alloy coating and method for manufacturing the same

• US 10,308,999 B2
• Filed: 12/18/2015
• Issued: 06/04/2019
• Est. Priority Date: 12/03/2015
• Status: Active Grant

• Current Assignee: Industrial Technology Research Institute
• Original Assignee: Industrial Technology Research Institute
• Inventors: Chou, Li-Shing, Hou, Yen-Yu, Yang, Chih-Chao, Pan, Yi-Tsung
• Primary Examiner(s): Walck, Brian D
• Application Number:
  US14/974,127
• Publication Number:
  US 20170159156A1
• Time in Patent Office: 1,264 Days
• Field of Search: 148325
• CPC Class Codes: B23K 2101/34 Coated articles , e.g. plated or painted; Surface treated articles
• CPC Class Codes: B23K 2103/04 Steel or steel alloys
• CPC Class Codes: B23K 26/0006 taking account of the properties of the material involved B23K26/32, B23K26/40 take precedence
• CPC Class Codes: B23K 26/354 by melting
• CPC Class Codes: C22C 33/003 making amorphous alloys
• CPC Class Codes: C22C 33/0207 Using a mixture of prealloyed powders or a master alloy mixtures of metal powder in general B22F1/09
• CPC Class Codes: C22C 33/0285 with Cr, Co, or Ni having a minimum content higher than 5%
• CPC Class Codes: C22C 38/005 containing rare earths, i.e. Sc, Y, Lanthanides
• CPC Class Codes: C22C 38/02 containing silicon
• CPC Class Codes: C22C 38/22 with molybdenum or tungsten
• CPC Class Codes: C22C 38/32 with boron
• CPC Class Codes: C23C 4/06 Metallic material
• CPC Class Codes: C23C 4/08 containing only metal elements C23C4/073 takes precedence
• CPC Class Codes: C23C 4/131 Wire arc spraying
• CPC Class Codes: C23C 4/134 Plasma spraying
• CPC Class Codes: C23C 4/137 Spraying in vacuum or in an inert atmosphere
• CPC Class Codes: C23C 4/18 After-treatment

Abstract

A method of manufacturing an iron-based alloy coating is provided, which includes (a) providing an iron-based alloy powder having a chemical formula of Fe_aCr_bMo_cSi_dB_eY_f, wherein 48≤a≤50; 21≤b≤23; 18≤c≤20; 2≤d≤3; 2≤e≤4; and 0<f≤2. The method also includes step (b) thermal spraying the iron-based alloy powder to form an amorphous iron-based alloy coating, and step (c) laser re-melting the amorphous iron-based alloy coating, wherein the iron-based alloy coating is densified and remains amorphous.

Claims

1. An iron-based alloy coating, having a composition of:

Fe_aCr_bMo_cSi_dB_eY_f,

wherein 48≤

a≤

50;

21≤

b≤

23;

18≤

c≤

20;

2≤

d≤

3;

2≤

e≤

4; and

0<

f≤

2,

wherein the iron-based alloy coating is amorphous and has a porosity of less than 0.5%.

2. The iron-based alloy coating as claimed in claim 1, having a thickness of 30 μ

m to 300 μ

m.

3. The iron-based alloy coating as claimed in claim 1, having a pore size less than 2 μ

m.

4. A method of manufacturing an iron-based alloy coating, comprising:

(a) providing an iron-based alloy powder having a chemical formula of Fe_aCr_bMo_cSi_dB_eY_f, wherein 48≤

a≤

50;

21≤

b≤

23;

18≤

c≤

20;

2≤

d≤

3;

2≤

e≤

4; and

0<

f≤

2;

(b) thermal spraying the iron-based alloy powder to form an amorphous iron-based alloy coating; and

(c) laser re-melting the amorphous iron-based alloy coating, wherein the iron-based alloy coating is densified and remains amorphous.

5. The method as claimed in claim 4, wherein the iron-based alloy coating has a thickness of 30 μ

m to 300 μ

m after step (c).

6. The method as claimed in claim 4, wherein the iron-based alloy coating has a pore size less than 2 μ

m and a porosity of less than 0.5% after step (c).

7. The method as claimed in claim 4, wherein the iron-based alloy powder in step (a) has a diameter of 25 μ

m to 60 μ

m.

8. The method as claimed in claim 4, wherein thermal spraying the iron-based alloy powder in step (b) comprises melting the iron-based alloy powder using an electric arc, and then spraying the melted iron-based alloy powder onto a substrate using a gas mixture of argon and hydrogen.

9. The method as claimed in claim 4, wherein laser re-melting the amorphous iron-based alloy coating in step (c) utilizes a laser power of 80 W to 150 W, and a depth of the amorphous iron-based alloy coating scanned by a laser is between 30 μ

m and 300 μ

m.