IRON-BASED ALLOY COATING AND METHOD FOR MANUFACTURING THE SAME

• US 20170159156A1
• Filed: 12/18/2015
• Published: 06/08/2017
• 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, PAN, Yi-Tsung, YANG, Chih-Chao
• Granted Patent: US 10,308,999 B2
• Time in Patent Office: Days
• 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.

10. The method as claimed in claim 4, wherein providing the iron-based alloy powder in step (a) comprises:

forming an iron-based master alloy;

melting the iron-based master alloy;

impacting the melted iron-based master alloy with a high-pressure gas to vaporize the melted iron-based master alloy; and

cooling the vaporized iron-based master alloy to obtain the iron-based alloy powder.