Wear-resistant, corrosion-resistant Ni-Cr-Mo thermal spray powder and method
View Patent ↗Enhancing wear and corrosion resistance of an industrial component by depositing a Ni-based alloy coating having a thickness of at least about 50 microns onto a surface of the industrial component by high velocity oxyfuel propulsion of a Ni-based alloy powder containing a) Cr, b) from about 15 to about 25 wt % Mo, c) no more than about 1 wt % Fe, and d) no more than about 1 wt % elements having an atomic number greater than 42. A Ni-based alloy powder for HVOF deposition containing a) Cr, b) from about 15 to about 25 wt % Mo, c) no more than about 1 wt % Fe, and d) no more than about 1 wt % elements having an atomic number greater than 42. A Ni-based coating on an industrial component having enhanced corrosion and wear resistance.
1. A method for enhancing wear and corrosion resistance of an industrial component comprising depositing a Ni-based alloy coating having a thickness of at least about 50 microns onto a surface of the industrial component by high velocity oxyfuel propulsion of a Ni-based alloy powder containing a) Cr, b) from about 15 to about 25 wt % Mo, c) no more than about 1 wt % Fe, and d) no more than about 1 wt % elements having an atomic number greater than 42.
2. The method of claim 1 wherein the Ni-based alloy powder contains no more than about 0.1 wt % C.
3. The method of claim 1 wherein the Ni-based alloy powder contains between about 20 and about 25 wt % Cr.
4. The method of claim 1 wherein the Ni-based alloy powder contains between about 22 and about 24 wt % Cr.
5. The method of claim 1 wherein the Ni-based alloy powder contains between about 17 and 19 wt % Mo.
6. The method of claim 1 wherein the Ni-based alloy powder contains no more than about 0.5 wt % Si.
7. The method of claim 1 wherein the alloy powder consists essentially of, by approximate weight percent:
Mo
15-25
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
8. The method of claim 1 wherein the alloy powder consists essentially of, by approximate weight percent:
Mo
17-19
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
9. The method of claim 1 wherein the alloy powder consists essentially of, by approximate weight percent:
Mo
15-25
Cr
22-24
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
10. The method of claim 1 wherein the alloy powder consists essentially of, by approximate weight percent:
Mo
17-19
Cr
22-24
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
11. The method of claim 1 wherein the alloy powder consists essentially of, by approximate weight percent:
Mo
15-25
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 0.5
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
12. The method of claim 1 wherein the alloy powder consists essentially of, by approximate weight percent:
Mo
17-19
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 0.5
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
13. The method of claim 1 wherein the alloy powder consists essentially of, by approximate weight percent:
Mo
15-25
Cr
22-24
C
less than 0.1
Si
less than 0.5
Fe
less than 0.5
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
14. The method of claim 1 wherein the alloy powder consists essentially of, by approximate weight percent:
Mo
17-19
Cr
22-24
C
less than 0.1
Si
less than 0.5
Fe
less than 0.5
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
15. A Ni-based alloy powder for application to industrial components by HVOF deposition to impart wear and corrosion resistance, the powder comprising about 15-25 wt % Mo, about 20-25 wt % Cr, less than about 1 wt % elements having an atomic number greater than 42, less than about 0.1 wt % C, and less than about 1 wt % Fe.
16. The Ni-based alloy powder of claim 15 consisting essentially of, by approximate weight percent:
Mo
15-25
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
17. The Ni-based alloy powder of claim 15 consisting essentially of, by approximate weight percent:
Mo
17-19
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
18. The Ni-based alloy powder of claim 15 consisting essentially of, by approximate weight percent:
Mo
15-25
Cr
22-24
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
19. The Ni-based alloy powder of claim 15 consisting essentially of, by approximate weight percent:
Mo
17-19
Cr
22-24
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
20. The Ni-based alloy powder of claim 15 consisting essentially of, by approximate weight percent:
Mo
15-25
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 0.5
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
21. The Ni-based alloy powder of claim 15 consisting essentially of, by approximate weight percent:
Mo
17-19
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 0.5
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
22. The Ni-based alloy powder of claim 15 consisting essentially of, by approximate weight percent:
Mo
15-25
Cr
22-24
C
less than 0.1
Si
less than 0.5
Fe
less than 0.5
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
23. The Ni-based alloy powder of claim 15 consisting essentially of, by approximate weight percent:
Mo
17-19
Cr
22-24
C
less than 0.1
Si
less than 0.5
Fe
less than 0.5
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities.
24. The Ni-based alloy powder of claim 15 having a size of at least 60% between about 10 microns and about 45 microns.
25. A Ni-based coating on an industrial component which imparts wear and corrosion resistance, and which coating has a composition, by approximate weight percent, of the following:
Mo
15-25
Cr
20-25
C
less than 0.1
Si
less than 0.5
Fe
less than 1
less than 1% of elements having an atomic number greater than 42
Ni
balance
and incidental impurities;
wherein the coating has corrosion resistance in reducing sulfuric acid characterized by less than about 0.20 mm/year thickness loss when tested according to ASTM specification G31-72 in a 10% H 2 SO 4 solution at boiling (about 102 C), corrosion resistance in oxidizing acid HNO 3 characterized by less than about 0.4 mm/year thickness when tested according to ASTM specification G31-72 in a 65% solution at 66 C, and corrosion resistance in reducing acid HCl characterized by less than about 0.1 mm/year thickness loss when tested according to ASTM specification G31-72 in a 5% HCl solution at 66 C;
wherein the coating has a thickness between about 50 and about 1250 microns; and
wherein the coating is deposited by HVOF deposition.