Composite wires for coating substrates and methods of use
View Patent ↗A composite wire for producing a wear resistant and corrosion resistant coating on a substrate by thermal spraying, spray and fuse, or welding techniques are disclosed. The physical properties of the coating are particularly suited for high-temperature erosion-corrosion environments. The resultant coating exhibits good hardness, toughness, and bonding characteristics. The composite wire comprises a metallic outer sheath and an inner core containing boron carbide and chrome carbide.
1. A composite wire for producing a wear resistant and corrosion resistant coating on a substrate, said composite wire consisting of a tubular metallic outer sheath encapsulating a powdered inner core, said inner core comprising a mixture of boron carbide of at least 35% by weight, and chrome carbide in an amount between about 67% and about 185% by weight of the amount of boron carbide.
2. The composite wire of claim 1 , wherein the outer sheath is formed of an essentially pure metal.
3. The composite wire of claim 1 , wherein the outer sheath is formed of an alloy comprising a base metal.
4. The composite wire of claim 3 , wherein the base metal of the alloy is selected from the group consisting of iron, nickel, aluminum, molybdenum, tantalum, copper, and titanium.
5. The composite wire of claim 3 , wherein the alloy is a nickel base alloy.
6. The composite wire of claim 5 , wherein the nickel base alloy comprises chromium.
7. The composite wire of claim 6 , wherein the nickel base alloy comprises at least about 40% by weight of nickel.
8. The composite wire of claim 7 , wherein the nickel base alloy further comprises molybdenum.
9. The composite wire of claim 8 , wherein the nickel base alloy is an alloy 625.
10. The composite wire of claim 1 , wherein the inner core comprises substantially equivalent amounts of chrome carbide and boron carbide.
11. The composite wire of claim 1 , wherein the inner core further comprises another carbide in addition to boron carbide and chrome carbide.
12. The composite wire of claim 1 , wherein the inner core further comprises at least one carbide selected from the group consisting of tungsten carbide, vanadium carbide and titanium carbide.
13. The composite wire of claim 1 , wherein the inner core further comprises a metal powder.
14. The composite wire of claim 1 , wherein the inner core further comprises a composite powder.
15. The composite wire of claim 14 , wherein the inner core further comprises tungsten carbide nickel powder.
16. The composite wire of claim 1 , wherein the inner core further comprises a boride.
17. The composite wire of claim 16 , wherein the inner core further comprises at least one boride selected from the group consisting of chrome boride, nickel boride, and iron boride.
18. The composite wire of claim 1 , wherein the inner core further comprises an oxide.
19. The composite wire of claim 18 , wherein the inner core further comprises at least one oxide selected from the group consisting of aluminum oxide, chrome oxide, and zirconium oxide.