Non-magnetic, strong carbide forming alloys for powder manufacture

1. An alloy comprising:

a matrix having a FCC-BCC transition temperature at or below 950K; and

extremely hard particles exhibiting a hardness of 1000 Vickers or greater, the extremely hard particles having:

an extremely hard particle fraction of 5 mole % or greater; and

an extremely hard particle melt range of 200K or less;

wherein the alloy comprises Fe and, in weight percent:

C: 2.25 to 4.95;

Cr: 9 to 18.15;

Mn: 7.65 to 15.95; and

V: 9.0 to 17.6.

2. The alloy of claim 1 , wherein the matrix comprises at least 7 mole % chromium.

3. The alloy of claim 1 , the alloy comprising:

at least 90% volume fraction austenite in the matrix;

a fraction of the extremely hard particles is 5 volume % or greater;

an ASTM G65 abrasion loss of 1.5 g or less;

a relative magnetic permeability of 1.03μ or lower; and

a corrosion resistance of 5 mpy or less in salt water according to ASTM G31;

wherein the matrix does not contain any extremely hard particles that begin to form at a temperature greater than 200K above a formation temperature of the matrix.

4. The alloy of claim 1 , further comprising, in weight percent:

V: 12.15 to 17.6.

5. The alloy of claim 1 , wherein the alloy is a powder.

6. The alloy of claim 1 , wherein a powder feedstock forming the alloy comprises Fe and, in weight %:

C: 3.0, Cr: 12.0, Mn: 12.0, V: 15.0;

C: 4.0, Cr: 16.0, Mn: 12.0, V: 15.0;

C: 4.0, Cr: 16.0, Mn: 13.4, V: 15.1;

C: 3.0, Cr: 12.1, Mn: 9.8, V: 14.9;

C: 3.8, Cr: 16.0, Mn: 13.7, V: 14.7;

C: 2.8, Cr: 12.5, Mn: 10.4, V: 15.3;

C: 3.9, Cr: 16.1, Mn: 14.0, V: 15.6;

C: 2.9, Cr: 12.1, Mn: 9.6, V: 14.4;

C: 2.6, Cr: 11.9, Mn: 11.6, V: 10.0; or

C: 2.6, Cr: 11.9, Mn: 8.5, V: 10.6.

7. A drill pipe tool joint, drill collar, down hole stabilizer or oilfield component used in directional drilling applications with the alloy of claim 1 applied as a hardfacing layer.

8. An alloy comprising:

Fe;

C: 2.25 to 4.95;

Cr: 9 to 18.15;

Mn: 7.65 to 15.95; and

V: 9.0 to 17.6

a matrix comprising at least 90% volume fraction austenite; and

extremely hard particles exhibiting a hardness of 1000 Vickers or greater, the extremely hard particles having a fraction of 5 volume % or greater;

wherein the matrix does not contain any extremely hard particles that begin to form at a temperature greater than 200K above a formation temperature of the matrix.

9. The alloy of claim 8 , wherein the matrix comprises at least 7 weight % chromium.

10. The alloy of claim 8 , further comprising, in weight percent:

V: 12.15 to 17.6.

11. The alloy of claim 8 , wherein the alloy is a powder.

12. The alloy of claim 8 , wherein a powder feedstock forming the alloy comprises Fe and, in weight %:

C: 3.0, Cr: 12.0, Mn: 12.0, V: 15.0;

C: 4.0, Cr: 16.0, Mn: 12.0, V: 15.0;

C: 4.0, Cr: 16.0, Mn: 13.4, V: 15.1;

C: 3.0, Cr: 12.1, Mn: 9.8, V: 14.9;

C: 3.8, Cr: 16.0, Mn: 13.7, V: 14.7;

C: 2.8, Cr: 12.5, Mn: 10.4, V: 15.3;

C: 3.9, Cr: 16.1, Mn: 14.0, V: 15.6;

C: 2.9, Cr: 12.1, Mn: 9.6, V: 14.4;

C: 2.6, Cr: 11.9, Mn: 11.6, V: 10.0; or

C: 2.6, Cr: 11.9, Mn: 8.5, V: 10.6.

13. A drill pipe tool joint, drill collar, down hole stabilizer or oilfield component used in directional drilling applications with the alloy of claim 8 applied as a hardfacing layer.

14. The alloy of claim 1 , wherein the alloy is a wire.

15. The alloy of claim 1 , wherein the alloy comprises 10.8 wt. % to 13 wt. % chromium.

16. The alloy of claim 1 , wherein the alloy comprises 9.4 wt. % to 12 wt. % chromium.

17. The alloy of claim 8 , wherein the alloy is a wire.

18. The alloy of claim 8 , wherein the alloy comprises 10.8 wt. % to 13 wt. % chromium.

19. The alloy of claim 8 , wherein the alloy comprises 9.4 wt. % to 12 wt. % chromium.