Oxidation controlled twin wire arc spray materials
Disclosed herein are embodiments of alloys which can be particularly advantageous in twin wire arc spray methods for coating of a substrate. In some embodiments, a plurality of alloys can be used to form both hard and soft particles on a surface. In some embodiments, chromium can be minimized or eliminated.
1. An iron-based cored wire alloy feedstock configured for twin wire arc thermal spray applications, the cored wire alloy feedstock comprising:
a powder and a sheath, wherein the powder and sheath combination have a composition comprising Fe and, in wt. %:
0<Al≤2.5;
Cr: about 10-15;
0<Mn≤2;
Ni: about 15-25; and
Si: about 2.97-5.
2. The cored wire alloy feedstock of claim 1 , wherein the cored wire alloy feedstock is configured to form the coating after oxidation in a twin wire arc thermal spray application.
3. The cored wire alloy feedstock of claim 1 , wherein the sheath has a diameter of 1/16″ and a ratio of the powder to the sheath is about 20-40% by weight.
4. The cored wire alloy feedstock of claim 1 , wherein the microhardness of the coating is 200 Vickers or below.
5. The cored wire alloy feedstock of claim 1 , wherein the microhardness of the coating is 100 Vickers or below.
6. The cored wire alloy feedstock of claim 1 , wherein the weighted solute fraction is less than 6 wt. % at a melting temperature of the cored wire alloy feedstock.
7. The cored wire alloy feedstock of claim 1 , wherein the weighted solute fraction of the coating is less than 2 wt. % at a melting temperature of the cored wire alloy feedstock.
8. The cored wire alloy feedstock of claim 1 , wherein the composition comprises Fe and, in wt. %:
Al: about 1.5;
Cr: about 11.27;
Mn: about 1.03;
Ni: about 20; and
Si: about 3.3.
9. The cored wire alloy feedstock of claim 1 , wherein the composition comprises Fe and, in wt. %:
Al about 1.5, C about 1, Mn about 1, Si about 3.25; or
Al about 1.5, Cr about 11.27, Mn about 1.03, Ni about 20, and Si about 3.3.
10. The cored wire alloy feedstock of claim 1 , wherein the austenite ferrite transition temperature is below about 950K.
11. A twin wire arc spray process using the cored wire alloy feedstock of claim 1 as a cored wire alloy feedstock.
12. An iron-based cored wire alloy feedstock configured for twin wire arc thermal spray applications, the cored wire alloy feedstock comprising:
a powder and a sheath, wherein the powder and sheath combination have a composition comprising at least 50 wt. % Fe and, in wt. %:
Al: 1.35-1.65;
Cr: 10-12.397;
Ni: 18-22; and
Si: about 2.97-3.63.
13. The iron-based cored wire alloy feedstock of claim 12 , wherein the sheath has a diameter of 1/16″ and a ratio of the powder to the sheath is about 20-40% by weight.
14. The iron-based cored wire alloy feedstock of claim 12 , wherein the composition comprises Fe and, in wt. %
Mn: 0.927-1.133.
15. The iron-based cored wire alloy feedstock of claim 12 , wherein the composition comprises Fe and, in wt. %:
Al about 1.5, C about 1, Mn about 1, Si about 3.25; or
Al about 1.5, Cr about 11.27, Mn about 1.03, Ni about 20, and Si about 3.3.