Chromium free and low-chromium wear resistant alloys
Disclosed herein are embodiments of hardfacing/hardbanding materials, alloys, or powder compositions that can have low chromium content or be chromium free. In some embodiments, the alloys can contain transition metal borides and borocarbides with a particular metallic component weight percentage. The disclosed alloys can have high hardness and ASTM G65 performance, making them advantageous for hardfacing/hardbanding applications.
1. A thermal spray feedstock material comprising:
between about 1.16-about 2.2 wt. % B;
between about 2.0-about 2.8 wt. % C;
between about 12.5-about 19.5 wt. % Mo;
between about 8.0-about 14.0 wt. % V; and
an amount of Fe;
wherein the thermal spray feedstock material is configured to form a microstructure and is characterized by having, under thermodynamic equilibrium conditions:
a total mole fraction of transition metal borides and borocarbides of between about 12.5% and about 30%, wherein a metallic portion of the transition metal borides and borocarbides comprises greater than or equal to about 15 wt. % W+Mo; and
a mole fraction of isolated carbides of between about 12.5% and about 25%, wherein isolated carbides are defined as MC carbides, and wherein the isolated carbides have a metallic component greater than or equal to about 50 wt. % V.
2. A coating formed from the thermal spray feedstock material of claim 1 .
3. The coating of claim 2 , wherein the coating is formed from a thermal spray process.
4. The coating of claim 3 , wherein the thermal spray process is an arc spray process.
5. The coating of claim 2 , wherein the coating has a hardness of greater than or equal to about 55 HRC.
6. The thermal spray feedstock material of claim 1 , wherein the thermal spray feedstock material comprises a powder.
7. The thermal spray feedstock material of claim 1 , wherein the thermal spray feedstock material is at least one of a first wire, a second wire, or a combination of the first and second wires.
8. The thermal spray feedstock material of claim 1 , wherein the thermal spray feedstock comprises:
B: about 1.85;
C: about 2.15;
Mo: about 15.70;
V: about 11.0; and
an amount of Fe.
9. The thermal spray feedstock material of claim 1 , comprising less than or equal to about 0.01 wt. % chromium.
10. The thermal spray feedstock material of claim 1 , wherein an FCC-BCC transition temperature of the thermal spray feedstock material under equilibrium solidification conditions is less than or equal to about 1300K.
11. A thermal spray feedstock material consisting of:
between about 1.16-about 2.2 wt. % B;
between about 2.0-about 2.8 wt. % C;
between about 12.5-about 19.5 wt. % Mo;
between about 8.0-about 14.0 wt. % V;
a balance of Fe and incidental impurities;
wherein the thermal spray feedstock material is configured to form a microstructure and is characterized by having, under thermodynamic equilibrium conditions:
a total mole fraction of transition metal borides and borocarbides of between about 12.5% and about 30%, wherein a metallic portion of the transition metal borides and borocarbides comprises greater than or equal to about 15 wt. % W+Mo; and
a mole fraction of isolated carbides of between about 12.5% and about 25%, wherein isolated carbides are defined as MC carbides, and wherein the isolated carbides have a metallic component greater than or equal to about 50 wt. % V.
12. The thermal spray feedstock material of claim 8 , wherein the thermal spray feedstock consists of:
B: about 1.85;
C: about 2.15;
Mo: about 15.70;
V: about 11.0;
a balance of Fe and incidental impurities.
13. A coating formed from the thermal spray feedstock material of claim 11 .
14. The coating of claim 13 , wherein the coating is formed from a thermal spray process.
15. The coating of claim 14 , wherein the thermal spray process is an arc spray process.
16. The thermal spray feedstock material of claim 11 , wherein the thermal spray feedstock material comprises a powder.
17. The thermal spray feedstock material of claim 11 , wherein the thermal spray feedstock material is at least one of a first wire, a second wire, or a combination of the first and second wires.
18. The thermal spray feedstock material of claim 1 , wherein the mole fraction of isolated carbides is between about 15% and about 25%.
19. The thermal spray feedstock material of claim 11 , wherein the mole fraction of isolated carbides is between about 15% and about 25%.