System and method for applying high temperature corrosion resistant amorphous based coatings
An embodiment relates to a material comprising a ceramic formed from an amorphous metal alloy (amorphous metal ceramic composite), wherein the composite exhibits a higher corrosion resistance than that of Haynes 230 when exposed to molten chlorides such as KCl or MgCl 2 or combinations thereof at temperatures up to 750° C. Yet, another embodiment relates to a method comprising obtaining a substrate, forming a coating of an amorphous metal alloy, heating the coating, and transforming at least a portion the amorphous metal alloy into an amorphous metalceramic composite.
1. A material comprising a composite comprising an amorphous metal ceramic composite comprising an iron-based amorphous metal alloy and a ceramic formed from the iron-based amorphous metal alloy,
wherein the composite exhibits a higher corrosion resistance than that of a Haynes 230 alloy when immersed in a molten chloride salt comprising KCl and MgCl 2 in a ratio of 68/32 for 300 hours at a temperature of 750° C.;
wherein the iron-based amorphous metal alloy is fully amorphous up to 650° C. and starts to crystallize at a temperature higher than 650° C., and
the ceramic comprises a boride and a carbide;
wherein the iron-based amorphous metal alloy comprising Fe 100-(a+b+c) (Cr a X b Y c ); wherein a is about 10 to 50 wt. %; b is between 0 to 30 wt. %, and c is between 0 to 10 wt. %; wherein X and Y are elements, and X is selected from the group consisting of molybdenum, copper, cobalt, aluminum, titanium, tungsten, niobium, silicon, vanadium, and combinations thereof, and Y is selected from the group consisting of boron, carbon, silicon, and combinations thereof.
2. The material of claim 1 , wherein the composite exhibits no corrosion when immersed in the molten chloride salt at the temperature of 750° C.
3. The material of claim 1 , wherein the composite is formed from the iron-based amorphous metal alloy within 300 hours of exposing the iron-based amorphous metal alloy above 650° C.
4. The material of claim 1 , wherein the composite is not fully amorphous or at least partially crystalline.
5. The material of claim 1 , wherein the amorphous metal ceramic composite is configured to be a component of a solar concentrator.
6. The material of claim 5 , wherein the component comprises a lens or a mirror.
7. The material of claim 1 , wherein the composite exhibits substantially no corrosion when immersed in the molten chloride salt for at least 300 hours.
8. The material of claim 1 , wherein the composite comprises a coating.
9. The material of claim 1 , wherein the iron-based amorphous metal alloy comprising Fe 100-(a+b+c) (Cr a X b Y c ); wherein a is about 10 to 50 wt. %; b is greater than 10 to 30 wt. %, and c is between 0 to 10 wt. %;
wherein the iron-based amorphous alloy comprises B, C and Si in a range of about 0 to about 10% by weight in total.
10. The material of claim 1 , wherein the amorphous metal ceramic composite is in form of particles with a particle size ranging from about 10 μm to about 60 μm.
11. A material comprising a composite comprising an amorphous metal ceramic composite comprising a nickel-based amorphous metal alloy and a ceramic formed from the nickel-based amorphous metal alloy, wherein the composite exhibits a higher corrosion resistance than that of a Haynes 230 alloy when immersed in a molten chloride salt comprising KCl and MgCl 2 in a ratio of 68/32 at a temperature of 750° C., wherein the nickel-based amorphous metal alloy is fully amorphous up to 600° C. and starts to crystallize at a temperature higher than 600° C.;
and the ceramic comprises a boride and a carbide.
12. The material of claim 11 , wherein the nickel-based amorphous metal alloy comprising Ni 100-(a+b+c) (Cr a X b Y c );
wherein a is about 10 to 50 wt. %; b is between 0 to 30 wt. %, and c is greater than 0 to 10 wt. %;
wherein X and Y are elements, and X is selected from the group consisting of molybdenum, copper, cobalt, aluminum, titanium, tungsten, niobium, silicon, vanadium, and combinations thereof, and Y is selected from the group consisting of boron, carbon, silicon, and combinations thereof.
13. The material of claim 12 ,
wherein the nickel-based amorphous alloy comprises Mo and C less than 5% by weight in total.
14. The material of claim 12 , wherein the nickel-based amorphous alloy comprises B, C and Si in a range of about 0 to about 30% by weight in total.
15. The material of claim 11 , wherein the nickel-based amorphous metal alloy is in form of particles with a particle size ranging from about 10 μm to about 60 μm.
16. The material of claim 11 , wherein the composite comprises a coating.
17. The material of claim 11 , wherein the composite exhibits substantially no corrosion when immersed in the molten chloride salt for at least 300 hours.
18. The material of claim 11 , wherein the composite exhibits no corrosion when immersed in the molten chloride salt at the temperature of 750° C.
19. The material of claim 11 , wherein the composite is formed from the nickel-based amorphous metal alloy within 300 hours of exposing the amorphous metal alloy above 600° C.
20. The material of claim 11 , wherein the amorphous metal ceramic composite is configured to be a component of a solar concentrator.