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 metal ceramic composite.
1 . A method comprising obtaining a substrate, forming a coating of an amorphous metal alloy, heating the coating, and transforming at least a portion of the amorphous metal alloy into a composite comprising an amorphous metal ceramic composite, wherein the amorphous metal ceramic composite comprises the amorphous metal alloy and a ceramic formed from the amorphous metal alloy, wherein the amorphous metal alloy starts to crystallize at a temperature above 600° C.; and further comprising forming a second layer of the coating of the amorphous metal alloy and bonding with a previous layer of the coating on the substrate.
2 . The method of claim 1 , wherein the formation of the coating comprises spraying a thermal and/or a non-thermal spray of the amorphous metal alloy.
3 . The method of claim 1 , wherein the composite exhibits a higher corrosion resistance than that of Haynes 230 when immersed in a molten chloride salt at a temperature at 750° C. for a period of 300 hours.
4 . The method of claim 3 , wherein the composite exhibits no corrosion when exposed to the molten chloride salt at a temperature at 750° C. for the period of 300 hours.
5 . The method of claim 3 , wherein the molten salt comprises KCl, MgCl 2 , NaCl, LiCl or combination thereof.
6 . The method of claim 1 , wherein the coating of the amorphous metal alloy comprises powder of the amorphous metal alloy.
7 . The method of claim 6 , wherein the powder has a particle size of about 10 micrometers to 60 micrometers.
8 . The method of claim 6 , comprising spraying a thermal spray to melt particles of the powder and atomizing them to form the coating on the substrate.
9 . The method of claim 8 , wherein the thermal spray comprises a High Velocity Oxy-Fuel (HVOF) thermal spray.
10 . The method of claim 1 , wherein the ceramic comprises a boride and a carbide.
11 . The method of claim 10 , wherein the ceramic comprises at least one of chromium boride, chromium carbide, molybdenum boride and ternary carbide of ferro-molybdenum.
12 . The method of claim 1 , wherein the composite is not fully amorphous or at least partially crystalline.
13 . The method of claim 1 , wherein the amorphous metal alloy is partially amorphous.
14 . The method of claim 1 , wherein the amorphous metal alloy comprises a nickel-based alloy or an iron-based alloy.
15 . The method of claim 14 , wherein the iron-based alloy comprises 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.
16 . The method of claim 14 , wherein the nickel-based alloy comprises 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.
17 . The method of claim 1 , wherein a strength to weight ratio of the amorphous metal ceramic composite is about 400 to 500.
18 . The method of claim 1 , wherein about 87% of the amorphous metal ceramic composite crystallizes at 750° C.
19 . The method of claim 1 , wherein the composite exhibits higher corrosion resistance than that of Haynes 230 when immersed in FLiNak at a temperature at 750° C. for a period of 300 hours.