Granted Patent B2

US 12,227,853 · App. 17/442,532 · Granted Feb 18, 2025

Inventor: Cameron Eibl (Encinitas, CA)

Assignee: Oerlikon Metco (US) Inc.

C23C4/08C22C38/02C22C38/04C22C38/06C22C38/32C23C4/123

Abstract

Claims (52)

1. A thermal spray feedstock material comprising Fe and, in wt. %:

B: about 0.2 to about 2.5;

C: about 0.15 to about 2.0; and

Mo: at most about 1;

wherein the thermal spray feedstock material comprises a powder having ≥7 wt % and ≤80 wt % of particles being larger than about 44 microns and smaller than about 90 microns; and

wherein the thermal spray feedstock material is configured to form a matrix and is characterized by having, under thermodynamic equilibrium conditions:

a solidus temperature less than or equal to about 1550K;

a liquidus temperature less than or equal to about 1750K;

between about 5 and about 35 mol % of total hard particles at 1300K; and

greater than or equal to about 15 mol % of a mole fraction of liquid 25K above the solidus temperature;

wherein a difference between the liquidus temperature and the solidus temperature is between about 30 and about 150K.

2. The thermal spray feedstock material of claim 1 , further comprising at most about 0.5 wt. % Cr.

3. The thermal spray feedstock material of claim 1 , further comprising at most about 1.0 wt. % Mn.

4. The thermal spray feedstock material of claim 1 , wherein the thermal spray feedstock material is selected from the group consisting of, in wt. %:

B: about 0.6, C: about 0.3, Si: about 1.0, Fe: bal;

B: about 1.5, C: about 0.2, Si: about 1.0, Fe: bal;

B: about 0.3, C: about 1.4, Si: about 5.0, Fe: bal;

B: about 0.6, C: about 1.8, Si: about 5.0, Fe: bal; and

B: about 2.2, C: about 1.1, Si: about 6.0, Fe: bal.

5. The thermal spray feedstock material of claim 1 , wherein the thermal spray feedstock material is configured to form a matrix and is characterized by having, under thermodynamic equilibrium conditions:

a solidus temperature less than or equal to about 1500K;

a liquidus temperature less than or equal to about 1700K; and

between about 5 and about 35 mol % of total hard particles at 1300K;

wherein a difference between the liquidus temperature and the solidus temperature is between about 35 and about 150K.

6. A coating formed from the thermal spray feedstock material of claim 1 .

7. The coating of claim 6 , wherein the coating comprises:

a bulk coating hardness of between about 290 HV0.3 and about 600 HV0.3; and

an individual particle hardness of between 550 HV0.1 and about 950 HV0.1.

8. The coating of claim 6 , wherein the coating comprises:

between about 5 and about 35 vol. % total hard phases;

between about 5 and about 35 vol. % of a total spinel phase; and

between about 5 and about 35 vol. % of a total aluminum rich oxide phase.

9. The coating of claim 6 , wherein the coating is deposited on an internal surface of a cylinder bore of an internal combustion engine.

10. A thermal spray feedstock material consisting of, in wt. %:

Al: about 1.5 to about 4.5; and

C: about 0.2 to about 1.6;

Cr: less than 0.5;

other elements and inevitable impurities: less than 1% each; and

Fe: balance;

wherein the thermal feedstock material comprises a powder that, under equilibrium solidification conditions with 4 wt % oxygen added, forms a matrix having at 1300K about 7.5 to about 30 mol % oxide phase comprising greater than 10 wt % aluminum.

11. The material of claim 10 , consisting of:

C: about 0.9 to about 1.4;

Al: about 3 to about 3.8;

Cr: less than 0.5;

other elements and inevitable impurities: less than 1% each; and

Fe: balance.

12. The material of claim 10 , wherein B, N, Ca, Ti, V, Co, Ni, Cu, Zn, Y, Zr, Nb, Mo, Pd, Ag, Cd, In, Sn, La, Hf, Ta, W, Pt, and Au are each at a maximum amount of 0.5 wt. %.

13. The material of claim 10 , wherein the other elements and inevitable impurities comprise at least one of Si and Mn each at a maximum amount of 0.5 wt. %.

14. A coating on an internal bore of an engine formed from the material claim 10 .

15. The coating of claim 14 , wherein the coating has a HV 0.3 hardness in excess of 450.

16. The thermal spray feedstock material of claim 1 , further comprising Si in an amount not more than about 7 wt. %.

17. The material of claim 10 , wherein Cr is at most about 0.25 wt. %.

Assignments (1)

Continuity (2)

References Cited (400)