Abstract: Disclosed herein are iron-based alloys having a microstructure comprising a fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferritic matrix comprises <10 ?m carbide precipitates. Also disclosed are methods of welding comprising forming a crack free hardbanding weld overlay coating with such an iron-based alloy. Also disclosed are families of alloys capable of forming crack-free weld overlays after multiple welding passes.

Abstract: A class of nickel based alloys having a fine grain structure resistant to stress corrosion cracking, and methods of alloy design to produce further alloys within the class are presented. The alloys act as suitable welding materials in similar applications to that of Alloy 622. The fine-grained structure of these novel alloys may also be advantageous for other reasons as well such as wear, impact, abrasion, corrosion, etc. These alloys have similar phases to Alloy 622 in that they are composed primarily of austenitic nickel, however the phase morphology is a much finer grained structure opposed to the long dendritic grains common to Alloy 622 when it is subject to cooling rates from a liquid state inherent to the welding process.

Abstract: Disclosed herein are iron-based alloys having a microstructure comprising a fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferritic matrix comprises <10 ?m Nb and W carbide precipitates. Also disclosed are methods of welding comprising forming a crack free hardbanding weld overlay coating with such an iron-based alloy. Also disclosed are methods of designing an alloy capable of forming a crack free hardbanding weld overlay, the methods comprising the steps of determining an amorphous forming epicenter composition, determining a variant composition having a predetermined change in constituent elements from the amorphous forming epicenter composition, and forming and analyzing an alloy having the variant composition.

Abstract: Disclosed herein are iron-based alloys having a structure comprising fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferritic matrix comprises <10 ?m Nb and W carbide precipitates. Also disclosed are methods of welding comprising forming a crack free hardbanding weld overlay coating with such an iron-based alloy. Also disclosed are methods of designing an alloy capable of forming a crack free hardbanding weld overlay, the methods comprising the step determining an amorphous forming epicenter composition, determining a variant composition having a predetermined change in constituent elements from the amorphous forming epicenter composition, and forming and analyzing an alloy having the variant composition.

Abstract: A work piece for use in abrasive environments with hardbanding is provided. The work piece has at least a protective layer deposited onto at least a portion to be protected. The deposited layer exhibits a hardness of at least 50 Rc, a wear rate of less than 0.5 grams of mass loss as measured according to ASTM G65-04, Procedure A, a wear rate on a contacting secondary body comprising carbon steel of less than 0.005 grams as measured according to modified ASTM G77 wear test. The deposited alloy forms an iron matrix comprising embedded hard particles in an amount of less than 15 vol. %. The embedded hard particles have an average particle size of ranging from 100 nm to 5 ?m. In one embodiment, the deposition is via welding.

Abstract: A method for protecting a work piece for use in abrasive environments with hardbanding is provided. The layer is deposited onto at least a portion of the work piece to be protected. The deposited layer exhibits a hardness of at least 50 Rc, a wear rate of less than 0.5 grams of mass loss as measured according to ASTM G65-04, Procedure A, a wear rate on a contacting secondary body comprising carbon steel of less than 0.005 grams as measured according to modified ASTM G77 wear test. The deposited alloy forms an iron matrix comprising embedded hard particles in an amount of less than 15 vol. %. The embedded hard particles have an average particle size of ranging from 100 nm to 5 ?m. In one embodiment, the deposition is via welding.

Abstract: Equipment having a protective coating layer for use in abrasive environments, e.g., sulfur-containing environments, is disclosed. The coating is formed from a single-component feedstock, as a Fe-based alloy composition comprising at least two refractory elements selected from Cr, V, Nb, Mo and W in an amount of up to 30% each and a total concentration of up to 40%. In one embodiment, the coating is applied by thermal spraying, followed by heat treatment for at least a portion of the refractory elements in the coating to fuse into the substrate forming a metallurgically bonded coating. The coating has an adhesion strength of at least 7,000 psi measured according to ASTM D4541. The coating layer is further characterized as being impermeable to corrosive environments showing no pin holes in the ferroxyl test according to ASTM A967 Practice E.

Abstract: A method for forming protective coatings on equipment is disclosed. The coating is formed from a single-component Fe-based alloy composition comprising at least two refractory elements selected from Cr, V, Nb, Mo and W in an amount of up to 30% each and a total concentration of up to 40%. In one embodiment, the single-component coating layer is applied by thermal spraying, followed by heat treatment for at least a portion of the refractory elements to fuse into the substrate forming a metallurgical bond. The coating has an adhesion strength of at least 7,000 psi measured according to ASTM D4541. The coating is further characterized as being impermeable to corrosive environments showing no pin holes in the ferroxyl test according to ASTM A967 Practice E.

Abstract: Equipment (work piece) for use in corrosive resistant coating on equipment is disclosed. The equipment has at least a portion of its surface coated with a layer formed from a NiCrMo alloy composition containing at least two gettering components selected from Al, Si, and Ti in an amount of up to 25 wt. %. The coating in one embodiment is applied on the equipment using a thermal spray technique, e.g., twin wire arc spray, forming coatings of 5-50 mils thickness having a fine-scale micro-pore structure. The coating layer is characterized as having excellent adhesion strength and corrosion resistant properties, even when applied with varying parameters as in manual on-site coating applications. In one embodiment, the coating layer has an impurity content of less than 15%.

Abstract: A method for forming protective corrosive resistant coatings on equipment is disclosed. The coating is formed from a NiCrMo alloy composition containing at least two gettering components selected from Al, Si, and Ti in an amount of up to 25 wt. %. The coating in one embodiment is applied using a thermal spray technique, e.g., twin wire arc spray, forming coatings of 5-50 mils thickness having a fine-scale micro-pore structure which is effectively non-permeable in aggressive solutions, and resist selective oxidation in thermal spraying of components for maximized corrosion performance The coating is further characterized as having excellent adhesion strength even when applied with varying parameters as in manual on-site coating applications.

Abstract: A method to protect and modify surface properties of articles is disclosed. In one embodiment of the method, an intermediate layer is first deposited onto a substrate of the article. The intermediate layer has a thickness of at least 2 mils containing a plurality of pores with a total pore volume of 5 to 50% within a depth of at least 2 mils. A lubricant material is deposited onto the intermediate layer, wherein the lubricant material infiltrates at least a portion of the pores and forms a surface layer. The surface layer can be tailored with the selection of the appropriate material for the intermediate layer and the lubricant material, for the surface layer to have the desired surface tension depending on the application.

Abstract: Disclosed herein is an article having a surface modified to alter its surface tension property and increase resistance to sand abrasion as characterized by a material volume loss of less than 75 mm3 according to ASTM G65-04 Procedure B. In one embodiment of the method, an intermediate layer is first deposited onto a substrate of the article. At least a substrate on the article is protected by a coating layer, which comprises: an intermediate layer adjacent to the substrate with a thickness of at least 2 mils containing a plurality of pores with a total pore volume of 5 to 50% within a depth of at least 2 mils; and a surface layer comprising a lubricant material deposited onto the intermediate layer. The lubricant material infiltrates at least a portion of the pores for the coating to have the desired surface tension depending on the application.

Abstract: A class of nickel based alloys having a fine grain structure resistant to stress corrosion cracking, and methods of alloy design to produce further alloys within the class are presented. The alloys act as suitable welding materials in similar applications to that of Alloy 622. The fine-grained structure of these novel alloys may also be advantageous for other reasons as well such as wear, impact, abrasion, corrosion, etc. These alloys have similar phases to Alloy 622 in that they are composed primarily of austenitic nickel, however the phase morphology is a much finer grained structure opposed to the long dendritic grains common to Alloy 622 when it is subject to cooling rates from a liquid state inherent to the welding process.

Abstract: Disclosed herein are iron-based alloys having a microstructure comprising a fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferritic matrix comprises <10 ?m carbide precipitates. Also disclosed are methods of welding comprising forming a crack free hardbanding weld overlay coating with such an iron-based alloy. Also disclosed are families of alloys capable of forming crack-free weld overlays after multiple welding passes.

Abstract: Disclosed herein are iron-based alloys having a microstructure comprising a fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferritic matrix comprises <10 ?m Nb and W carbide precipitates. Also disclosed are methods of welding comprising forming a crack free hardbanding weld overlay coating with such an iron-based alloy. Also disclosed are methods of designing an alloy capable of forming a crack free hardbanding weld overlay, the methods comprising the steps of determining an amorphous forming epicenter composition, determining a variant composition having a predetermined change in constituent elements from the amorphous forming epicenter composition, and forming and analyzing an alloy having the variant composition.

Abstract: Disclosed herein are iron-based alloys having a structure comprising fine-grained ferritic matrix and having a 60+ Rockwell C surface, wherein the ferrific matrix comprises <10 ?m Nb and W carbide precipitates. Also disclosed are methods of welding comprising forming a crack free hardbanding weld overlay coating with such an iron-based alloy. Also disclosed are methods of designing an alloy capable of forming a crack free hardbanding weld overlay, the methods comprising the step determining an amorphous forming epicenter composition, determining a variant composition having a predetermined change in constituent elements from the amorphous forming epicenter composition, and forming and analyzing an alloy having the variant composition.

Abstract: The present invention provides a method for coating an article comprising applying a thermal spray coating to the article; applying a brazing material to the article; and heating the brazing material to at least a brazing temperature of the brazing material to form a resultant coating on the article, wherein the resultant coating is characterized by at least partial metallurgical bonding or at least partial alloying between the thermal spray coating and the brazing material.