NON-MAGNETIC METAL ALLOY COMPOSITIONS AND APPLICATIONS
Disclosed are non-magnetic metal alloy compositions and applications that relate to non-magnetic metal alloys with excellent wear properties for use in dynamic three-body tribological wear environments. In some embodiments, the disclosure can relate to a drilling component for use in directional drilling applications capable of withstanding service abrasion. In some embodiments, a hardbanding for protecting a drilling component for use in directional drilling can be provided. In some embodiments, thermodynamic, microstructure, and performance criteria can be determined for hardbanding alloys.
Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
BACKGROUND1. Field
The disclosure relates to non-magnetic metal alloys with excellent wear properties for use in dynamic three-body tribological wear environments.
2. Description of the Related Art
Conditions of abrasive wear can be damaging as they often involve sand, rock particles, or other extremely hard media wearing away against a surface. Applications which see severe abrasive wear typically utilize materials of high hardness, 40 Rc+, encompassing hard metals or carbides.
In certain wear applications, e.g., exploration wells in crude oil or natural gas fields such as directional bores and the like, it is advantageous for drilling string components including drill stems to be made of materials with magnetic permeability values below 1.02 or possibly even less than 1.01 (API Specification 7 regarding drill string components), in order to be able to follow the exact position of the bore hole and to ascertain and correct deviations from its projected course.
A number of disclosures are directed to non-magnetic alloys for use in forming drilling components including U.S. Pat. No. 4,919,728 which details a method for manufacturing non-magnetic drilling string components, and U.S. Patent Publication No. 2005/0047952 which describes a non-magnetic corrosion resistant high strength steel, although both the patent and application describe magnetic permeability of less than 1.01. Both the patent and application are hereby incorporated by reference in their entirety. The compositions described have a maximum of 0.15 wt. % carbon, 1 wt. % silicon and no boron. The low levels and absence of the above mentioned hard particle forming elements suggests that the alloys would not precipitate sufficient, if any, hard particles. It can be further expected that inadequate wear resistance and hardness for high wear environments would be provided.
Further, U.S. Pat. No. 4,919,728 describes alloys which contain carbon levels below 0.25 wt. % while U.S. Patent Publication No. 2005/0047952 details carbon levels below 0.1 wt. %. With these levels of carbon in conjunction with the absence of boron, few hard particles can form which impart wear resistance to a hardband.
Also in U.S. Pat. No. 4,919,728, a method for cold working at various temperatures is used to achieve the desired properties. Cold working is not possible in coating applications such as hardfacing. The size and geometry of the parts would require excessive deformations loads as well as currently unknown methods to uniformly cold work specialized parts such as tool joints.
Additionally, U.S. Patent Publication No. 2010/0009089, hereby incorporated by reference in its entirety, details a non-magnetic for coatings adapted for high wear applications where non-magnetic properties are required. The alloys listed in this publication are nickel-based with preformed tungsten carbide hard spherical particles poured into the molten weld material during welding in the amount of 30-60 wt. %.
Disclosures offering alloying solutions for competing wear mechanisms in oil & gas drilling hardfacing applications include but are not limited to U.S. Pat. Nos. 4,277,108; 4,666,797; 6,117,493; 6,326,582; 6,582,126; 7,219,727; and U.S. Patent Publication No. 2002/0054972. U.S. Publication Nos. 2011/0220415 and 2011/004069 disclose an ultra-low friction coating for drill stem assemblies. U.S. Pat. Nos. 6,375,895, 7,361,411, 7,569,286, 20040206726, 20080241584, and 2011/0100720 disclose the use of hard alloys for the competing wear mechanisms. The patents and patent applications listed in this paragraph are hereby incorporated by reference in their entirety.
There is still a need for non-magnetic alloy compositions for hardbanding components for use in directional drilling applications that have resistance to abrasion. There is also a need for an improved method to protect drill collars from heavy abrasion during drilling operations.
SUMMARYDisclosed herein are metallic alloys, work pieces having a least a portion of its surface covered by a layer of a metallic alloy, methods of manufacturing the alloys, methods of applying the alloys to a work piece or other components, and uses of such alloys in different applications. In one embodiment, a work piece can have at least a portion of its surface covered by a layer which can comprise an austenitic matrix microstructure containing fine-scaled hard particles comprising one or more of boride, carbide, borocarbide, nitride, carbonitride, aluminide, oxide, intermetallic, or laves phase, wherein the layer comprises a macro-hardness of 40 HRC or above and a relative magnetic permeability of 1.02 or less.
In some embodiments, the macro-hardness of the layer can be 45 HRC or more. In some embodiments, the macro-hardness of the layer can be between 45 and 60 HRC, or between 50 and 60 HRC. In some embodiments, the relative magnetic permeability of the layer can be 1.01 or less.
In some embodiments, a surface of the of the layer can exhibit high wear resistance as characterized by an ASTM G65 dry sand wear test mass loss of 1.5 grams or less. In some embodiments, the surface of the layer can exhibit high wear resistance as characterized by an ASTM G65 dry sand wear test mass loss of 0.35 grams or less. In some embodiments, the surface of the layer can have a mass loss measured by ASTM G105 testing of below 0.5 grams.
In some embodiments, the austenitic matrix can contain fine-scaled hard particles up to 50 vol. % with average sizes between 100 nm-20 μm. In some embodiments, the austenitic matrix can contain fine-scaled hard particles up to 30 vol. % (or up to about 30 vol. %) with average sizes between 1-5 μm.
In some embodiments, the layer can comprise in wt. % of Fe: bal, Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5. In some embodiments, the layer can comprise in wt. % of Fe: bal, B: 0-1, C: 0.85-3, Cr: 0-20, Mn: 0-12, Nb: 0-4, Ni: 0-10, Ti: 0-6, V: 0-6, and W: 0-15. In some embodiments, the alloy composition can be selected from group consisting of alloys comprising in wt. %:
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 4, W: 5, Ti: 0.25;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 16, Cr: 5, Nb: 4, V: 0.5, C: 3.25, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.75, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 1, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 3, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 9, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 18, Nb: 4, Ni: 5, V: 0.5, C: 2, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 1, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, Ni: 10, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 10, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, Mn: 4.7, Mo: 1.4, Ni: 7.2, Si: 1.1, Cr: 26.4, C: 1.9;
Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 2.5, V: 0.5, C; 1.5, W: 4;
Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 1, V: 0.5, C: 1.5, W: 4;
Fe: bal, C: 2.25, Cr: 20, Mn: 5, Nb: 4, Ni: 10, Ti: 0.2, V: 0.5, W: 4;
Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 4;
Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 6, W: 2;
Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, V: 2;
Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, Ti: 2, V: 2, W: 4; and combinations thereof.
In some embodiments, the layer does not contain preformed carbides. In some embodiments, the layer can be used as a hardfacing layer configured to protect oilfield components used in directional drilling applications against abrasive wear.
Disclosed is a method of forming a coated work piece which can comprise depositing a layer on at least a portion of a surface of a work piece, wherein the layer comprises an austenitic matrix microstructure containing fine-scaled hard particles comprising one or more of boride, carbide, borocarbide, nitride, carbonitride, aluminide, oxide, intermetallic, and laves phase, and wherein the layer comprises a macro-hardness of 40 HRC or above and a relative magnetic permeability of 1.02 or less.
In some embodiments, the relative magnetic permeability of the layer can be 1.01 or less. In some embodiments, the portion of the surface can be preheated to a temperature of 200° C. or greater prior to deposition of the layer. In some embodiments, the layer can be deposited in a thickness of 1 mm to 10 mm. In some embodiments, the method can further comprise cooling the layer at a rate ranging from 50 to 5000 K/s. In some embodiments, the layer can comprise in wt. % of Fe: bal, Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5. In some embodiments, the layer can comprise in wt. % of Fe: bal, B: 0-1, C: 0.85-3, Cr: 0-20, Mn: 0-12, Nb: 0-4, Ni: 0-10, Ti: 0-6, V: 0-6, and W: 0-15. In some embodiments, the alloy composition can be selected from group consisting of alloys comprising in wt. %:
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 4, W: 5, Ti: 0.25;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 16, Cr: 5, Nb: 4, V: 0.5, C: 3.25, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.75, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 1, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 3, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 9, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 18, Nb: 4, Ni: 5, V: 0.5, C: 2, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 1, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, Ni: 10, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 10, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, Mn: 4.7, Mo: 1.4, Ni: 7.2, Si: 1.1, Cr: 26.4, C: 1.9;
Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 2.5, V: 0.5, C; 1.5, W: 4;
Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 1, V: 0.5, C: 1.5, W: 4;
Fe: bal, C: 2.25, Cr: 20, Mn: 5, Nb: 4, Ni: 10, Ti: 0.2, V: 0.5, W: 4;
Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 4;
Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 6, W: 2;
Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, V: 2;
Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, Ti: 2, V: 2, W: 4;
and combinations thereof.
In some embodiments, the macro-hardness of the layer can be 50 HRC or more, the relative magnetic permeability of the layer can be 1.01 or less, a surface of the layer can exhibit high wear resistance as characterized by an ASTM G65 dry sand wear test mass loss of 0.35 grams or less, and the austenitic matrix can contain fine-scaled hard boride, carbide, or boro-carbide particles up to 30 vol. % with average sizes between 1-5 μm. In some embodiments, the layer does not contain preformed carbides.
Also disclosed is a work piece which can have at least a portion of its surface covered by a layer which can comprise an alloy having an FCC-BCC transition temperature equal to or below 900-950K and an equilibrium total concentration of hard precipitates greater than 20-30 mole percent at a temperature of 1300K.
In some embodiments, the hard precipitates can comprise at least one of cementite, iron boride, (W,Fe)B, NbC, (Nb,Ti)C, Ti2B, (Cr,Mn)23(C,B)6, Cr3C2, Cr5Si, Cr2B, SiC, Mn7C3, W6C, WC, FeNbNi laves, WFe laves and combinations thereof. In some embodiments, the layer can comprise in wt. % of Fe: bal, Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5. In some embodiments, the layer can comprise in wt. % of Fe: bal, B: 0-1, C: 0.85-3, Cr: 0-20, Mn: 0-12, Nb: 0-4, Ni: 0-10, Ti: 0-6, V: 0-6, and W: 0-15.
In some embodiments, the FCC-BCC transition temperature can be equal to or below 850K. In some embodiments, the equilibrium total concentration of hard precipitates can be greater than 20 and less than 30 mole percent at a temperature of 1300K. In some embodiments, the layer exhibits a corrosion rate of 2 mils per year or less in water having 100,000 ppm NaCl, 500 ppm acetic acid, and 500 ppm sodium acetate in tap water under ASTM G31. In some embodiments, the layer can comprise a macro-hardness of 40 HRC or more, a relative magnetic permeability of 1.01 or less, and can exhibit high wear resistance as characterized by ASTM G65 dry sand wear test mass loss of 0.35 grams or less.
Also disclosed is an alloy comprising, in weight %. Fe: bal, B: 0-1, C: 0.85-3, Cr: 0-20, Mn: 0-12, Nb: 0-4, Ni: 0-10, Ti: 0-6, V: 0-6, and W: 0-15, wherein the alloy comprises the following properties when present in an undiluted form and cooled from a liquid state at a rate of 50K/s or greater: a macro-hardness of 40 HRC or greater, and a relative magnetic permeability of 1.02 or less.
In some embodiments, the alloy composition can be selected from group consisting of alloys comprising in wt. %:
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 4, W: 5, Ti: 0.25;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 16, Cr: 5, Nb: 4, V: 0.5, C: 3.25, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.75, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 1, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 3, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 9, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
Fe: bal, Mn: 10, Cr: 18, Nb: 4, Ni: 5, V: 0.5, C: 2, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 1, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, Ni: 10, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 10, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
Fe: bal, Mn: 4.7, Mo: 1.4, Ni: 7.2, Si: 1.1, Cr: 26.4, C: 1.9;
Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 2.5, V: 0.5, C; 1.5, W: 4
Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 1, V: 0.5, C: 1.5, W: 4
Fe: bal, C: 2.25, Cr: 20, Mn: 5, Nb: 4, Ni: 10, Ti: 0.2, V: 0.5, W: 4
Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 4
Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4
Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4
Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 6, W: 2
Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, V: 2
Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, Ti: 2, V: 2, W: 4
and combinations thereof.
In some embodiments, the alloy composition can be tested from a sample produced in an arc melting furnace with a chilled copper base. In some embodiments, the alloy composition is tested from a sample sectioned from the top layer of a six layer weld.
The present disclosure relates to a non-magnetic metal alloy for use in single or multi-stage tribological processes involving multiple bodies of varying hardness, and applications employing the metal alloy, e.g., hardbanding (or hardfacing) applications. For example, the disclosure can be used to manufacture a coating for a drilling component for use in directional drilling applications capable of withstanding service abrasion. The drilling component can have at least one surface protected by, for example, a welded layer comprising one of the metal alloy compositions disclosed below. In some embodiments, the disclosure can be defined by the alloy compositions and compositional ranges which meet certain thermodynamic, microstructural, and performance criteria.
The following terms will be used throughout the specification and will have the following meanings unless otherwise indicated.
“Casing” as used herein is defined as a metal pipe or tube used as a lining for water, oil, or gas well.
“Coating” as used herein is comprised of one or more adjacent layers and any included interfaces. Coating also refers to a layer placed directly on the substrate of a base body assembly to be protected, or the hardbanding placed on a base substrate material. In another embodiment, “coating” refers to the top protective layer. “Coating” may be used interchangeably with “hardbanding,” as defined below.
A “layer” as used herein is a thickness of a material that may serve a specific functional purpose such as reduced coefficient of friction, high stiffness, or mechanical support for overlying layers or protection of underlying layers.
“Hardband” (or “hardface”) as used herein refers to a process to deposit a layer of a special material, e.g., super hard metal, onto drill pipe tool joints, collars and heavy weight pipe in order to protect both the casing and drill string components from wear associated with drilling practices. “Hardbanding” (or “hardband” or “hardfacing”) as used herein refers to a layer of superhard material to protect at least a portion of the underlying equipment or work piece, e.g., tool joint, from wear such as casing wear. Hardbanding can be applied as an outermost protective layer, or an intermediate layer interposed between the outer surface of the body assembly substrate material and the buttering layer(s), buffer layer, or a coating.
“Hard particles” as used herein include but are not limited to any single or combination of hard boride, carbide, borocarbide, nitride, carbonitride, aluminide, oxide, intermetallic, or laves phase. In some embodiments, hard particles can be one of cementite, iron boride, (W,Fe)B, NbC, (Nb,Ti)C, Ti2B, (Cr,Mn)23(C,B)6, Cr3C2, Cr5Si, Cr2B, SiC, Mn7C3, W6C, WC, FeNbNi laves, WFe laves and combinations thereof.
“As-welded” as used herein refers to the condition of a weld without work hardening, heat treating, etc. or any other process which alter the properties or microstructure through post-welding processing.
The terms “approximately”, “about”, and “substantially” as used herein represent an amount close to the stated amount that still performs a desired function or achieves a desired result. For example, the terms “approximately”, “about”, and “substantially” may refer to an amount that is within less than 10% of, within less than 5% of, within less than 1% of, within less than 0.1% of, and within less than 0.01% of the stated amount.
Metal Alloy CompositionEmbodiments of a metal alloy for hardfacing can be characterized as having an austenitic microstructure (face centered cubic gamma phase) and comprising, in wt. %: Mn: 8-20 (or about 8 to about 20), Cr: 0-6 (or about 0 to about 6), Nb: 2-8 (or about 2 to about 8), V: 0-3 (or about 0 to about 3), C: 1-6 (or about 1 to about 6), B: 0-1.5 (or about 0 to about 1.5), W: 0-10 (or about 0 to about 10), Ti: 0-0.5 (or about 0 to about 0.5), balance Fe and impurities as trace elements. The alloy may comprise Mn, Cr, Nb, V, C, B, W, Ti, Fe, and impurities. Embodiments of a non-magnetic composition can have minimal, if any, cracking in the coating and a high resistance to abrasive wear.
In some embodiments, the alloy can be composed of the followings in wt. %:
Fe: bal, Mn: 10 (or about 10), Cr: 5 (or about 5), Nb: 4 (or about 4), V: 0.5 (or about 0.5), C: 4 (or about 4), W: 5 (or about 5), Ti: 0.25 (or about 0.25);
Fe: bal, Mn: 10 (or about 10), Cr: 5 (or about 5), Nb: 4 (or about 4), V: 0.5 (or about 0.5), C: 3.5 (or about 3.5), W: 5 (or about 5), Ti: 0.20 (or about 0.20);
Fe: bal, Mn: 16 (or about 16), Cr: 5 (or about 5), Nb: 4 (or about 4), V: 0.5 (or about 0.5), C: 3.25 (or about 3.25), W: 5 (or about 5), Ti: 0.20 (or about 0.20);
Fe: bal, Mn: 10 (or about 10), Cr: 5 (or about 5), Nb: 4 (or about 4), V: 0.5 (or about 0.5), C: 3 (or about 3), W: 5 (or about 5), Ti: 0.20 (or about 0.20);
Mn: 8-16 (or about 8 to about 16), Cr: 3-6 (or about 3 to about 6), Nb: 3-6 (or about 3 to about 6), V: 0-1 (or about 0 to about 1), C: 1.5-5 (or about 1.5 to about 5), B: 0-1.5 (or about 0 to about 1.5), W: 3-6 (or about 3 to about 6), Ti: 0-0.5 (or about 0 to about 0.5), balance Fe and impurities as trace elements; and
B: 0-1 (or about 0 to about 1), C: 1.5-3 (or about 1.5 to about 3), Cr: 0-20 (or about 0 to about 20), Mn: 0-10 (or about 0 to about 10), Nb: 0-4 (or about 0 to about 4), Ni: 0-10 (or about 0 to about 10), Ti: 0-5 (or about 0 to about 5), V: 0-5 (or about 0 to about 5), W: 0-15 (or about 0 to about 15). The above alloys may comprise Mn, Cr, Nb, Ni, V, C, W, Ti, B, Fe, and impurities, and combinations thereof.
In some embodiments, combinations of the above described alloy compositions can be used. Embodiments of alloys described above can incorporate the above elemental constituents a total of 100 wt. %. In some embodiments, the alloy may include, may be limited to, or may consist essentially of the above named elements. In some embodiments, the alloy may include 2% (or about 2%) or less of impurities. Impurities may be understood as elements or compositions that may be included in the alloys due to inclusion in the feedstock components, through introduction in the manufacturing process. In another embodiment, the feedstock can contain silicon in the amount such that the final alloy contains 0.15 wt. % (or about 0.15 wt. %) although the ingot form did not contain any.
In some embodiments of the present disclosure, hard particles can be precipitated from molten metal during solidification of the alloy. In some embodiments, the austenitic microstructure of the above described alloys can contain embedded hard particles in an amount of 50 vol. % (or about 50 vol. %) or less. Accordingly, the soft austenite matrix of the alloy can provide toughness and ductility, while the precipitated hard particles can impart wear resistance. The soft matrix can further prevent spalling of the hard particles. The fine distribution of hard particles can also allow for uniform wear and prevents selective wear of the soft matrix.
Other alloys, such as those listed in U.S. Patent Publication No. 2010/0009089, hereby incorporated by reference in its entirety, use preformed carbides or borides which are poured into the solidifying metal during welding. These carbides and borides are larger where the particle size ranges from 50-180 (or about 50 to about 180) μm. Particles this large often spall due to poor adhesion with the matrix and break leading to reduced wear resistance. Further, using preformed carbides requires a large hopper directly above the welding arc in order to feed the particles into the molten weld. In this process, feeding the carbides into the weld too quickly or too slowly can be detrimental to the performance of the weld. Also, not only does the welding wire need to be purchased, but preformed carbides as well increasing the overall cost of applying the hardface. On the other hand, embodiments of alloys described in the present disclosure can be deposited using standard welding process without feeding preformed carbides into the weld. This simplifies the application process allowing for more uniform and repeatable hardfaced layers both on a single part and between multiple parts.
In some embodiments, the metal alloy can be applied as a coating of Fe-based (austenitic) matrix containing fine-scaled hard boride, carbide, and complex carbide or boro-carbide particles, e.g., borocarbide particles (e.g., M2B or MC, where M is a transition metal) having average particle sizes of 100 nm-20 μm (or about 100 nm to about 20 μm), in an amount of 50 vol. % (or about 50 vol. %) or less. In another embodiment, the hard particles are present in an amount of 30 vol. % (or about 30 vol. %) or less. In some embodiments, the carbide particles have an average particle size of 1-5 (or about 1 to about 5) μm.
In some embodiments, the boride phase can be represented as M2B, wherein M is a transition metal. In some embodiments, the embedded hard particles in the austenitic Fe-based matrix can contain Nb, Cr, and W with both carbon and/or boron. In some embodiments, the particles can be in the form of embedded Nb carbide and Fe—W-boro carbide precipitates. In another embodiment, the Nb carbide precipitates are 5 μm (or about 5 μm) or less in size. In some embodiments, the Nb carbide precipitates first at higher temperatures, acting as a site for lower temperature forming carbides to nucleate.
Method for Designing HardbandingIn some embodiments, the alloy may be formed by blending various feedstock materials together, which may then be melted in a hearth or furnace and formed into ingots. The ingots can be re-melted and flipped one or more times, which may increase homogeneity of the ingots.
Each ingot produced was evaluated by examining its microstructure, hardness and magnetic permeability. Incremental changes in composition were made in each successive ingot, leading to the final alloys. The compositions of the ingots made are listed in Table I.
Each composition after melting into ingot form was sectioned on a wet abrasive saw as to avoid heating the ingot and subsequently altering the microstructure. The magnetic permeability was measured using a Low-Mu Magnetic Permeability Tester manufactured by Severn Engineering. A reference standard with a known magnetic permeability was placed in the tester. The tester was comprised of the reference standard and a pivoting magnet. The magnet extended from the side of the tester opposite the reference standard. The magnet tip was brought into contact with the surface of the ingot. If the magnet was not attracted to the ingot, then the magnetic permeability was less than that of the reference standard being used. The magnetic permeability of each ingot composition is listed in Table II.
After magnetic permeability was measured, each ingot composition was tested for hardness using a Rockwell C hardness tester. An average of 5 hardness measurements was recorded as the hardness of that ingot. The hardness of each ingot composition is detailed in Table II. Ingots A1-A11 were made prior to having a magnetic permeability test method. Therefore, they were evaluated using a hand-magnet as either magnetic or non-magnetic, and only those alloys showing no magnetism using the hand magnet were hardness tested.
Achieving both a sufficiently low magnetic permeability and high as-welded hardness can be difficult, as non-magnetic austenite is softer than the magnetic ferrite. For example, if a magnetic and a non-magnetic alloy with the same volume percentage of hard particles is examined, the non-magnetic alloy will be significantly softer. However, as shown in Table II, embodiments of the present disclosure can achieve both high hardness and low magnetic permeability.
The microstructure of each ingot was evaluated by optical microscopy. Embodiments of the disclosed alloys can contain a sufficient amount of the ductile austenite matrix along with embedded hard particles. Furthermore, a large volume fraction of finely distributed hard particles can be found in embodiments of the disclosed alloys. Large interconnected hard particles can be undesirable due to increasing the brittleness of the ingot, as shown in
A work piece having at least a portion of its surface coated or having a welded layer of the austenitic alloy composition, e.g., a hardbanding layer, can be characterized as having an as-welded macro-hardness as measured via standard Rockwell C test of 40 Rc, 45 Rc, or 50 Rc (or about 40 Rc, about 45 Rc, or about 50 Rc) or greater.
The alloy composition as deposited on the surface of a work piece can be characterized as being crack-free, as inspected by any of magnetic particle inspection, eddy current inspection, etching, visual inspection, hardness checking, dye penetration inspection, or ultrasound inspection. The absence of cracks in the coating can protect the underlying part from exposure to any corrosive media present.
When applied as coatings, e.g., hardbanding, for protection of work pieces, the fine-grained microstructural features in embodiments of the above disclosed alloy can provide durability and prevent wear on secondary “softer” bodies which come into contact with the work piece protected by the coatings. However, when the hardbanding material comes into contact with some softer materials, such as mild steel, the hardbanding alloy may not aggressively grind away the mild steel. This grinding away commonly happens in drilling environments where a hardbanded pipe is run inside a mild steel casing. Hardbands with preformed carbides, due to the large size of the carbides, can aggressively cut away at the casing, creating problems.
According to embodiments of the disclosure, the component protected by the alloy can be characterized as having elevated wear resistance with a dry sand abrasion mass loss (ASTM G65-04 procedure A, hereby incorporated by reference in its entirety) of 0.6 grams (or about 0.6 grams) or less, or 0.35 grams (or about 0.35 grams) or less. Further, under a modified ASTM G77 test, where the load is increased up to 5000 lb./ft. (or about 5000 lb./ft.), and mineral oil is used as a lubricant, embodiments of the present disclosure can generate 1 mg (or about 1 mg) or less of material loss on casing steel.
Embodiments of the above disclosed alloys can have low magnetic permeability as well. Magnetic permeability is the measure of how well a material can support a magnetic field within it. The relative magnetic permeability of a vacuum is 1. For example, an austenite phase described as a component of this disclosure can be naturally paramagnetic. However, ferrite, which composes typical hardbanding applications, is ferromagnetic. When a magnet is brought into close proximity or contact with a ferromagnetic hardband, it exhibits attractive forces. A magnet exhibits no detectable attraction to an entirely austenitic material.
The definition of a non-magnetic material suitable for use on a drill collar is <1.01 according to API Specification 7. Even slight amounts of ferrite or martensite in a mainly austenitic material can cause the magnetic permeability to exceed 1.01, and therefore embodiments of the disclosed alloy can avoid the formation of ferrite or martensite in a mainly austenitic material. Ferrite and martensite can increased the overall permeability as they have a magnetic permeability greater than 50 depending on the alloy composition.
The alloy composition in some embodiments can be further characterized as having magnetic permeability values (using a Low-Mu Permeability Tester) of 1.02 or less, 1.01 or less, or 1.005 or less (or about 1.02 or less, about 1.01 or less, or about 1.005 or less). The alloy when applied as hardbanding on drill stem components can provide paramagnetic behavior for the operator to be able to monitor the progress of the bore hole required in directional drillings. In some embodiments, the magnetic permeability was measured at a commercial testing facility and the results are illustrated in
A magnetic field gradient is a measure of the uniformity of the magnetic field. In some embodiments, embodiments of the above described alloys can maintain a magnetic field gradient of ±0.05 (or ±about 0.05) microtesla which can meet the requirements of API Specification 7, hereby incorporated by reference in its entirety. In some embodiments, the commercially measured magnetic field gradient was <0.05 microtesla (or <about 0.05 microtesla). In some embodiments, no hot spots exceeding the 0.05 microtesla (or about 0.05 microtesla) range were found. This indicates a uniform magnetic field, as shown in
The following example is intended to be non-limiting.
An alloy composition of Alloy 1 (Mn: 10%, Cr: 5%, Nb: 4%, V: 0.5%, C: 3.5%, W: 5%, Ti: 0.25%, Fe: balance) was produced in the form of a 1/16″ cored wire. The alloy was arc-welded onto a 6⅝″ outer diameter box Stainless Steel tool joint pre-heated to 450° F. The joint was rotated at a rotation rate of one full rotation every 2 min and 30 sec. The welding parameters are 290 amps, 29.5 volts and a 1″ wire stickout. The welding head was moved through the action of an oscillator at a rate of 58 cycle/min, resulting in a weld bead approximately 1″ wide and 4/32″ thick. Three consecutive beads were made, one next to another to produce three adjacent 1″ beads for a total width of roughly 3″. The joint was wrapped in insulation to reduce the cooling rate and allowed to cool to room temperature. The as-welded tool joint can be seen in
The microstructure of the weld bead was examined with optical micrographs as shown in
In some embodiments, alloys, such as the ones disclosed above, can be defined by the specific compositions and compositional ranges which meet certain thermodynamic, microstructural, and performance criteria outlined in the below disclosure. A listing of potential alloy compositions can be created that comply partially or fully with different thermodynamic, microstructural, and performance criteria.
Metal Alloy CompositionCertain metal alloy compositions can be achieved that result in certain desired performances. These metal alloys can be created, for example, by looking at thermodynamic and microstructural criteria. While the explicit criteria are further defined below, this section discusses the alloy compositions that at least partially meet those criteria.
Table III shows a series of alloy compositions evaluated using both modeling and experimental techniques. As discussed below, Tγ→α is the FCC to BCC transition temperature, Σhard is the summed fraction of hard phases at 1300K (or about 1300K), μ is the relative magnetic permeability, and HRC is the Rockwell C hardness.
The 33 alloys shown in Table III meet at least some of the performance, microstructural, and thermodynamic criteria further described below (64.5% meet all criteria). Because there is such a high correlation between the alloys meeting all of the criteria (64.5%), if an alloy meets one of these criteria classes, it is highly likely that it meets all the described criteria, thermodynamic, microstructural, and performance.
After producing a table meeting the below described criteria, a general alloy composition can be determined. For example, based at least in part on Table III, and the manufacturing variances of selected wires, an alloy composition that will meet the described criteria can comprise B, C, Cr, Mn, Nb, Ni, Ti, V, W, Fe, and impurities, and combinations thereof, and can contain in wt. %:
B: 0-1 (or about 0 to about 1), C: 0.85-3 (or about 0.85 to about 3), Cr: 2-27 (or about 2 to about 27), Mn: 0-12 (or about 0 to about 12), Nb: 0-4 (or about 0 to about 4), Ni: 0-10 (or about 0 to about 10), Ti: 0-2 (or about 0 to about 2), V: 0-6 (or about 0 to about 6), W: 0-5 (or about 0 to about 5), and Fe: bal.
In some embodiments, the alloy can be described by a series of compositional ranges which meet the specified thermodynamic criteria. A listing of specific alloy compositions which meet the specified thermodynamic criteria, described below, are listed in Table IV. Based at least in part on Table IV, an alloy composition can comprise C, Cr, Mn, Nb, Ni, Ti, V, W, Fe, and impurities, and combinations thereof, and can contain in wt. %:
C: 1.5-3 (or about 1.5 to about 3), Cr: 0-20 (or about 0 to about 20), Mn: 0-10 (or about 0 to about 10), Nb: 0-4 (or about 0 to about 4), Ni: 0-10 (or about 0 to about 10), Ti: 0-0.2 (or about 0 to about 0.2), V: 0-0.5 (or about 0 to about 0.5), W: 0-5 (or about 0 to about 5), and Fe: bal.
In some embodiments, B can be added to the composition for the purposes of increasing hardness and wear resistance, while not affecting the magnetic properties of the material. Based at least in part on Table IV, an alloy composition having B can comprise B, C, Cr, Mn, Nb, Ni, Ti, V, W, Fe, and impurities, and combinations thereof, and can contain in wt. %:
B: 0-1 (or about 0 to about 1), C: 1.5-3 (or about 1.5 to about 3), Cr: 0-20 (or about 0 to about 20), Mn: 0-10 (or about 0 to about 10), Nb: 0-4 (or about 0 to about 4), Ni: 0-10 (or about 0 to about 10), Ti: 0-0.2 (or about 0 to about 0.2), V: 0-0.5 (or about 0 to about 0.5), W: 0-5 (or about 0 to about 5), and Fe: bal.
In some embodiments, the summed Mn+Ni concentration does not fall below 10 wt. % (or below about 10 wt. %).
Further described are certain compositional ranges using Table IV that can meet the below described criteria. Non-limiting examples of such alloy compositions can comprise C, Cr, Mn, Nb, Ni, Ti, V, W, Fe, and impurities, and combinations thereof, and can contain in wt. %:
C: 1.5-3 (or about 1.5 to about 3), Cr: 0-20 (or about 0 to about 20), Mn: 10 (or about 10), Nb: 0-4 (or about 0 to about 4), Ni: 0-10 (or about 0 to about 10), Ti: 0-0.2 (or about 0 to about 0.2), V: 0-0.5 (or about 0 to about 0.5), W: 0-5 (or about 0 to about 5), and Fe: bal.
C: 1.5-3 (or about 1.5 to about 3), Cr: 0-20 (or about 0 to about 20), Mn: 5 (or about 5), Nb: 0-4 (or about 0 to about 4), Ni: 5-10 (or about 5 to about 10), Ti: 0-0.2 (or about 0 to about 0.2), V: 0-0.5 (or about 0 to about 0.5), W: 0-5 (or about 0 to about 5), and Fe: bal.
C: 1.5-2.25 (or about 1.5 to about 2.25), Cr 0-20 (or about 0 to about 20), Nb: 0-4 (or about 0 to about 4), Ni: 10 (or about 10), Ti: 0-0.2 (or about 0 to about 0.2), V: 0-0.5 (or about 0 to about 0.5), W: 0-5 (or about 0 to about 5), and Fe: bal.
In some embodiments, the Ti, V, and/or W concentration can be increased for the purposes of increasing the hard particle fraction, while not affecting the magnetic properties of the material. Based at least in part on Table III, Table IV, and the manufacturing variances of selected wires the alloy can comprise B, C, Cr, Mn, Nb, Ni, Ti, V, W, Fe, and impurities, and can contain, in wt. %:
B: 0-1 (or about 0 to about 1), C: 0.85-3 (or about 0.85 to about 3), Cr: 0-20 (or about 0 to about 20), Mn: 0-10 (or about 0 to about 10), Nb: 0-4 (or about 0 to about 4), Ni: 0-10 (or about 0 to about 10), Ti: 0-6 (or about 0 to about 6), V: 0-6 (or about 0 to about 6), W: 0-15 (or about 0 to about 15), and Fe: bal.
In some embodiments the alloys can be described by the measured chemical compositions of manufactured 1/16″ metal cored wires. Alloys 1, 8, 14, 15, 22, and 23 were produced in the form of 1/16″ metal cored wires for the purposes of weld testing. Each wire chemistry was measured using inductively coupled plasma optical emission spectroscopy and a LECO carbon analyzer. The results of the analysis for each material are described below in weight %:
Alloy 1: Al: 0.09, B: 0.01, C: 3.13, Cr: 5.52, Cu: 0.03, Mo: 0.02, Mn: 9.58, Nb: 3.85,
Ni: 0.01, P: 0.016, S: 0.006, Si: 0.17, Ti: 0.18, V: 0.51, W: 4.88;
Alloy 8: Al: 0.08, B: 0.01, C: 2.61, Cr: 11.95, Cu: 0.09, Mo: 0.03, Mn: 9.97, Nb: 4.00,
Ni: 4.84, P: 0.016, S: 0.007, Si: 0.49, Ti: 0.29, V: 0.61, W: 4.36;
Alloy 14 (run 1): Al: 0.04, B: 0.01, C: 1.75, Cr: 14.60, Cu: 0.21, Mo: 0.13, Mn: 7.66,
Nb: 2.81, Ni: 5.22, P: 0.019, S: 0.007, Si: 0.64, Ti: 0.12, V: 0.39, W: 3.58;
Alloy 14 (run 2): B: 0.01, C: 2.06, Co: 0.29, Cr: 14.93, Cu: 0.32, Mo: 0.24, Mn: 9.28,
Nb: 3.89, Ni: 5.69, P: 0.260, S: 0.006, Si: 0.41, Ti: 0.27, V: 0.46, W: 5.84;
Alloy 15: Al: 0.05, B: 0.98, C: 0.85, Co: 0.03, Cr: 12.38, Cu: 0.12, Mo: 0.03, Mn: 9.36,
Nb: 3.79, Ni: 5.40, P: 0.030, S: 0.006, Si: 0.39, Ti: 0.18, V: 0.77, W: 4.55;
Alloy 22: B: 0.02, C: 1.87, Co: 0.09, Cr: 26.44, Cu: 0.27, Mo: 4.68, Mn: 4.68, Ni: 7.19,
P: 0.024, S: 0.007, Si: 1.09, Ti: 0.01, V: 0.08, W: 0.04;
Alloy 23: B: 0.01, C: 1.74, Co: 0.02, Cr: 18.6, Cu: 0.20, Mo: 0.04, Mn: 11.16, Nb: 3.63,
Ni: 1.02, P: 0.270, S: 0.006, Si: 0.39, Ti: 0.17, V: 0.77, W: 4.55
In all cases, the balance is Fe. Due to the manufacturing process, Al, B, Co, Cu, Mo, Ni, P, S, and W have been added in measurable quantities in alloys where the nominal composition does not contain these elements. In some embodiments, the alloys were present in their undiluted form and cooled from a liquid state at a rate of 50K/s or greater. In all cases, the alloys were welded onto test coupons and were shown to exhibit at least the minimum performance criteria of 40 HRC or greater and a relative magnetic permeability of below 1.02. In some embodiments, the alloy composition was tested from a sample produced in an arc melting furnace with a chilled copper base. In some embodiments, the alloy composition was tested from a sample sectioned from the top layer of a six layer weld.
In some embodiments, alloys can be defined by thermodynamic criteria that result in a specified performance of an alloy. For example, a thermodynamic criteria can be for alloys which possess an equilibrium FCC-BCC transition temperature equal to or below 900-950K (or about 900 to about 950K), and simultaneously possess an equilibrium total concentration of combined hard precipitates (carbides, borides, or borocarbides) in excess of 20-30 mole percent (or about 20 to about 30 mole percent) at a temperature of 1300K (or about 1300K). This thermodynamic criteria than can be used to predict performance of embodiments of alloys having the specified FCC-BCC transition temperature and the hard phase fraction.
Thermodynamic criteria can be calculated using the CALPHAD method. A potential result of such calculations is an equilibrium phase diagram such as that shown in
In some embodiments, the FCC-BCC transition temperature can be an indicator of the final phase of a hardfacing weld. As shown in
In some embodiments, a thermodynamic criteria can be a FCC-BCC transition temperature at or below 950K (or about 950K). In some embodiments, a thermodynamic criteria can be a FCC-BCC transition temperature at or below 900K (or about 900K). 92% of the alloys evaluated in Table III that met this criteria were determined to be non-magnetic (relative permeability <1.02). In some embodiments, a thermodynamic criteria can be a FCC-BCC transition temperature at or below 850K (or about 850K). 100% of the alloys evaluated in Table III that met this criteria were determined to be non-magnetic (relative permeability <1.02).
Additionally, in some embodiments, the hard phase fraction can be an indicator of the hardness and/or wear resistance of the hardfacing alloy. Due to issues with predicting metastable processes with equilibrium calculations, the hard phase fraction can be calculated from at a temperature of 1300K (or about 1300K). Thus, the hard phases fraction of the weld can be considered ‘frozen in’ at this temperature due to the cooling rate of the hardfacing process, and not allowed to further change. This has been supported with experimental measurements. A hard phase fraction at or above 0.2-0.30 mole fraction (or about 0.2 to about 0.30 mole fraction) can be a positive indicator for reaching the wear and hardness performance criteria described in this disclosure. Out of the 33 alloys evaluated in Table III, 75% of those with a hard phase fraction of 20% or greater possessed greater than 40 HRC.
In some embodiments, a thermodynamic criteria can be a mole fraction of no less than 0.20 (or about 0.20) hard particles. In some embodiments, a thermodynamic criteria can be a mole fraction of no less than 0.25 (or about 0.25) hard particles. Out of the 33 alloys evaluated in Table III, 90% of those with a hard phase fraction of 25% or greater possessed greater than 40 HRC. In some embodiments, thermodynamic criteria can be a mole fraction of no less than 0.30 (or about 0.30) hard particles. Out of the 33 alloys evaluated as shown in Table III, 100% of those with a hard phase fraction of 30% or greater possessed greater than 40 HRC.
In the specific example of Alloy 1, shown in
In some embodiments, the thermodynamic criteria can be useful for defining alloy performance used in processes with cooling rates from 1K/s to 10,000 K/s (or about 1K/s to about 10,000 K/s). In some embodiments, the thermodynamic criteria can be useful for defining alloy performance used in processes with cooling rates from 10K/s to 100K/s (or about 10K/s to about 100K/s), 1K/s to 500 K/s (or about 1K/s to about 500K/s), or 50 K/s to about 500 K/s (or about 50 K/s to about 500 K/s).
Microstructural CriteriaIn some embodiments, an alloy can be defined by the microstructural criteria which result in a specified performance of the alloy. The microstructural criteria of this disclosure can be divided into two categories, the matrix phase and the hard precipitates. In some embodiments, the disclosure can be defined by a set of microstructural features such as, for example, alloys which possess an 90-95% (or about 90 to about 95%) or greater volume fraction of austenite in the matrix phase, and possess a hard precipitate fraction (carbides, borides, or borocarbides) in excess of 20-30 (or about 20 to about 30) volume percent when deposited as a hardfacing layer.
In some embodiments, the matrix phase can be austenitic iron, which is the non-magnetic form of iron or steel. In some embodiments, the matrix can be predominantly austenitic in order for specified performance criteria to be met. In some embodiments of this disclosure, the matrix can be at least 90%, 95%, or 99% austenite (or about 90%, about 95%, or about 99% austenite). Ferrite and martensite are the two most common and likely forms of the matrix phase in this alloy space, however both are highly magnetic and may prevent the hardfacing alloy from meeting the magnetic performance requirements if present in sufficient quantities. Therefore, ferrite and martensite can be minimized in embodiments of the alloys.
Further, hard precipitates can precipitate into embodiments of alloys. Hard precipitates can be defined as carbide, boride, or borocarbide phases which can be present in a range of morphologies. In some embodiments, the hard precipitate volume fraction can exceed 20 volume % (or about 20 volume %). This can ensure that the hardfacing alloy meets the hardness and wear resistance performance criteria discussed in this disclosure.
In some embodiments, such as those having some level of impact resistance or mechanical toughness, there may be an upper limit on the hard phase fraction. For example, embodiments could have a hard phase fraction greater than 20% (or greater than about 20%), but lower than 30% (or lower than about 30%).
Furthermore, in some embodiments, manufacturing processes can be controlled. For example, by varying welding parameters, a high rate of dilution with the base material can be achieved, which can result in an artificially low hard phase volume fraction using alloys of this disclosure. In some embodiments, the disclosed alloys can be used as either feedstock chemistry for a specific coating process or as the final chemistry of the coating after process related effects, such as dilution with the base material, have occurred. Thus, embodiments of the disclosed alloy composition embodiments may possess a microstructure or performance characteristic outside of the specified bounds when used in certain coating deposition processes.
Performance CriteriaIn some embodiments, alloys can be defined by their performance. In some embodiments, two performance criteria can be 1) the relative magnetic permeability and 2) the wear resistance of the hardfacing layer.
For example, in some embodiments, alloys can have a relative magnetic permeability of 1.02 or less, or 1.01 or less (or about 1.02 or less, or about 1.01 or less), when deposited as a hardfacing layer. Further, in some embodiments, the durability of embodiments of the alloys can be defined by the ASTM G65 procedure A test, hereby incorporated by reference in its entirety, and the hardfacing layer can exhibit 1.5 grams or less mass loss when subjected to this test, below 1.0 grams or less, or below 0.5 grams or less (or below about 1.5 grams or less, below about 1.0 grams or less, or below about 0.5 grams or less). In some embodiments, the durability of embodiments of the alloys can be defined by mass loss measured in ASTM G105 testing can be below 0.5 grams, below 0.2 grams, or below 0.05 grams (or below about 0.5 grams, below about 0.2 grams, or below about 0.05 grams). In some embodiments, the durability of the alloy can be defined by the Rockwell C hardness, which, for example, can be 40, 45, or 50 HRC (or about 40, about 45, or about 50 HRC) or greater. Testing results of certain embodiments of alloys are shown in Table V.
In some embodiments, the hardfacing layer can have a minimum level of corrosion resistance. Certain embodiments of this disclosure have shown a desirable corrosion resistance to salt water, an environment relevant to many industries, such as oil and gas, mining, marine, construction, automotive, aerospace, and others. Embodiments which have demonstrated this resistance by exhibiting a corrosion rate of 2 mils per year or less (or about 2 mils per year or less) in the produced water (100,000 ppm NaCl, 500 ppm acetic acid, 500 ppm sodium acetate in tap water) include but are not limited to Alloy 14 and Alloy 15. The corrosion rate of Alloy 14 and 15 were measured at 2 mpy or less when tested under ASTM G31 in produced water.
In some embodiments, the hardfacing layer can have a minimum layer of impact resistance. It is expected that due to the austenitic matrix present in the embodiments of this disclosure, that such embodiments will inherently have high impact resistance, exceeding those of ferritic or martensitic hardfacing materials.
ApplicationsIn some embodiments, the alloys described above can be suitable for use as hardbanding/hardfacing in hard bodies wear applications. In these applications, the material loss in coatings is typically caused by abrasive wear of the harder abrading particles, such as sand, rock, or earth. To reduce the material loss in this process, the hardness of the coating can be increased and/or the amount of comparably hard particles (comparable as related to the abradable particles) or phases within the coating can be increased. In some embodiments, the alloys can contain a sufficient amount of hard particles and display a sufficient hardness property for the protected equipment under these conditions.
In some embodiments, the metal alloys can be applied onto a surface using techniques including, but not limited to, thermal spray coating, laser welding, weld-overlay, laser cladding, vacuum arc spraying, plasma spraying, and combinations thereof. In some embodiments, the alloys can be deposited as wire feedstock employing hardfacing known in the art, e.g., weld overlay. The alloys can be applied with mobile or fixed, semi or automatic welding equipment. In some embodiments, the alloys are applied using any of laser welding, shielded metal arc welding (SMAW), stick welding, plasma transfer arc welding (PTAW), gas metal arc-welding (GMAW), metal inert gas welding (MIG), submerged arc welding (SAW), or open arc welding (OAW), although the type of application is not limiting.
In some embodiments, the alloy can be deposited onto a machined surface. In some embodiments, the surface can be surface blast cleaned to white metal (e.g., ISO 8501-1, hereby incorporated by reference in its entirety). The depth of the machined surface can be grooved for flush type application depends on the welding applicator. In some embodiments for application on a used pipe, the existing hardbanding can be first completely removed by gouging, grinding, or using other suitable techniques.
The coating can be applied as raised (“proud”) or flush (“recessed”) coating. The coating can be applied on used equipment, e.g., pipe with no previous hardbanding, or to be hardbanded on new work pieces. The coating can be deposited over pre-existing weld deposits and many other previous hard-facing and hard-banding deposits. In some embodiments, the old hardbanding on the equipment is first removed before the application of the alloy
The disclosed alloys can be particularly useful for oil & gas applications, such as for prolonging service life. For example, the alloys can be used for work pieces employed in directional drilling operations as coating for drill stem assemblies, exposed outer surface of a bottom hole assembly, coatings for tubing coupled to a bottom hole assembly, coatings for casings, hardbanding on at least a portion of the exposed outer surface of the body, and as coatings for oil and gas well production devices, such as disclosed in U.S. Patent Publication No. 2011/0042069A1, hereby incorporated by reference in its entirety. Examples further include devices for use in drilling rig equipment, marine riser systems, tubular goods, wellhead, formation and sandface completions, lift equipment, etc. Specific examples include drillpipe tool joints, drill collars, casings, risers, and drill strings. The coating can be on a least a portion of the inner surface of the work piece, at least a portion of the outer surface, or combinations thereof, preventing wear on the drill collar. The coatings can provide protection in operations with wear from vibration (stick-slip and torsional) and abrasion during straight hole or directional drilling, allowing for improved rates of penetration and enable ultra-extended reach drilling with existing equipment.
Besides the use as protective coatings, embodiments of the above disclosed alloys can be used in the fabrication of articles of manufacture, including drill collars and housings for containing measurement-while-drilling equipment used in the directional drilling of oil and gas wells. A drill collar can be made from a bar, which can be trepanned to form an internal bore to desired dimensions. Following trepanning, at least the interior surface can be treated so as to place it into compression, for example as by burnishing or peening.
Outside the oil & gas industry, the alloys can also be used as coatings or forming work pieces in many other applications, including but not limited to, coatings for fuel cell components, cryogenic applications, and the like, for equipment operating in corrosive environments with non-magnetic requirements.
In some embodiments, combinations of powders of the above described alloys may be contained in conventional steel sheaths, which when melted may provide the targeted alloy composition. The steel sheaths may include plain carbon steel, low, medium, or high carbon steel, low alloy steel, or stainless steel sheaths.
The ingots may then be melted and atomized or otherwise formed into an intermediate or final product. The forming process may occur in a relatively inert environment, including an inert gas. Inert gasses may include, for example, argon or helium. If atomized, the alloy may be atomized by centrifugal, gas, or water atomization to produce powders of various sizes, which may be applied to a surface to provide a hard surface.
The alloys may be provided in the form of stick, wire, powder, cored wire, billet, bar, rod, plate, sheet, and strip. In some embodiments, the alloys are formed into a stick electrode, e.g., a wire, of various diameters, e.g., 1-5 mm (or about 1 to about 5 mm). In some embodiments, the cored wire may contain flux, which may allow for welding without a cover gas and without porosity-forming in the weld deposit.
In some embodiments, the surfaces for deposition can be first preheated at a temperature of 200° C. (or about 200° C.). or greater, e.g., 275-500° C. (or about 275° C. to about 500° C.), for 0.01 hours to 100 hours (or about 0.01 to about 100 hours). In some embodiments, the preheat may reduce or prevent cracking of the deposited welds.
The alloy may be applied to a surface in one or more layers as an overlay. In some embodiments, each layer can have an individual thickness of 1 mm to 10 mm. In some embodiments, the overlay has a total thickness of 1 to 30 mm. In some embodiments, the width of the individual hard-band ranges from 5 mm to 40 mm. In another embodiment, the width of the total weld overlay ranges from 5 mm to 20 feet.
After deposition on a substrate, the alloy can be allowed to cool to form a protective coating. In some embodiments, the cooling rate can range from 100 to 5000 K/s (or about 100 to about 5000 K/s), a rate sufficient for the alloy to produce iron rich phases containing embedded hard particles (e.g., carbides, borides, and/or borocarbides). Embodiments of alloys that have been tested as welds (e.g. 1, 2, 3, 8, 14, and 15) have shown that ferrite formation can be prevented when the cooling rate is above 50 K/s (or above about 50 K/s). Embodiments of alloys that have been tested as ingots (e.g. all alloys in Table 2) have shown that ferrite formation is prevented when the cooling rate is above 1000 K/S (or above about 1000 K/s). After weld deposition, cooling in open air can cause a cooling rate which is too rapid, leading to cracking of the weld. Wrapping of the welded part with a thermally insulating blanket can be sufficient to reduce the cooling rate to an acceptable level.
Features, materials, characteristics, or groups described in conjunction with a particular aspect, embodiment, or example are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The protection is not restricted to the details of any foregoing embodiments. The protection extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.
While certain embodiments have been described, these embodiments have been presented by way of example only, and are not intended to limit the scope of protection. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms. Furthermore, various omissions, substitutions and changes in the form of the methods and systems described herein may be made. Those skilled in the art will appreciate that in some embodiments, the actual steps taken in the processes illustrated and/or disclosed may differ from those shown in the figures. Depending on the embodiment, certain of the steps described above may be removed, others may be added. Furthermore, the features and attributes of the specific embodiments disclosed above may be combined in different ways to form additional embodiments, all of which fall within the scope of the present disclosure.
Although the present disclosure includes certain embodiments, examples and applications, it will be understood by those skilled in the art that the present disclosure extends beyond the specifically disclosed embodiments to other alternative embodiments and/or uses and obvious modifications and equivalents thereof, including embodiments which do not provide all of the features and advantages set forth herein. Accordingly, the scope of the present disclosure is not intended to be limited by the specific disclosures of preferred embodiments herein, and may be defined by claims as presented herein or as presented in the future.
Claims
1. A work piece having at least a portion of its surface covered by a layer comprising an austenitic matrix microstructure containing fine-scaled hard particles comprising one or more of boride, carbide, borocarbide, nitride, carbonitride, aluminide, oxide, intermetallic, and laves phase, wherein the layer comprises a macro-hardness of 40 HRC or more and a relative magnetic permeability of 1.02 or less.
2. The work piece of claim 1, wherein the macro-hardness of the layer is 45 HRC or more.
3. The work piece of claim 2, wherein the macro-hardness of the layer is between 45 and 60 HRC.
4. The work piece of claim 1, wherein the relative magnetic permeability of the layer is 1.01 or less.
5. The work piece claim 1, wherein a surface of the of the layer exhibits high wear resistance as characterized by an ASTM G65 dry sand wear test mass loss of 1.5 grams or less.
6. The work piece of claim 5, wherein the surface of the layer exhibits high wear resistance as characterized by an ASTM G65 dry sand wear test mass loss of 0.35 grams or less.
7. The work piece of claim 1, wherein the surface of the layer has a mass loss measured by ASTM G105 testing of below 0.5 grams.
8. The work piece of claim 1, wherein the austenitic matrix contains fine-scaled hard particles up to 50 vol. % with average sizes between 100 nm-20 μm.
9. The work piece of claim 8, wherein the austenitic matrix contains fine-scaled hard particles up to 30 vol. % with average sizes between 1-5 μm.
10. The work piece of claim 1, wherein the layer comprises in wt. % of Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5.
11. The work piece of claim 1, wherein the layer comprises in wt. % of B: 0-1, C: 0.85-3, Cr: 0-20, Mn: 0-12, Nb: 0-4, Ni: 0-10, Ti: 0-6, V: 0-6, and W: 0-15.
12. The work piece of claim 1, wherein the alloy composition is selected from group consisting of alloys comprising in wt. %:
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 4, W: 5, Ti: 0.25;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 16, Cr: 5, Nb: 4, V: 0.5, C: 3.25, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.75, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 1, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 3, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 9, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 18, Nb: 4, Ni: 5, V: 0.5, C: 2, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 1, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, Ni: 10, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 10, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, Mn: 4.7, Mo: 1.4, Ni: 7.2, Si: 1.1, Cr: 26.4, C: 1.9;
- Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 2.5, V: 0.5, C; 1.5, W: 4;
- Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 1, V: 0.5, C: 1.5, W: 4;
- Fe: bal, C: 2.25, Cr: 20, Mn: 5, Nb: 4, Ni: 10, Ti: 0.2, V: 0.5, W: 4;
- Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 4;
- Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
- Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
- Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 6, W: 2;
- Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, V: 2;
- Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, Ti: 2, V: 2, W: 4;
- and combinations thereof.
13. The work piece of claim 1, wherein the layer does not contain preformed carbides.
14. The work piece of claim 1, where the layer is used as a hardfacing layer configured to protect oilfield components used in directional drilling applications against abrasive wear.
15. A method of forming a coated work piece comprising:
- depositing a layer on at least a portion of a surface of a work piece;
- wherein the layer comprises an austenitic matrix microstructure containing fine-scaled hard particles comprising one or more of boride, carbide, borocarbide, nitride, carbonitride, aluminide, oxide, intermetallic, and laves phase; and
- wherein the layer comprises a macro-hardness of 40 HRC or more and a relative magnetic permeability of 1.02 or less.
16. The method of claim 15, wherein the relative magnetic permeability of the layer is 1.01 or less.
17. The method of claim 15, wherein the portion of the surface is preheated to a temperature of 200° C. or greater prior to deposition of the layer.
18. The method of claim 15, wherein the layer is deposited in a thickness of 1 mm to 10 mm.
19. The method of claim 15, further comprising cooling the layer at a rate ranging from 50 to 5000 K/s.
20. The method of claim 15, wherein the layer comprises in wt. % of Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5.
21. The method of claim 15, wherein the layer comprises in wt. % of B: 0-1, C: 0.85-3, Cr: 0-20, Mn: 0-12, Nb: 0-4, Ni: 0-10, Ti: 0-6, V: 0-6, and W: 0-15.
22. The method of claim 15, wherein the alloy composition is selected from group consisting of alloys comprising in wt. %:
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 4, W: 5, Ti: 0.25;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 16, Cr: 5, Nb: 4, V: 0.5, C: 3.25, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.75, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 1, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 3, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 9, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 18, Nb: 4, Ni: 5, V: 0.5, C: 2, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 1, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, Ni: 10, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 10, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, Mn: 4.7, Mo: 1.4, Ni: 7.2, Si: 1.1, Cr: 26.4, C: 1.9;
- Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 2.5, V: 0.5, C; 1.5, W: 4;
- Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 1, V: 0.5, C: 1.5, W: 4;
- Fe: bal, C: 2.25, Cr: 20, Mn: 5, Nb: 4, Ni: 10, Ti: 0.2, V: 0.5, W: 4;
- Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 4;
- Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
- Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
- Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 6, W: 2;
- Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, V: 2;
- Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, Ti: 2, V: 2, W: 4;
- and combinations thereof.
23. The method of claim 15, wherein the macro-hardness of the layer is 40 HRC or more, the relative magnetic permeability of the layer is 1.01 or less, a surface of the layer exhibits high wear resistance as characterized by an ASTM G65 dry sand wear test mass loss of 0.35 grams or less, and the austenitic matrix contains fine-scaled hard boride, carbide, or boro-carbide particles up to 30 vol. % with average sizes between 1-5 μm.
24. The method of claim 15, wherein the layer does not contain preformed carbides.
25. A work piece having at least a portion of its surface covered by a layer comprising an alloy having an FCC-BCC transition temperature equal to or below 900-950K and an equilibrium total concentration of hard precipitates greater than 20-30 mole percent at a temperature of 1300K.
26. The work piece of claim 25, wherein the hard precipitates comprise at least one of cementite, iron boride, (W,Fe)B, NbC, (Nb,Ti)C, Ti2B, (Cr,Mn)23(C,B)6, Cr3C2, Cr5Si, Cr2B, SiC, Mn7C3, W6C, WC, FeNbNi laves, WFe laves and combinations thereof.
27. The work piece of claim 25, wherein the layer comprises in wt. % of Mn: 8-20, Cr: 0-6, Nb: 2-8, V: 0-3, C: 1-6, B: 0-1.5, W: 0-10, Ti: 0-0.5.
28. The work piece of claim 25, wherein the layer comprises in wt. % of B: 0-1, C: 0.85-3, Cr: 0-20, Mn: 0-12, Nb: 0-6, Ni: 0-10, Ti: 0-6, V: 0-6, and W: 0-15.
29. The work piece of claim 25, wherein the FCC-BCC transition temperature is equal to or below 850K.
30. The work piece of claim 25, wherein the equilibrium total concentration of hard precipitates is great than 20 and less than 30 mole percent at a temperature of 1300K.
31. The work piece of claim 25, wherein the layer exhibits a corrosion rate of less than 2 mils per year in water having 100,000 ppm NaCl, 500 ppm acetic acid, and 500 ppm sodium acetate in tap water under ASTM G31.
32. The work piece of claim 25, wherein the layer comprises a macro-hardness of 40 HRC or more, a relative magnetic permeability of 1.01 or more, and exhibits high wear resistance as characterized by ASTM G65 dry sand wear test mass loss of 0.35 grams or less.
33. An alloy comprising, in weight %:
- Fe: bal, B: 0-1, C: 0.85-3, Cr: 0-20, Mn: 0-12, Nb: 0-4, Ni: 0-10, Ti: 0-6, V: 0-6, and W: 0-15;
- wherein the alloy comprises the following properties when present in an undiluted form and cooled from a liquid state at a rate of 50K/s or greater:
- a macro-hardness of 40 HRC or greater; and
- a relative magnetic permeability of 1.02 or less.
34. The alloy of claim 33, wherein the alloy composition is selected from group consisting of alloys comprising in wt. %:
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 4, W: 5, Ti: 0.25;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 16, Cr: 5, Nb: 4, V: 0.5, C: 3.25, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.75, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 1, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 3, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 5, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 9, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 2.5, W: 5, Ti: 0.20;
- Fe: bal, Mn: 10, Cr: 18, Nb: 4, Ni: 5, V: 0.5, C: 2, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 12, Nb: 4, Ni: 5, V: 0.5, C: 1, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, Ni: 10, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 10, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, B: 1, Mn: 10, Cr: 18, Nb: 4, V: 0.5, C: 3, W: 5, Ti: 0.20;
- Fe: bal, Mn: 4.7, Mo: 1.4, Ni: 7.2, Si: 1.1, Cr: 26.4, C: 1.9;
- Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 2.5, V: 0.5, C; 1.5, W: 4;
- Fe: bal, Mn: 10, Cr: 16.5, Mo: 0, Nb: 3, Ni: 1, V: 0.5, C: 1.5, W: 4;
- Fe: bal, C: 2.25, Cr: 20, Mn: 5, Nb: 4, Ni: 10, Ti: 0.2, V: 0.5, W: 4;
- Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 4;
- Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
- Fe: bal, B: 0.5, C: 1.5, Cr: 18, Mn: 10, Nb: 4, W: 4;
- Fe: bal, C: 2, Cr: 18, Mn: 10, Nb: 4, V: 6, W: 2;
- Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, V: 2;
- Fe: bal, C: 3, Cr: 18, Mn: 10, Nb: 4, Ti: 2, V: 2, W: 4;
- and combinations thereof.
35. The alloy of claim 33, wherein the alloy composition is tested from a sample produced in an arc melting furnace with a chilled copper base.
36. The method of claim 33, wherein the alloy composition is tested from a sample sectioned from the top layer of a six layer weld.
Type: Application
Filed: Oct 10, 2013
Publication Date: Oct 1, 2015
Inventors: Justin Lee Cheney (Encinitas, CA), John Hamilton Madok (San Diego, CA), Kyle Walter Rafa (Fremont, CA)
Application Number: 14/434,664