Abstract: A flame spray powder mix or blend is provided for producing metal coatings on metal substrates, such as ferrous metal substrates, e.g., steel, cast iron, among other metal substrates, the powder mix comprising agglomerates of at least one oxidizable metal, e.g., aluminum, homogeneously mixed or blended with a coating metal powder, such as nickel powder. The coating produced is characterized by a strong bond and also being substantially low in dispersed oxides.

Abstract: A flame spray powder mix is provided for producing metal coatings on metal substrates, such as ferrous metal substrates, e.g., steel, case iron, among other metal substrates, the powder mix comprising particles of at least one metal silicide, e.g., titanium disilicide, mixed with a coating metal powder, such as nickel powder. The amount of metal silicide in the powder mix preferably ranging from about 2% to 20% by weight.

Abstract: A coated electrode is provided comprising a metal core rod and a sheath coating enveloping said rod, said sheath consisting essentially of at least one hard phase-forming element in particulate form bonded to said rod, said sheath containing an amount of a solid metal halogenide ranging from over 0.01 to 3% by weight of said sheath effective to provide a weld deposit in which hard phases are uniformly distributed therethrough.

Abstract: A carbide laden consumable is produced using a mold having at least one U-shaped groove running along the surface thereof, the consumable being produced by charging a first layer of a powdered self-fluxing alloy into the groove, a second layer of a powdered refractory carbide on said first layer and a third layer of said self-fluxing alloy on the carbide layer, and the charged mold then passed through a heating furnace under a reducing atmosphere to produce by melting and cooling a consumable of markedly improved quality.

Abstract: The invention contemplates a method and means for making a dryer or the like roll having a ferrous metal surface provided with a surface coating of a hardfacing alloy, the ferrous metal surface having a thermal conductivity relative to silver taken as 1 cal/cm.sup.2 /cm/.degree.C./sec of at least about 0.06 the hardfacing alloy being a hardfacing heat, corrosion and wear resistant iron-group metal-base alloy mechanically and metallurgically bonded to said ferrous metal surface which is preferably made of cast iron, the hardfacing alloy coating having a thickness ranging from about 0.01 to 0.15 inch, the thermal conductivity of said coating being at least 0.05.

Abstract: A method and coating material are provided for improving the wear and abrasion resistance of a composite nickel-base hard facing alloy applied to metal substrates comprising the system Ni-Cr-Si-B having dispersed therein particles comprising tungsten carbide, the improvement residing in controlling the average particle size of tungsten carbide to below 10 microns, e.g. 0.1 to 10 microns, preferably an average size ranging from about 2 to 8 microns (such as 2 to 6 microns), at an average interparticle spacing of less than 15 microns, and preferably less than 10 microns, e.g. up to 5 microns, the hard facing coating produced being further characterized in that the coating exhibits metallographically a substantially uniform structure at the surface thereof with respect to said tungsten carbide particles.

Abstract: A method is provided for producing adherent metal coatings on metal substrates, such as ferrous metal substrates, e.g. steel, cast iron and other metal substrates said material comprising a plurality of ingredients physically combined in intimate contact with each other, each of said plurality of ingredients comprising by weight about 3% to 15% aluminum, about 2% to 15% of a refractory metal silicide and the balance essentially a metal selected from the group consisting of nickel-base, cobalt-base, iron-base and copper-base metals.

Abstract: A nickel-base wear and corrosion resistant alloy is provided containing by weight about 20% to 35% Cr, about 1% to 8% Si, about 1.7% to 3.5% C, 0 to 15% W and the balance essentially at least about 40% nickel, the amount of carbon present in said composition being stoichiometrically related to the chromium content to provide carbides based on the formula M.sub.7 C.sub.3, wherein M comprises essentially chromium, the amount of chromium in said M.sub.7 C.sub.3 compound ranging from about 65% to less than about 100% of the total chromium in said composition, the melting point of said alloy being less than about 1350.degree. C. The alloy has particular use in welding consumables for hard facing, for valve seats, for wear resistant sleeves and bushings (castings) and other uses.

Abstract: The apparatus of the invention employs a gas torch which has the feature of selective addition of metal powder to the gas flow. In use, the torch is caused to make a continuous succession of traverses of a workpiece region for preheating purposes and then, without interrupting the continuous operation of either the torch or the traversing cycles, a controlled flow of metal powder is caused to enter the torch flow, enabling the bonding and progressive building of a metal coat to desired thickness. In the embodiments described, first and second different metal powders are thus successively coated to the substrate without interrupting the continuous operation. Different embodiments are described in the particular context of applying uniform circumferential coatings to a cylindrical workpiece such as a shaft.

Abstract: The apparatus and method of the invention employ a gas torch which has the feature of selective addition of metal powder to the gas flow, in a cyclical pattern of metal-spraying and non-spraying (fusing) utilization of the same torch. The torch is caused to make short and relatively rapid transverse oscillations of sweep across the width of a swath along the workpiece, the swath developing in the course of a relatively slow feed (e.g., a longitudinal feed) of the torch with respect to the workpiece. The rate of torch feed and the duty cycle of metal application (vs. non-spraying) are related to the effective width of the metal "bead" thus sprayed, so as to assure (1) overlapping of adjacent beads and (2) fusing of adjacent beads to each other and to the workpiece.

Abstract: A method and coating material are provided for improving the wear and abrasion resistance of a composite nickel-base hard facing alloy applied to metal substrates comprising the system Ni-Cr-Si-B having dispersed therein particles comprising tungsten carbide, the improvement residing in controlling the average particle size of tungsten carbide to below 10 microns, e.g. 0.1 to 10 microns, preferably an average size ranging from about 2 to 8 microns (such as 2 to 6 microns), at an average interparticle spacing of less than 15 microns, and preferably less than 10 microns, e.g. up to 5 microns, the hard facing coating produced being further characterized in that the coating exhibits metallographically a substantially uniform structure at the surface thereof with respect to said tungsten carbide particles.

Abstract: A boiler tube coating and method are disclosed in which industrial steel tubes or pipes, for example, steel boiler tubes and/or integrated panels of steel boiler tubes, are provided with a fused overlay of a corrosion and erosion resistant coating comprised of a refractory hard component, e.g. tungsten carbide, dispersed through a corrosion resistant matrix alloy.

Abstract: An alloy-coated ferrous metal substrate is disclosed, the ferrous metal making up said substrate having a thermal conductivity relative to silver taken as 1 cal./sq.cm/cm/.degree. C/sec at substantially ambient temperature of at least about 0.06, the alloy coating being selected from the group consisting of a self-fluxing heat and corrosion resistant iron-group metal-base alloy and a self-fluxing copper-base alloy fused and metallurigically bonded to said ferrous metal substrate, said alloy coating having a thickness of about 0.005 to 0.15 inch, the thermal conductivity of said coating being at least about 0.05.

Abstract: A method is set forth for the production of shaped parts from a multi-component silver-copper alloy containing at least one metal from the group consisting of tin and indium and optionally zinc. The alloy is hot worked and then subsequently subjected to cold working, each of the cold working steps being preceded by a special equilibrating heat treatment. The invention resides in using the special equilibrating heat treatment to improve the cold workability of the alloy.

Abstract: A drier roll having a ferrous metal surface is provided with a surface coating of a hardfacing alloy, the ferrous metal surface having a thermal conductivity relative to silver taken as 1 cal/cm.sup.2 /cm/.degree. C/sec of at least about 0.06, the hardfacing alloy being a hardfacing heat, corrosion and wear resistant iron-group metal-base alloy mechanically and metallurgically bonded to said ferrous metal surface which is preferably made of cast iron, the hardfacing alloy coating having a thickness ranging from about 0.01 to 0.15 inch, the thermal conductivity of said coating being at least 0.05.

Abstract: A filler metal composition and method are provided for producing strong brazed joints between metal parts, e.g. steel parts, assembled in joint-forming relationship with each other, the filler metal comprising an indium-containing silver brazing alloy consisting essentially by weight of about 30% to 70% Ag, about 3% to 20% In, about 3% to 20% Zn, up to about 0.5% Si and the balance essentially copper.

Abstract: An arc welding power supply of the type which employs a saturable reactor circuit to control the supply power from an alternating current source to the welding electrode. A control circuit varies the current through the control winding of the saturable reactor to provide the desired welding current. An additional circuit monitors the welding current and disables the saturable reactor control circuit when the welding current drops below a low threshold value, thus reducing the open circuit voltage between the welding electrode and workpiece and minimizing the danger of electric shock to the welder while changing electrodes. The saturable reactor is connected in series with the primary winding of a transformer which also serves as the output winding of the saturable reactor.

Abstract: A metaliferous flame spray material is provided for producing adherent metal coatings on metal substrates, such as ferrous metal substrates, e.g. steel, cast iron and other metal substrates, said material comprising a plurality of ingredients physically combined in intimate contact with each other, each of said plurality of ingredients comprising by weight about 3% to 15% aluminum, about 2% to 15% of a refractory metal silicide and the balance essentially a metal selected from the group consisting of nickel-base, cobalt-base, iron-base and copper-base metals.

Abstract: A metal spray powder blend is provided characterized by the property of forming a dense coating on a metal substrate comprising a self-fluxing nickel-base alloy powder having intimately associated with the surface thereof by blending an aluminum powder ranging in amount from about 0.5 to 5% by weight, the average size ratio of the nickel-base alloy powder to the aluminum powder being over 5:1, the aluminum powder having an average particle size of less than about 15 microns. A preferred method of spraying the powder is to gravity feed it into the flame of a metal spraying torch.

Abstract: A method and coating material are provided for improving the wear and abrasion resistance of a composite nickel-base hard facing alloy applied to metal substrates comprising the system Ni-Cr-Si-B having dispersed therein particles comprising tungsten carbide, the improvement residing in controlling the average particle size of tungsten carbide to below 10 microns, e.g. 0.1 to 10 microns, preferably an average size ranging from about 2 to 8 microns (such as 2 to 6 microns), at an average interparticle spacing of less than 15 microns, and preferably less than 10 microns, e.g. up to 5 microns, the hard facing coating produced being further characterized in that the coating exhibits metallographically a substantially uniform structure at the surface thereof with respect to said tungsten carbide particles.