Abstract: The invention describes a method for producing ternary and binary ceramic powders and their thermal spraying capable of manufacturing thermal sprayed coatings with superior properties. Powder contain at least 30% by weight ternary ceramic, at least 20% by weight binary molybdenum borides, at least one of the binary borides of Cr, Fe, Ni, W and Co and a maximum of 10% by weight of nano and submicro-sized boron nitride. The primary crystal phase of the manufactured thermal sprayed coatings from these powders is a ternary ceramic, while the secondary phases are binary ceramics. The coatings have extremely high resistance against corrosion of molten metal, extremely thermal shock resistance and superior tribological properties at low and at high temperatures.

Abstract: The invention describes a method for producing ternary and binary ceramic powders and their thermal spraying capable of manufacturing thermal sprayed coatings with superior properties. Powder contain at least 30% by weight ternary ceramic, at least 20% by weight binary molybdenum borides, at least one of the binary borides of Cr, Fe, Ni, W and Co and a maximum of 10% by weight of nano and submicro-sized boron nitride. The primary crystal phase of the manufactured thermal sprayed coatings from these powders is a ternary ceramic, while the secondary phases are binary ceramics. The coatings have extremely high resistance against corrosion of molten metal, extremely thermal shock resistance and superior tribological properties at low and at high temperatures.

Abstract: The invention describes a method for producing ternary and binary ceramic powders and their thermal spraying capable of manufacturing thermal sprayed coatings with superior properties. Powder contain at least 30% by weight ternary ceramic, at least 20% by weight binary molybdenum borides, at least one of the binary borides of Cr, Fe, Ni, W and Co and a maximum of 10% by weight of nano and submicro-sized boron nitride. The primary crystal phase of the manufactured thermal sprayed coatings from these powders is a ternary ceramic, while the secondary phases are binary ceramics. The coatings have extremely high resistance against corrosion of molten metal, extremely thermal shock resistance and superior tribological properties at low and at high temperatures.

Abstract: The present invention concerns methods and apparatus for forming a clad product, such as a clad pipe or tube. Particular embodiments include a method for metallurgically bonding cladding material onto a metal substrate, the method including a step of providing a metal substrate comprising a pipe or a tube having a cladding composition arranged along an interior surface of the substrate to form a coated substrate, the interior surface arranged within an interior cavity of the substrate. A further step includes inserting a heat source into an interior cavity of the substrate, the heat source comprising an infrared, microwave, or radio frequency heat source, the heat source being mounted on a heat source-retaining housing, the housing comprising a cantilevered structure. An additional step includes applying heat discharged from the heat source to the coated substrate along the coated interior surface until the cladding composition metallurgically bonds to the substrate.

Abstract: The present invention concerns methods and apparatus for forming a clad product, such as a clad pipe or tube. Particular embodiments include a method for metallurgically bonding cladding material onto a metal substrate, the method including a step of providing a metal substrate comprising a pipe or a tube having a cladding composition arranged along an interior surface of the substrate to form a coated substrate, the interior surface arranged within an interior cavity of the substrate. A further step includes inserting a heat source into an interior cavity of the substrate, the heat source comprising an infrared, microwave, or radio frequency heat source, the heat source being mounted on a heat source-retaining housing, the housing comprising a cantilevered structure. An additional step includes applying heat discharged from the heat source to the coated substrate along the coated interior surface until the cladding composition metallurgically bonds to the substrate.

Abstract: A heterogeneous composite body that is spall resistant and comprises a substantially discontinuous cermet phase in a substantially continuous metal rich matrix phase. The heterogeneous composite body is typically bonded to a substrate to form a hardfacing on the substrate. The heterogeneous composite body exhibits ductile phase toughening with a strain to failure of at least about 2 percent, a modulus of elasticity of less than about 35 million pounds per square inch, and a density of less than about 7 grams per cubic centimeter. The metal rich matrix phase between the ceramic rich regions in the heterogeneous composite body has an average minimum span of about 0.5 to 8 microns to allow ductility in the heterogeneous composite body. The heterogeneous composite body has a Vicker's hardness number of greater than approximately 500. The ceramic rich regions exhibit high hardness as compared with the matrix phase.

Abstract: The invention describes a method for producing ternary and binary ceramic powders and their thermal spraying capable of manufacturing thermal sprayed coatings with superior properties. Powder contain at least 30% by weight ternary ceramic, at least 20% by weight binary molybdenum borides, at least one of the binary borides of Cr, Fe, Ni, W and Co and a maximum of 10% by weight of nano and submicro-sized boron nitride. The primary crystal phase of the manufactured thermal sprayed coatings from these powders is a ternary ceramic, while the secondary phases are binary ceramics. The coatings have extremely high resistance against corrosion of molten metal, extremely thermal shock resistance and superior tribological properties at low and at high temperatures.

Abstract: A heterogeneous composite body that is spall resistant and comprises a substantially discontinuous cermet phase in a substantially continuous metal rich matrix phase. The heterogeneous composite body is typically bonded to a substrate to form a hardfacing on the substrate. The heterogeneous composite body exhibits ductile phase toughening with a strain to failure of at least about 2 percent, a modulus of elasticity of less than about 35 million pounds per square inch, and a density of less than about 7 grams per cubic centimeter. The metal rich matrix phase between the ceramic rich regions in the heterogeneous composite body has an average minimum span of about 0.5 to 8 microns to allow ductility in the heterogeneous composite body. The heterogeneous composite body has a Vicker's hardness number of greater than approximately 500. The ceramic rich regions exhibit high hardness as compared with the matrix phase.

Abstract: The present invention concerns methods and apparatus for forming a clad product, such as a clad pipe or tube. Particular embodiments include a method for metallurgically bonding cladding material onto a metal substrate, the method including a step of providing a metal substrate comprising a pipe or a tube having a cladding composition arranged along an interior surface of the substrate to form a coated substrate, the interior surface arranged within an interior cavity of the substrate. A further step includes inserting a heat source into an interior cavity of the substrate, the heat source comprising an infrared, microwave, or radio frequency heat source, the heat source being mounted on a heat source-retaining housing, the housing comprising a cantilevered structure. An additional step includes applying heat discharged from the heat source to the coated substrate along the coated interior surface until the cladding composition metallurgically bonds to the substrate.

Abstract: A composite body that is spall resistant and comprises a substantially discontinuous cermet phase in a substantially continuous metal rich matrix phase. The composite body is typically bonded to a substrate to form a hardfacing on the substrate. The composite body exhibits ductile phase toughening with a strain to failure of at least about 2 percent, a modulus of elasticity of less than about 46 million pounds per square inch, and a density of less than about 7 grams per cubic centimeter. The metal rich matrix phase between the ceramic rich regions in the composite body has an average minimum span of about 0.5 to 8 microns to allow ductility in the composite body. The composite body has a Vicker's hardness number of greater than approximately 650. The discontinuous cermet phase is in the form of ceramic rich regions embedded within the composite body, and it includes ceramic particles and a cermet binder. The ceramic particles having a Moh's hardness of at least approximately 7.