Abstract: Alloy compositions and associated articles are described herein which, in some embodiments, exhibit enhancements to ductility and processing capabilities without significant sacrifices to hardness, wear resistance, and/or corrosion resistance. An alloy, in some embodiments, comprises 0-40 wt. % nickel, 14-20 wt. % chromium, 24-35 wt. % molybdenum, 0-15 wt. % iron, 0-1.5 wt. % manganese, 0.01-0.1 wt. % carbon, 0-15 wt. % tungsten, and the balance cobalt, wherein the alloy has a configurational entropy greater than 1.5R, where R is the universal gas constant.

Abstract: In one aspect, cobalt-based alloys are described herein comprising composition and microstructure permitting a balance of hardness, toughness and wear resistance desirable for wood cutting applications. A cobalt-based alloy comprises a chromium rich carbide phase in an amount of 15-30 volume percent, a tungsten-rich phase in an amount of 9-15 volume percent and a balance of cobalt-rich solid solution matrix comprising nickel, chromium, vanadium and tungsten.

Abstract: Methods of superalloy article repair are provided. In some embodiments, a method for repairing a nickel-based superalloy article comprises providing a layered assembly over a damaged region of the nickel-based superalloy article, the layered assembly comprising a nickel-based superalloy preform, an infiltration alloy preform and a melting point depressant component. The layered assembly is heated to form a nickel-based filler alloy metallurgically bonded to the damaged region, wherein primary carbide and secondary carbide phases are present in the nickel-based filler alloy in a combined amount of 0.5 to 10 vol. %.

Abstract: Powder alloy compositions and associated additive manufacturing techniques are described herein for production of sintered articles with microstructure and/or enhanced wear and corrosion resistance. In some embodiments, an article comprises sintered cobalt-based alloy having chromium carbide precipitates dispersed therein, the chromium carbide precipitates having an average size less than 4 ?m.

Abstract: Cobalt-based alloy compositions are described herein having properties compatible with thermal spray and sintering techniques. Such alloy compositions can provide claddings to a variety of metallic substrates having complex geometries, wherein the claddings exhibit desirable density, hardness, wear resistance and corrosion resistance. Briefly, an alloy composition described herein comprises 15-25 wt. % chromium, 15-20 wt. % molybdenum, 0-15 wt. % tungsten, 10-20 wt. % nickel, 2.5-3.5 wt. % boron, 2.5-4.5 wt. % silicon, 1-2 wt. % carbon and the balance cobalt, wherein a ratio of boron to silicon (B/Si) in the alloy composition ranges from 0.5 to 1.0.

Abstract: In one aspect, cobalt-based alloys are described herein comprising composition and microstructure permitting a balance of hardness, toughness and wear resistance desirable for wood cutting applications. A cobalt-based alloy comprises a chromium rich carbide phase in an amount of 15-30 volume percent, a tungsten-rich phase in an amount of 9-15 volume percent and a balance of cobalt-rich solid solution matrix comprising nickel, chromium, vanadium and tungsten.

Abstract: Methods of superalloy article repair are provided. In some embodiments, a method for repairing a nickel-based superalloy article comprises providing a layered assembly over a damaged region of the nickel-based superalloy article, the layered assembly comprising a nickel-based superalloy preform, an infiltration alloy preform and a melting point depressant component. The layered assembly is heated to form a nickel-based filler alloy metallurgically bonded to the damaged region, wherein primary carbide and secondary carbide phases are present in the nickel-based filler alloy in a combined amount of 0.5 to 10 vol. %.

Abstract: Cobalt-based alloy compositions are described herein having properties compatible with thermal spray and sintering techniques. Such alloy compositions can provide claddings to a variety of metallic substrates having complex geometries, wherein the claddings exhibit desirable density, hardness, wear resistance and corrosion resistance. Briefly, an alloy composition described herein comprises 15-25 wt. % chromium, 15-20 wt. % molybdenum, 0-15 wt. % tungsten, 10-20 wt. % nickel, 2.5-3.5 wt. % boron, 2.5-4.5 wt. % silicon, 1-2 wt. % carbon and the balance cobalt, wherein a ratio of boron to silicon (B/Si) in the alloy composition ranges from 0.5 to 1.0.

Abstract: A surgical implant component comprising an implant component body manufactured from a Co-based substrate alloy comprising Co, Cr, Mo, Si, and C, and a coating on a bone-ingrowth surface of the component body manufactured from a Co-based coating alloy comprising Co, Cr, Mo, Si, C and B. The coating is a network of fused particles of the Co-based coating alloy with spherical particles, irregular aspherical particles, and between about 35 and about 70 volume % porosity. A method of manufacturing the foregoing surgical implant component.

Abstract: A surgical implant component comprising an implant component body manufactured from a Co-based substrate alloy comprising Co, Cr, Mo, Si, and C, and a coating on a bone-ingrowth surface of the component body manufactured from a Co-based coating alloy comprising Co, Cr, Mo, Si, C and B. The coating is a network of fused particles of the Co-based coating alloy with spherical particles, irregular aspherical particles, and between about 35 and about 70 volume % porosity. A method of manufacturing the foregoing surgical implant component.

Abstract: A method for preparing an article is disclosed. The method comprises compacting a mixture of a first pre-alloyed powder and a lubricant to thereby form a green part having a green strength sufficient to permit mechanical handling; applying a slurry to a surface of the green part to thereby form a slurry coated green part, wherein the slurry comprises a second pre-alloyed powder, a binder, and a solvent; and heating the coated green part to a temperature below a solidus temperature of the first pre-alloyed powder and between a solidus temperature and a liquidus temperature of the second pre-alloyed powder to thereby solid state sinter the first pre-alloyed powder into a sintered core and to liquid state sinter the second pre-alloyed powder into a continuous alloy coating over the sintered core.

Abstract: A method of imparting high-temperature, degradation resistance to a component involving applying a metal slurry comprising a Co-based metallic composition comprising Co, Cr, W, Si, C, and B, a binder, and a solvent to a surface of the component, and sintering the Co-based metallic composition to form a substantially continuous Co-based alloy coating on the surface of the body.

Abstract: A method of imparting high-temperature, degradation resistance to a metallic component involving applying a metal slurry comprising a Co-based metallic composition containing Co, Cr, Mo, Si, and B, a binder, and a solvent to a surface of the component, and sintering the Co-based metallic composition to form a substantially continuous Co-based alloy coating on the surface of the body.

Abstract: A method for preparing a metal-based part, the method comprising applying a slurry to a surface of a temporary substrate to thereby form a slurry-coated temporary substrate, wherein the slurry comprises a Co-, Ni-, or Fe-based metal-based material, a binder, and a solvent; drying the slurry-coated temporary substrate to remove the solvent and to thereby form a coating layer having green strength; heating the coating layer to remove the binder; heating the coating layer to sinter the metal-based material into a continuous metal alloy layer; and separating the substrate from the coating layer. A powder metallurgy preform comprising a powder metallurgy green coating on a preform substrate.

Abstract: A method of imparting high-temperature, degradation resistance to a component associated with an internal combustion engine involving applying a metal slurry comprising a Co-based metallic composition, a binder, and a solvent to a surface of the component, and sintering the Co-based metallic composition to form a substantially continuous Co-based alloy coating on the surface of the body. An internal combustion engine component comprising a metallic substrate and a Co-based metallic coating thereon which has a thickness between about 100 and about 1000 microns.

Abstract: A method for preparing a metal-based part, the method comprising applying a slurry to a surface of a temporary substrate to thereby form a slurry-coated temporary substrate, wherein the slurry comprises a Co-, Ni-, or Fe-based metal-based material, a binder, and a solvent; drying the slurry-coated temporary substrate to remove the solvent and to thereby form a coating layer having green strength; heating the coating layer to remove the binder; heating the coating layer to sinter the metal-based material into a continuous metal alloy layer; and separating the substrate from the coating layer. A powder metallurgy preform comprising a powder metallurgy green coating on a preform substrate.

Abstract: A method for preparing an article is disclosed. The method comprises compacting a mixture of a first pre-alloyed powder and a lubricant to thereby form a green part having a green strength sufficient to permit mechanical handling; applying a slurry to a surface of the green part to thereby form a slurry coated green part, wherein the slurry comprises a second pre-alloyed powder, a binder, and a solvent; and heating the coated green part to a temperature below a solidus temperature of the first pre-alloyed powder and between a solidus temperature and a liquidus temperature of the second pre-alloyed powder to thereby solid state sinter the first pre-alloyed powder into a sintered core and to liquid state sinter the second pre-alloyed powder into a continuous alloy coating over the sintered core.

Abstract: A method of imparting high-temperature, degradation resistance to a component associated with an internal combustion engine involving applying a metal slurry comprising a Co-based metallic composition, a binder, and a solvent to a surface of the component, and sintering the Co-based metallic composition to form a substantially continuous Co-based alloy coating on the surface of the body. An internal combustion engine component comprising a metallic substrate and a Co-based metallic coating thereon which has a thickness between about 100 and about 1000 microns.