Abstract: A thermal spray material feedstock is provided for “flash-carbide” coatings. Flash carbide coatings are thin, dense, and smooth thermal spray coatings that self-activate the substrate. Flash-carbide coatings form and peen the coating to impart compressive stress for good adhesion and corrosion resistance. To achieve this combination of properties and performance, a powder that includes fine, dense, and angular particles is used; however, this powder alone results in a poor deposition efficiency of typically less than 20%. The present disclosure mitigates the poor deposition efficiency of this powder alone by providing a composition having two or more different particles at a specific ratio to improve deposition efficiency with sufficient optimized stress and corrosion properties and, in some cases, an increase in coating performance.

Abstract: The invention relates to a thermal spray powder on a tungsten carbide basis, as well as to a method for the manufacture of such a spray powder for the thermal coating of a substrate, in particular for the thermal coating of a brake disc for a vehicle. In accordance with the invention, the spray powder includes, apart from impurities, WC in the range of 60% to 75% by weight, Cr3C2 in the range of 14% to 22% by weight and Ni in the range of 11% to 23% by weight. The invention further relates to a sub-strate, in particular for a brake disc having a thermal spray layer on a tungsten carbide basis, as well as to a method for the manufacture of a thermal spray layer on a substrate.

Abstract: The invention relates to a thermal spray powder on a tungsten carbide basis, as well as to a method for the manufacture of such a spray powder for the thermal coating of a substrate, in particular for the thermal coating of a brake disc for a vehicle. In accordance with the invention, the spray powder includes, apart from impurities, WC in the range of 60% to 75% by weight, Cr3C2 in the range of 14% to 22% by weight and Ni in the range of 11% to 23% by weight. The invention further relates to a substrate, in particular for a brake disc having a thermal spray layer on a tungsten carbide basis, as well as to a method for the manufacture of a thermal spray layer on a substrate.