CA2486352A1 - Hard metallic materials, hard metallic coatings, methods of processing metallic materials and methods of producing metallic coatings - Google Patents

Hard metallic materials, hard metallic coatings, methods of processing metallic materials and methods of producing metallic coatings Download PDF

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CA2486352A1
CA2486352A1 CA002486352A CA2486352A CA2486352A1 CA 2486352 A1 CA2486352 A1 CA 2486352A1 CA 002486352 A CA002486352 A CA 002486352A CA 2486352 A CA2486352 A CA 2486352A CA 2486352 A1 CA2486352 A1 CA 2486352A1
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composition
elements
hardness
powder
wire
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CA2486352C (en
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Daniel J. Branagan
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Bechtel BWXT Idaho LLC
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F5/00Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product
    • B22F5/12Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of wires
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/56General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering characterised by the quenching agents
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/08Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools with one or more parts not made from powder
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00Making metallic powder or suspensions thereof
    • B22F9/002Making metallic powder or suspensions thereof amorphous or microcrystalline
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/22Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by the composition or nature of the material
    • B23K35/24Selection of soldering or welding materials proper
    • B23K35/30Selection of soldering or welding materials proper with the principal constituent melting at less than 1550 degrees C
    • B23K35/3053Fe as the principal constituent
    • B23K35/3093Fe as the principal constituent with other elements as next major constituents
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/68Temporary coatings or embedding materials applied before or during heat treatment
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/52Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C33/00Making ferrous alloys
    • C22C33/02Making ferrous alloys by powder metallurgy
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/18Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/22Ferrous alloys, e.g. steel alloys containing chromium with molybdenum or tungsten
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/18Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/32Ferrous alloys, e.g. steel alloys containing chromium with boron
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C45/00Amorphous alloys
    • C22C45/02Amorphous alloys with iron as the major constituent
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C30/00Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C4/00Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • C23C4/131Wire arc spraying
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2998/00Supplementary information concerning processes or compositions relating to powder metallurgy
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B22CASTING; POWDER METALLURGY
    • B22FWORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F2999/00Aspects linked to processes or compositions used in powder metallurgy
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23KSOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K9/00Arc welding or cutting
    • B23K9/04Welding for other purposes than joining, e.g. built-up welding
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2201/00Treatment for obtaining particular effects
    • C21D2201/03Amorphous or microcrystalline structure
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12014All metal or with adjacent metals having metal particles
    • Y10T428/12021All metal or with adjacent metals having metal particles having composition or density gradient or differential porosity
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12014All metal or with adjacent metals having metal particles
    • Y10T428/12028Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063Nonparticulate metal component
    • Y10T428/12097Nonparticulate component encloses particles

Abstract

The invention includes a method of producing a hard metallic material by forming a mixture containing at least 55% iron and at least one of B, C, Si and P. The mixture is formed into an alloy and cooled to form a metallic material having a hardness of greater than about 9.2 GPa. The invention includes a method of forming a wire by combining a metal strip and a powder. The strip and the powder are rolled to form a wire containing at least 55% iron and from 2-7 additional elements including at least one of C, Si and B. The invention also includes a method of forming a hardened surface on a substrate by processing a solid mass to form a powder, applying the powder t o a surface to form a layer containing metallic glass, and converting the glas s to a crystalline material having a nanocrystalline grain size.

Claims (52)

1. A method of producing a hard metallic material, comprising:
providing a mixture of elements, the mixture comprising at least about 55 percent Fe by weight, and at least one element selected from the group consisting of B, C, Si and P;
forming the mixture into an alloy; and cooling the alloy at a rate of less than about 5000 K per second to form a metallic material having a hardness of greater than about 9.2 GPa.
2. The method of claim 1 wherein the metallic material is in ingot form.
3. The method of claim 1 wherein the mixture comprises at least one transition metal selected from the group consisting of W, Mo, Cr and Mn.
4. The method of claim 1 wherein the mixture comprises one or more of Al and Gd.
5. The method of claim 1 wherein the mixture comprises at least two of B, C and Si.
6. The method of claim 1 wherein the mixture comprises B, C and Si at an atomic ratio of B17C5Si1.
7. The method of claim 1 wherein the mixture comprises a composition selected from the group consisting of Fe63B17C3Si3, (Fe0.8Cr0.2)79B17W2C2, Fe63B17C3Si5, Fe63B17C2W2, Fe63B17C8, Fe63B17C5, (Fe0.8Cr0.2)78Mo2W2B12C5Si1, Fe63B17C5W5, Fe63B17C5Si5, (Fe0.8Cr0.2)76Mo2W2B14C5Si1, (Fe0.8Cr0.2)73Mo2W2B16C4Si1Mn2, Fe63Cr8Mo2B17C5, (Fe0.8Cr0.2)76Mo2B17C6Si1, Fe63Cr81Mo2B17C5Si1/Al4, (Fe0.8Cr0.2)75W2B17C5Si1, Fe63B17C5Si1, (Fe0.8Cr0.2)73Mo2W2B17C5Si1, (Fe0.8Cr0.2)72Mo2W2B17C5Si1Gd1, (Fe0.8Cr0.2)71Mo2W2B17C5Si1Gd2, and (Fe0.8Cr0.2)74Mo2W2B17C4Si1.
8. The method of claim 1 wherein the alloy comprises a melting temperature of less than or equal to about 1550°C.
9. The method of claim 1 wherein the mixture consists essentially of fewer than 11 elements.
10. The method of claim 1 wherein the mixture consists essentially of fewer than 9 elements.
11. A metallic material comprising:
at least 55% Fe;
at least one of B, Si, P and C;
a total element composition consisting essentially of fewer than 11 elements;
a melting temperature between about 1100°C and about 1250.°C and a hardness of greater than about 9.2 GPa.
12. The metallic material of claim 11 wherein the material is a cast material.
13. The metallic material of claim 11 wherein the material is in ingot form.
14. The metallic material of claim 11 wherein the total element composition consists of fewer than 11 elements.
15. The metallic material of claim 11 comprising B, Si and C.
16. The metallic material of claim 11 wherein the total elemental composition consists essentially of fewer than 9 elements.
17. The metallic material of claim 11 comprising a composition selected from the group consisting of Fe63B17C3Si3, (Fe0.8Cr0.2)79B17W2C2, Fe63B17C3Si6, Fe63B17C2W2, Fe63B17C8, Fe63B17C5, (Fe0.8Cr0.2)78Mo2W2B12C5Si1, Fe63B17C5W5, Fe63B17C5Si5, (Fe0.8Cr0.2)76Mo2W2B14C5Si1, Fe0.8Cr0.2)73Mo2W2B16C4Si1Mn2, Fe63Cr8Mo2B17C5, (Fe0.8Cr0.2)75Mo2B17C5Si1, Fe63Cr8Mo2B17C5Si1AI4, (Fe0.8Cr0.2)75W2B17C5Si1, Fe63B17C5Si1, (Fe0.8Cr0.2)73Mo2W2B17C5Si1, (Fe0.8Cr0.2)72Mo2W2B17C5Si1Gd1, (Fe0.8Cr0.2)71Mo2W2B17C5Si1Gd2, and (Fe0.8Cr0.2)74Mo2W2B17C4Si1.
18. A method of forming a wire, comprising:
providing a metal strip having a first composition;
providing a powder comprising a second composition; and combining the first composition and the second composition by rolling the metal strip together with the powder to form a wire comprising a third composition, the third composition containing at least 55 weight percent Fe and from two to seven additional elements, the two to seven additional elements comprising at least two element selected from the group consisting of C, Si and B.
19. The method of claim 18 wherein the powder comprises a metallic glass.
20. The method of claim 18 wherein the third composition comprises at least one transition elements selected from the group consisting of W, Mo, Cr and Mn.
21. The method of claim 18 wherein the third composition comprises C, Si and B.
22. The method of claim 21 wherein the C, Si and B are present in the third composition at an atomic ratio of B17C5Si1.
23. The method of claim 18 wherein the third composition comprises at least one member selected from the group consisting of Fe63B17C3Si3, (Fe0.8Cr0.2)79B17W2C2, Fe63B17C3Si5, Fe63B17C2W2, Fe63B17C8, Fe63B17C5, (Fe0.8Cr0.2)78Mo2W2B12C5Si1, Fe63B17C5W5, Fe63B17C5Si5, (Fe0.8Cr0.2)76Mo2W2B14C5Si1,(Fe0.8Cr0.2)73Mo2W2B16C4Si1Mn2, Fe63Cr8Mo2B17C5, (Fe0.8Cr0.2)75Mo2B17C5Si1, Fe63Cr8Mo2B17C5Si1Al4, (Fe0.8Cr0.2)75W2B17C5Si1, Fe63B17C5Sil, (Fe0.8Cr0.2)73Mo2W2B17C5Si1, (Fe0.8Cr0.2)72Mo2W2B17C5Si1,Gd1, (Fe0.8Cr0.2)71Mo2W2B17C5Si1Gd2, and (Fe0.8Cr0.2)74Mo2W2B17C4Si1.
24. The method of claim 18 wherein the wire comprises a diameter of from about 0.035 inches to about 0.188 inches.
25. A wire comprising a total composition consisting essentially of fewer than 11 elements, the fewer than 11 elements comprising Fe and at least two elements selected from the group consisting of C, Si and B, the Fe present in the total composition being at least about 55% of the total composition by weight.
26 26. The wire of claim 25 further comprising:
a metal sheath comprising a first sub-composition; and a core comprising a powder having a second sub-composition, wherein the first sub-composition and the second sub-composition are collectively comprised by the total composition of the wire.
27. The wire of claim 26 wherein the powder comprises a metallic glass.
28. The wire of claim 25 wherein the total composition comprises a member selected from the group consisting of Fe63B17C3Si3, (Fe0.8Cr0.2)79B17W2C2, Fe63B17C3Si5, Fe63B17C2W2, Fe63B17C8, Fe63B17C5, (Fe0.8Cr0.2)78Mo2W2B12C5Si1, Fe63B17C5W5, Fe63B17C5Si5, (Fe0.8Cr0.2)76Mo2W2B14C5Si1, (Fe0.8Cr0.2)73Mo2W2B16C4Si1Mn2, Fe63Cr8Mo2B17C5, (Fe0.8Cr0.2)75Mo2B17C5Si1, Fe63Cr8Mo2B17C5Si1Al4, (Fe0.8Cr0.2)75W2B17C5Si1, Fe63B17C5Si1, (Fe0.8Cr0,2)73Mo2W2B17C5Si1, (Fe0.8Cr0.2)72Mo2W2B17C5Si1Gd1, (Fe0.8Cr0.2)71Mo2W2B17C5Si1Gd2, and (Fe0.8Cr0.2)74Mo2W2B17C4Si1.
29. A method of forming a hardened surface on a substrate, comprising:
providing a solid mass comprising a first hardness;
processing the solid mass to form a powder;
applying the powder to a surface of a substrate to form a layer having a second hardness, at least some of the layer comprising metallic glass; and converting at least some of the metallic glass to a crystalline material having a nanocrystalline grain size, the converting hardening the layer to form a hardened layer having a third hardness that is greater than the first hardness and greater than the second hardness.
30. The method of claim 29 wherein the solid mass comprises an ingot form.
31. The method of claim 29 wherein the powder comprises at least some amorphous structure.
32. The method of claim 29 wherein the converting comprises heating the layer to a temperature between about 600°C
and a melting temperature of the metallic glass.
33. The method of claim 29 wherein the solid mass comprises a first toughness, wherein the layer prior to the converting comprises a second toughness, and wherein the hardened layer comprises a third toughness, the second toughness and the third toughness each being equal to or greater than the first toughness.
34. The method of claim 29 wherein the solid mass comprises a composition of from 3 to 11 elements, the composition comprising at least about 55 percent iron by weight, and at least two of B, C and Si.
35. The method of claim 33 wherein the composition comprises fewer than nine elements.
36. The method of claim 33 wherein the composition comprises at least one transition metal.
37. The method of claim 29 wherein the layer is formed on the surface of a substrate in an absence of an interfacial layer.
38. The method of claim 29 wherein the solid mass comprises a composition selected from the group consisting of Fe63Mo2Si1, Fe63Cr8Mo2, Fe63Mo2Al4, (Fe0.8Cr0.2)81B17W2, (Fe0.8Mo0.2)83B17, Fe63B17Si1, Fe63Cr8Mo2C5, Fe63Mo2C5, Fe80Mo20, Fe63Cr8Mo2B17, Fe83B17, Fe63B17Si5, Fe63B17C2, Fe63B17C3Si3, (Fe0.8Cr0.2)79B17W2C2, Fe63B17C3Si5, Fe63B17C2W2, Fe63B17C8, Fe63B17C5, (Fe0.8Cr0.2)78Mo2W2B12C5Si1, Fe63B17C5W5, Fe63B17C5Si5, (Fe0.8Cr0.2)76Mo2W2B14C5Si1, (Fe0.8Cr0.2)73Mo2W2B16C4Si1Mn2, Fe63Cr8Mo2B17C5, (Fe0.8Cr0.2)75Mo2B17C5Si1, Fe63Cr8Mo2B17C5Si1Al4, (Fe0.8Cr0.2)75W2B17C6Si1, Fe63B17C5Si1, (Fe0.8Cr0.2)73Mo2W2B17C5Si1, (Fe0.8Cr0.2)72Mo2W2B17C5Si1Gd1, (Fe0.8Cr0.2)71Mo2W2B17C5Si1Gd2, and (Fe0.8Cr0.2)74Mo2W2B17C4Si1.
39. The method of claim 29 wherein the first hardness is at least about 9.2 GPa.
40. The method of claim 29 wherein the applying the powder to the surface comprises at least one of plasma spray thermal deposition, diamond jet thermal deposition and high-velocity oxy-fuel thermal deposition.
41. The method of claim 29 further comprising:
prior to the applying the powder to the surface, combining the powder with a metal strip to form a wire, the wire having a final composition comprising at least 55% iron by weight and at least one element selected from the group consisting of Si, C, P
and B; and wherein the applying the powder to the surface comprises at least one of twin-roll wire arc deposition, single-roll wire arc deposition and high-velocity wire arc deposition.
42. A method of protecting a surface, comprising:
providing a surface; and applying an initially-formed layer of a material on the surface, the material comprising at least 55% Fe by weight and fewer than additional elements, the fewer than 10 additional elements comprising at least two of B, C and Si, the initially-formed layer comprising an initial hardness of at least about 9.2 GPa, having a tensile elongation of from about 0.5% to about 60%.
43. The method of claim 41 wherein the surface is a metallic surface.
44. The method of claim 41 wherein the initially-formed layer comprises an amorphous structure.
45. The method of claim 41 further comprising:
converting the initially-formed layer into a hardened layer comprising an increased hardness, the increased hardness being greater than the initial hardness.
46. The method of claim 44 wherein the hardened layer comprisies a nanocomposite microstructure having a grain size of from about 75 nm to about 125 nm, and having second phase precipitates of about 20 nm at grain boundaries.
47. A hardfacing material comprising:
an Fe-based alloy comprising at least one of C, B and Si and comprising fewer than eleven elements; and at least some devitrified structure comprising a nanocrystalline grain size, the hardfacing material having a hardness of at least about 9.2 GPa, having a tensile elongation of from about 5% to about 180%.
48. A hardfacing material comprising an Fe-based alloy comprising at least one of C, B and Si and comprising fewer than eleven elements, the hardfacing material having at least some amorphous glass structure, having a hardness of at least about least about 9.2 GPa, having a tensile elongation of from about 0.5% to about 60%.
49. The hardfacing material of claim 47 wherein the Fe-based alloy comprises C, B and Si present in the alloy at an atomic ratio of B17C5Si1.
50. The hardfacing material of claim 47 wherein the Fe-based alloy comprises a composition selected from the group consisting of Fe63Mo2Si1, Fe63Cr8Mo2, Fe63Mo2Al4, (Fe0.8Cr0.2)81B17W2, (Fe0.8Mo0.2)83B17, Fe63B17Si1, Fe63Cr8Mo2C5, Fe63Mo2C5, Fe80Mo20, Fe63Cr8Mo2B17, Fe83B17, Fe63B17Si5, Fe63B17C2, Fe63B17C3Si3, (Fe0.8Cr0.2)79B17W2C2, Fe63B17C3Si5, Fe63B17C2W2, Fe63B17C8, Fe63B17C5, (Fe0.8Cr0.2)78Mo2W2B12C5Si1, Fe63B17C5W5, Fe63B17C5Si5, (Fe0.8Cr0.2)76Mo2W2B14C5Si1, (Fe0.8Cr0.2)73Mo2W2B16C4Si1Mn2, Fe63Cr8Mo2B17C5, (Fe0.8Cr0.2)75Mo2B17C5Si1, Fe63Cr8Mo2B17C5Si1Al4, (Fe0.8Cr0.2)75W2B17C5Si1, Fe63B17C5Si1, (Fe0.8Cr0.2)73Mo2W2B17C5Si1, (Fe0.8Cr0.2)72Mo2W2B17C5Si1Gd1, (Fe0.8Cr0.2)71Mo2W2B17C5Si1Gd2, and (Fe0.8Cr0.2)74Mo2W2B17C4Si1.
51. The hardfacing material of claim 47 comprising a porosity of less than or equal to about 5%.
52. The hardfacing material of claim 47 comprising a porosity of less than or equal to about 1%.
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