US4626476A
Expired / Lapsed
US
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Wear and corrosion resistant coatings applied at high deposition rates
Assignee: Praxair ST Technology Inc
•
Filing: 1986-02-20
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Granted: 1986-12-02
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Expires: 2006-02-20
Abstract
Abstract A coating composition applied to a substrate by a thermal spray process which consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Inventors
- 👤 Calvin H. Londry
- 👤 Thomas A. Adler
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-05 20:44
CPC Classifications
C; C22; C22C; C22C29/00; C22C29/02; C22C29/06; C22C29/08; C23; C23C; C23C4/00; C23C4/04; C23C4/06; C23C4/067; Y; Y10; Y10T; Y10T428/00; Y10T428/31504; Y10T428/31678
Claims Analysis
Total Claims: 45
Claim 1
Independent Claim
47 words
A coating composition applied to a substrate by a thermal spray process which consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 2
Dependent Claim
47 words
A coating composition applied to a substrate by a thermal spray process which consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 3
Dependent Claim
45 words
A coated substrate having a coating composition according to claim 1 consisting essentially of from about 5.5 to about 7.5 weight percent cobalt, from about 5.5 to about 7.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 4
Dependent Claim
38 words
A coated substrate having a coating composition according to claim 1 having a mechanical strength sufficient to withstand an hydraulic pressure in excess of about 13,000 pounds per square inch at a coating thickness of about 0.0060 inch.
Claim 5
Dependent Claim
22 words
A coated substrate having a coating composition according to claim 1 having a hardness value in excess of 1000 DPH 300 .
Claim 6
Dependent Claim
60 words
A coated substrate having a coating composition according to claim 1 wherein the substrate is a metallic material selected from the group consisting of steel, stainless steel, iron base alloys, nickel, nickel base alloys, cobalt, cobalt base alloys, chromium, chromium base alloys, titanium, titanium base alloys, aluminum, aluminum base alloys, copper, copper base alloys, refractory metals, and refractory-metal base alloys.
Claim 7
Dependent Claim
28 words
A coated substrate having a coating composition according to claim 1 wherein the substrate is a non-metallic material selected from the group consisting of carbon, graphite and polymers.
Claim 8
Dependent Claim
40 words
A coated substrate having a coating composition according to claim 1 consisting essentially of about 8.0 to about 10.5 weight percent cobalt, about 5.0 to 8.0 weight percent chromium, about 3.0 to 4.0 weight percent carbon and the balance tungsten.
Claim 9
Dependent Claim
42 words
A coated substrate having a coating composition according to claim 1 consisting essentially of about 9.7 to about 10.1 weight percent cobalt, about 5.0 to about 5.3 weight percent chromium, about 3.4 to about 3.7 weight percent carbon and the balance tungsten.
Claim 10
Dependent Claim
53 words
An article comprising a substrate and a coating applied to said substrate by a thermal spray process, said coating consisting essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 11
Dependent Claim
53 words
An article comprising a substrate and a coating applied to said substrate by a thermal spray process, said coating consisting essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 12
Dependent Claim
43 words
An article according to claim 9 wherein said coating consists essentially of from about 5.5 to about 7.5 weight percent cobalt, from about 5.5 to about 7.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 13
Dependent Claim
119 words
An article comprising a substrate and a coating applied to said substrate by a D-Gun deposition process, wherein said coating consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten, and wherein said coating has a hardness value in excess of about 1000 DPH 300 , an average volume loss of about 1.0 mm 3 per 1000 revolutions when subjected to a standard dry sand/rubber wheel abrasion test and a mechanical strength sufficient to withstand an hydraulic pressure in excess of about 13,000 pounds per square inch at a coating thickness of about 0.006 inch.
Claim 14
Dependent Claim
119 words
An article comprising a substrate and a coating applied to said substrate by a D-Gun deposition process, wherein said coating consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten, and wherein said coating has a hardness value in excess of about 1000 DPH 300 , an average volume loss of about 1.0 mm 3 per 1000 revolutions when subjected to a standard dry sand/rubber wheel abrasion test and a mechanical strength sufficient to withstand an hydraulic pressure in excess of about 13,000 pounds per square inch at a coating thickness of about 0.006 inch.
Claim 15
Dependent Claim
24 words
An article according to claim 11 wherein the major phase of said coating comprises W 2 C and a minor phase comprises cubic WC.
Claim 16
Dependent Claim
119 words
An article comprising a substrate and a coating applied to said substrate by a plasma spray process, wherein said coating consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten, and wherein said coating has a hardness value in excess of about 775 DPH 300 , an average volume loss of about 6.7 mm 3 per 1000 revolutions when subjected to a standard dry sand/rubber wheel abrasion test and a mechanical strength sufficient to withstand an hydraulic pressure in excess of about 9,300 pounds per square inch at a coating thickness of about 0.006 inch.
Claim 17
Dependent Claim
119 words
An article comprising a substrate and a coating applied to said substrate by a plasma spray process, wherein said coating consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten, and wherein said coating has a hardness value in excess of about 775 DPH 300 , an average volume loss of about 6.7 mm 3 per 1000 revolutions when subjected to a standard dry sand/rubber wheel abrasion test and a mechanical strength sufficient to withstand an hydraulic pressure in excess of about 9,300 pounds per square inch at a coating thickness of about 0.006 inch.
Claim 18
Dependent Claim
24 words
An article according to claim 13 wherein the major phase of said coating comprises W 2 C and a minor phase comprises cubic WC.
Claim 19
Dependent Claim
56 words
A powdered coating composition for applying a high strength, wear and corrosion resistant coating onto a substrate by a thermal spray process consisting essentially of from about 8.0 to about 11.0 weight percent cobalt, from about 8.0 to about 11.0 weight percent chromium, from about 4.0 to about 5.5 weight percent carbon and the balance tungsten.
Claim 20
Dependent Claim
56 words
A powdered coating composition for applying a high strength, wear and corrosion resistant coating onto a substrate by a thermal spray process consisting essentially of from about 8.0 to about 11.0 weight percent cobalt, from about 8.0 to about 11.0 weight percent chromium, from about 4.0 to about 5.5 weight percent carbon and the balance tungsten.
Claim 21
Dependent Claim
14 words
A powdered coating composition according to claim 15 consisting of cast and crushed powder.
Claim 22
Dependent Claim
56 words
A powdered coating composition for applying a high strength, wear and corrosion resistant coating onto a substrate by a thermal spray process consisting essentially of from about 8.0 to about 12.0 weight percent cobalt, from about 6.0 to about 11.0 weight percent chromium, from about 2.5 to about 5.5 weight percent carbon and the balance tungsten.
Claim 23
Dependent Claim
56 words
A powdered coating composition for applying a high strength, wear and corrosion resistant coating onto a substrate by a thermal spray process consisting essentially of from about 8.0 to about 12.0 weight percent cobalt, from about 6.0 to about 11.0 weight percent chromium, from about 2.5 to about 5.5 weight percent carbon and the balance tungsten.
Claim 24
Dependent Claim
14 words
A powdered coating composition according to claim 17 consisting of cast and crushed powder.
Claim 25
Dependent Claim
121 words
In a method for coating a substrate wherein a powdered coating material is suspended within a high temperature, high velocity gaseous stream and heated to a temperature at least close to the melting point thereof, said gaseous stream being directed against a surface of said substrate to deposit said powdered coating material and form a coating thereon, the improvement for increasing the strength and wear resistance of said coating, said improvement comprising a powdered coating material having a composition such that the coating deposited onto said substrate consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 26
Dependent Claim
121 words
In a method for coating a substrate wherein a powdered coating material is suspended within a high temperature, high velocity gaseous stream and heated to a temperature at least close to the melting point thereof, said gaseous stream being directed against a surface of said substrate to deposit said powdered coating material and form a coating thereon, the improvement for increasing the strength and wear resistance of said coating, said improvement comprising a powdered coating material having a composition such that the coating deposited onto said substrate consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 27
Dependent Claim
56 words
A method according to claim 19 wherein the powdered coating material has a composition such that the coating deposited onto said substrate consists essentially of from about 5.5 to about 7.5 weight percent cobalt, from about 5.5 to about 7.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 28
Dependent Claim
51 words
A method according to claim 19 wherein the powdered coating material to be used has a composition consisting essentially of from about 8.0 to about 11.0 weight percent cobalt, from about 8.0 to about 11.0 weight percent chromium, from about 4.0 to about 5.5 weight percent carbon and the balance tungsten.
Claim 29
Independent Claim
120 words
A method for coating a substrate wherein a powdered coating material is suspended within a high temperature, high velocity gaseous stream and heated to a temperature at least close to the melting point thereof, said gaseous stream being directed against a surface of said substrate to deposit said powdered coating material and form a coating thereon, the improvement for increasing the strength and wear resistance of said coating, said improvement comprising a powdered coating material having a composition such that the coating deposited onto said substrate consists essentially of from about 8.0 to about 10.5 weight percent cobalt, from about 5.0 to about 8.0 weight percent chromium, from about 3.0 to about 4.0 weight percent carbon and the balance tungsten.
Claim 30
Independent Claim
120 words
A method for coating a substrate wherein a powdered coating material is suspended within a high temperature, high velocity gaseous stream and heated to a temperature at least close to the melting point thereof, said gaseous stream being directed against a surface of said substrate to deposit said powdered coating material and form a coating thereon, the improvement for increasing the strength and wear resistance of said coating, said improvement comprising a powdered coating material having a composition such that the coating deposited onto said substrate consists essentially of from about 8.0 to about 10.5 weight percent cobalt, from about 5.0 to about 8.0 weight percent chromium, from about 3.0 to about 4.0 weight percent carbon and the balance tungsten.
Claim 31
Dependent Claim
26 words
A method according to claim 22 wherein the powdered coating material is suspended within a high temperature, high velocity gaseous stream produced by plasma arc torch.
Claim 32
Dependent Claim
25 words
A method according to claim 22 wherein the powdered coating material has a composition which is substantially the same as the composition of said coating.
Claim 33
Dependent Claim
26 words
A method according to claim 22 wherein the powdered coating material is suspended within a high temperature, high velocity gaseous stream produced by a detonation device.
Claim 34
Dependent Claim
56 words
A method according to claim 22 wherein the powdered coating material has a composition such that the coating deposited onto said substrate consists essentially of from about 9.7 to about 10.1 weight percent cobalt, from about 5.0 to about 5.3 weight percent chromium, from about 3.4 to about 3.7 weight percent carbon and the balance tungsten.
Claim 35
Dependent Claim
46 words
A method according to claim 26 wherein the powdered coating to be used has a composition consisting essentially of from about 10.0 to about 12.0 weight percent cobalt, about 6.0 to 6.5 weight percent chromium, about 2.5 to 3.5 weight percent carbon and the balance tungsten.
Claim 36
Independent Claim
129 words
A method for coating a substrate comprising: feeding a mixture of oxygen and a fuel gas to the barrel of a detonation gun along with a powdered coating material; igniting the oxygen and fuel gas mixture to produce a detonation wave along said barrel which accelerates said powdered coating material in a high temperature, high velocity gaseous stream; and directing said gaseous stream against a surface of said substrate to deposit said powdered coating material and form a coating thereon, said powdered coating material having a composition such that the coating deposited onto said substrate consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 37
Independent Claim
129 words
A method for coating a substrate comprising: feeding a mixture of oxygen and a fuel gas to the barrel of a detonation gun along with a powdered coating material; igniting the oxygen and fuel gas mixture to produce a detonation wave along said barrel which accelerates said powdered coating material in a high temperature, high velocity gaseous stream; and directing said gaseous stream against a surface of said substrate to deposit said powdered coating material and form a coating thereon, said powdered coating material having a composition such that the coating deposited onto said substrate consists essentially of from about 4.0 to about 10.5 weight percent cobalt, from about 5.0 to about 11.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 38
Dependent Claim
56 words
A method according to claim 28 wherein the powdered coating material has a composition such that the coating deposited onto said substrate consists essentially of from about 5.5 to about 7.5 weight percent cobalt, from about 5.5 to about 7.5 weight percent chromium, from about 3.0 to about 5.0 weight percent carbon and the balance tungsten.
Claim 39
Dependent Claim
20 words
A method according to claim 28 wherein the ratio of oxygen to fuel gas in said mixture is approximately 1.0.
Claim 40
Dependent Claim
48 words
A method according to claim 30 wherein the powdered coating material has a composition consisting essentially of from about 8.0 to about 11.0 weight percent cobalt, from about 8.0 to about 11.0 weight percent chromium, from about 4.0 to about 5.5 weight percent carbon and the balance tungsten.
Claim 41
Independent Claim
129 words
A method for coating a substrate comprising: feeding a mixture of oxygen and a fuel gas to the barrel of a detonation gun along with a powdered coating material; igniting the oxygen and fuel gas mixture to produce a detonation wave along said barrel which accelerates said powdered coating material in a high temperature, high velocity gaseous stream; and directing said gaseous stream against a surface of said substrate to deposit said powdered coating material and form a coating thereon, said powdered coating material having a composition such that the coating deposited onto said substrate consists essentially of from about 8.0 to about 10.5 weight percent cobalt, from about 5.0 to about 8.0 weight percent chromium, from about 3.0 to about 4.0 weight percent carbon and the balance tungsten.
Claim 42
Independent Claim
129 words
A method for coating a substrate comprising: feeding a mixture of oxygen and a fuel gas to the barrel of a detonation gun along with a powdered coating material; igniting the oxygen and fuel gas mixture to produce a detonation wave along said barrel which accelerates said powdered coating material in a high temperature, high velocity gaseous stream; and directing said gaseous stream against a surface of said substrate to deposit said powdered coating material and form a coating thereon, said powdered coating material having a composition such that the coating deposited onto said substrate consists essentially of from about 8.0 to about 10.5 weight percent cobalt, from about 5.0 to about 8.0 weight percent chromium, from about 3.0 to about 4.0 weight percent carbon and the balance tungsten.
Claim 43
Dependent Claim
20 words
A method according to claim 32 wherein the ratio of oxygen to fuel gas in said mixture is approximately 1.0.
Claim 44
Dependent Claim
56 words
A method according to claim 32 wherein the powdered coating material has a composition such that the coating deposited onto said substrate consists essentially of from about 9.7 to about 10.1 weight percent cobalt, from about 5.0 to about 5.3 weight percent chromium, from about 3.4 to about 3.7 weight percent carbon and the balance tungsten.
Claim 45
Dependent Claim
48 words
A method according to claim 34 wherein the powdered coating material has a composition consisting essentially of from about 10.0 to about 12.0 weight percent cobalt, from about 6.0 to about 6.5 weight percent chromium, from about 2.5 to about 3.5 weight percent carbon and the balance tungsten.
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| 3.5 Years (Year 4) | 1989-12-01 | 1990-06-02 | 1990-12-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-12-01 | 1994-06-02 | 1994-12-02 | $3760.00 | Window Closed / Lapsed |
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