Deposition System, Method And Materials For Composite Coatings

Abstract

A composite powder for a deposition of a composite coating comprises a nonmetallic component and a metallic component, the metallic component having an amorphous structure or a nanocrystalline structure. The metallic component may include an amorphous metallic alloy. The metallic alloy may include constituents having the amorphous structure. The metallic component may include a combination of the metallic alloy existing in the amorphous state and constituents of the amorphous metallic alloy in the amorphous state. The composite metal-ceramic powders are used for depositing composite coatings on a selected surface. Disclosed are several methods and systems for producing such composite powders. Disclosed are also several methods and systems for depositing composite coatings. Advantageously, the deposited coatings exhibit high corrosion resistance, high wear resistance, and excellent structural properties.

1 . A sprayed composite coating comprising:
 a nonmetallic component, present in the range of about 40-84% by weight, wherein said nonmetallic component is selected from the group consisting of carbides, borides, nitrides, carbonitrides, oxides, oxycarbonitrides or a combination thereof and has a particle size of more than 0.2 microns; and   an amorphous component comprising an alloy including Fe, Co, Cu, or Ni, wherein said amorphous component has less than about 50% crystallinity; and   wherein at least some of the particles of said amorphous component are in a form of a plurality of splats of particles extended perpendicular to the spray direction.   
     
     
         2 . The composite coating of  claim 1 , further comprising a third metallic component. 
     
     
         3 . The composite coating of  claim 2  wherein said third metallic component comprises a crystalline metal comprising Co, Ni, Cr or combination thereof. 
     
     
         4 . The composite coating of  claim 2  wherein said nonmetallic component is imbedded in said third metallic component. 
     
     
         5 . The composite coating of  claim 1  wherein said nonmetallic component is imbedded in said amorphous component. 
     
     
         6 . The composite coating of  claim 2 , wherein said third metallic component is less than about 50% by volume of the total metallic phase. 
     
     
         7 . The composite coating of  claim 4 , wherein particles of said third metallic component imbedded with said nonmetallic component are in a form of a plurality of splats of particles extended perpendicular to the spray direction comprising third metallic component with imbedded particles of said nonmetallic component. 
     
     
         8 . The composite coating of  claim 1 , wherein said amorphous component alloy further comprises a transition metal selected from the group consisting of Mo, Cr, W or combinations thereof present at about 43% by weight or less. 
     
     
         9 . The composite coating of  claim 1 , wherein said amorphous component alloy further comprises an element selected from the group consisting of C, Si, B, Mn or combinations thereof present at about 14% by weight or less. 
     
     
         10 . A method for spraying a composite coating comprising:
 supplying a nonmetallic component, present in the range of about 40-84% by weight, wherein said nonmetallic component is selected from the group consisting of carbides, borides, nitrides, carbonitrides, oxides, oxycarbonitrides or a combination thereof and has a particle size of more than 0.2 microns;   supplying an amorphous component comprising an alloy including Fe, Co, Cu, or Ni, wherein said amorphous component has less than about 50% crystallinity;   wherein particles of said nonmetallic and said amorphous components are mixed together to provide a powder having particle size in the range of about 15 to 160 microns;   forming said composite coating from said nonmetallic component and amorphous component wherein at least some of the particles of said amorphous component are in a form of a plurality of splats of particles extended perpendicular to the spray direction.   
     
     
         11 . The method of  claim 10 , further comprising a third metallic component. 
     
     
         12 . The method of  claim 11  wherein said third metallic component comprises a crystalline metal comprising Co, Ni, Cr or combination thereof. 
     
     
         13 . The method of  claim 11  wherein said nonmetallic component is imbedded in said third metallic component. 
     
     
         14 . The method of  claim 10  wherein said nonmetallic component is imbedded in said amorphous component. 
     
     
         15 . The method of  claim 11 , wherein said third metallic component is less than about 50% by volume of the total metallic phase. 
     
     
         16 . The method of  claim 13 , wherein particles of said third metallic component imbedded with said nonmetallic component are in a form of a plurality of splats of particles extended perpendicular to the spray direction comprising third metallic component with imbedded particles of said nonmetallic component. 
     
     
         17 . The method of  claim 10 , wherein said amorphous component alloy further comprises a transition metal selected from the group consisting of Mo, Cr, W or combinations thereof present at about 43% by weight or less. 
     
     
         18 . The method of  claim 10 , wherein said amorphous component alloy further comprises an element selected from the group consisting of C, Si, B, Mn or combinations thereof present at about 14% by weight or less.