Wear resistant coating

Abstract

A brazing rod for forming a wear resistant coating on a substrate by a brazing process. The brazing rod includes a composite material having a plurality of round particles bound together by a binding material. Each of the plurality of round particles includes a round outer layer encapsulating a wear resistant element.

1 . A brazing rod for forming a wear resistant coating on a substrate by a brazing process, the brazing rod comprising a composite material comprising a plurality of round particles bound together by a binding material, each of the plurality of round particles comprising a round outer layer encapsulating a wear resistant element. 
     
     
         2 . A brazing rod defined by  claim 1 , wherein the binding material comprises a monolithic matrix of metallic binding material. 
     
     
         3 . A brazing rod defined by  claim 1 , wherein the binding material penetrates the round outer layer of each of the plurality of round particles. 
     
     
         4 . A brazing rod defined  claim 1 , wherein the wear resistant element of each of the plurality of round particles has a coating metallurgically bonded thereto, the coating being metallurgically bondable to the binding material. 
     
     
         5 . A brazing rod defined by  claim 1 , wherein the binding material is metallurgically bonded to at least one of an inner surface and an outer surface of the round outer layer of each of the plurality of round particles. 
     
     
         6 . A brazing rod defined by  claim 1 , wherein for each of the plurality of round particles the round outer layer has a density greater than that of the wear resistant element. 
     
     
         7 . A brazing rod defined by  claim 1 , wherein the wear resistant element of each of the plurality of round particles comprises a material having a Vickers hardness greater than at least one of 20 GPa and 40 GPa. 
     
     
         8 . A method for making a brazing rod for forming a wear resistant coating on a substrate by a brazing process, the method comprising the steps of:
 forming a mixture comprising a plurality of round particles, and a binding material for binding the plurality of round particles, wherein each of the plurality of round particles comprises a round outer layer encapsulating a wear resistant element;   configuring the mixture as a rod shape; and   binding the plurality of round particles with the binding material by heating the mixture configured as a rod shape.   
     
     
         9 . A method defined by  claim 8 , wherein the binding material comprises a metallic binding material and comprising the step of binding the plurality of round particles comprises the step of heating the mixture configured as a rod shape wherein the metallic binding material is melted to form a monolithic matrix of metallic binding material. 
     
     
         10 . A method defined by  claim 9 , further comprising the step of the metallic binding material so melted penetrating the round outer layer of each of the plurality of round particles. 
     
     
         11 . A method defined by  claim 8 , further comprising the step of metallurgically bonding the binding material to at least one of an inner surface and an outer surface of the round outer layer of each of the plurality of round particles. 
     
     
         12 . A method defined by  claim 9 , wherein the wear resistant element of each of the plurality of round particles has a coating metallurgically bonded thereto, the coating being metallurgically bondable to the wear resistant coating binder. 
     
     
         13 . A method defined by  claim 8 , wherein for each of the plurality of round particles the round outer layer has a density greater than that of the wear resistant element. 
     
     
         14 . A method defined by  claim 8 , wherein forming the mixture comprises including a fugitive binder in the mixture, the fugitive binder being removed from the mixture by the heating. 
     
     
         15 . A method defined by  claim 8 , wherein the wear resistant element of each of the plurality of round particles comprises a material having a Vickers hardness greater than at least one of 20 GPa and 40 GPa. 
     
     
         16 . A method defined by  claim 8 , wherein the step of configuring the mixture as a rod shape comprises at least one of the steps of, extruding the mixture, and using metal injection molding. 
     
     
         17 . A method defined by  claim 8 , wherein the step of configuring the mixture as a rod shape comprises the step of disposing the mixture in a mold configured for forming the brazing rod. 
     
     
         18 . A method of forming a wear resistant coating on a substrate, the method comprising the steps of:
 heating a brazing rod defined by  claim 1  to form a brazing rod melt; and   flowing the brazing rod melt over a surface of the substrate.   
     
     
         19 . A method defined by  claim 18 , wherein the wear resistant element of each of the plurality of round particles has a coating metallurgically bonded thereto, the coating being metallurgically bondable to the binding material. 
     
     
         20 . A method defined by  claim 19 , further comprising the step of the binding material penetrating the round outer layer of each of the plurality of round particles and forming a metallurgical bond with the coating. 
     
     
         21 . A wear resistant coating on a substrate, the wear resistant coating comprising:
 a composite material comprising a plurality of round particles bound together by a binding material, wherein each of the plurality of round particles comprises a round outer layer encapsulating a wear resistant element, the binding material penetrates the round outer layer and is metallurgically bonded to a coating metallurgically bonded to the wear resistant element of each of the plurality of particles, wherein the binding material is metallurgically bonded to at least one of a inner surface and a outer surface of the round outer layer of each of the plurality of round particles.