Multilayer overlays and methods for applying multilayer overlays

Abstract

A wear resistant multilayer overlay includes a first layer on at least a surface of an article, and a second layer metallurgically bonded to at least a portion of the first layer. The first layer includes a first continuous metallic matrix and at least one of first hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix, wherein the first hard particles are at least one of transition metal carbide particles and boron nitride particles. The second layer includes a second continuous metallic matrix and at least one of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts, embedded in the second continuous metallic matrix, wherein the second hard particles are at least one of transition metal carbide particles and boron nitride particles. Related methods and articles of manufacture also are disclosed.

I claim: 
     
         1 . A wear resistant multilayer overlay comprising:
 a first layer comprising a first continuous metallic matrix and at least one of first hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix, wherein the first hard particles are at least one of transition metal carbide particles and boron nitride particles; and   a second layer metallurgically bonded to at least a portion of the first layer, the second layer comprising a second continuous metallic matrix and at least one of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles and PCD compacts embedded in the second continuous metallic matrix, wherein the second hard particles are at least one of transition metal carbide particles and boron nitride particles.   
     
     
         2 . The wear resistant multilayer overlay of  claim 1 , wherein the first layer comprises blocky diamond particles embedded in the first continuous metallic matrix. 
     
     
         3 . The wear resistant multilayer overlay of  claim 1 , wherein the first metallic matrix and the second metallic matrix are metal alloys. 
     
     
         4 . The wear resistant multilayer overlay of  claim 3 , wherein the first metallic matrix and the second metallic matrix each individually comprise a material selected from a carbon steel, a stainless steel, and a nickel-chromium superalloy. 
     
     
         5 . The wear resistant multilayer overlay of  claim 1 , wherein the first hard particles and the second hard particles each individually comprise carbide particles of at least one of titanium, vanadium, chromium, manganese, iron, cobalt, nickel, copper, zinc, yttrium, zirconium, niobium, molybdenum, ruthenium, rhodium, palladium, silver, cadmium, hafnium, tantalum, and tungsten. 
     
     
         6 . The wear resistant multilayer overlay of  claim 1 , wherein the total concentration of first hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix is 25 to 85 volume percent based on the total volume of the first layer. 
     
     
         7 . The wear resistant multilayer overlay of  claim 1 , wherein the concentration of first hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix is 25 to 75 volume percent based on the total volume of the first layer. 
     
     
         8 . The wear resistant multilayer overlay of  claim 1 , wherein the concentration of first hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix is 25 to 60 volume percent based on the total volume of the first layer. 
     
     
         9 . The wear resistant multilayer overlay of  claim 6 , wherein the total concentration of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix is at least 30 volume percent based on the total volume of the first layer. 
     
     
         10 . The wear resistant multilayer overlay of  claim 1 , wherein the total concentration of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the second continuous metallic matrix is 10 to 85 volume percent based on the total volume of the second layer. 
     
     
         11 . The wear resistant multilayer overlay of  claim 1 , wherein the total concentration of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the second continuous metallic matrix is 10 to 50 volume percent based on the total volume of the second layer. 
     
     
         12 . The wear resistant multilayer overlay of  claim 1 , wherein the total concentration of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the second continuous metallic matrix is 25 to 50 volume percent based on the total volume of the second layer. 
     
     
         13 . The wear resistant multilayer overlay of  claim 2 , wherein the total concentration of blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix is up to 20 volume percent based on the total volume of the first layer. 
     
     
         14 . The wear resistant multilayer overlay of  claim 2 , wherein the total concentration of blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix is in the range of 0.5 to 20 volume percent based on the total volume of the first layer. 
     
     
         15 . The wear resistant multilayer overlay of  claim 1 , wherein at least 50 volume percent of the second hard particles embedded in the second continuous metallic matrix have a mesh size of −10 to +400. 
     
     
         16 . The wear resistant multilayer overlay of  claim 1 , wherein at least 50 volume percent of the second hard particles embedded in the second continuous metallic matrix have a mesh size of −30 to +400. 
     
     
         17 . The wear resistant multilayer overlay of  claim 1 , wherein at least 50 volume percent of the total volume of blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the second continuous metallic matrix has a size of −10 mesh to +0.01 micron in linear diameter. 
     
     
         18 . The wear resistant multilayer overlay of  claim 1 , wherein a thickness of the first layer is in the range of 3 to 15 mm. 
     
     
         19 . The wear resistant multilayer overlay of  claim 1 , wherein a thickness of the second layer is in the range of 3 to 8 mm. 
     
     
         20 . The wear resistant multilayer overlay of  claim 1  comprising:
 a first layer comprising a first continuous metallic matrix and at least one of first hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the first continuous metallic matrix, wherein
 the first hard particles are at least one of transition metal carbide particles and boron nitride particles, and 
 the total concentration of any first hard particles and blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts in the first layer is 25 to 85 volume percent based on the total volume of the first layer; and 
 
 a second layer metallurgically bonded to at least a portion of the first layer, the second layer comprising a second continuous metallic matrix, and at least one of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the second metallic matrix, wherein the second hard particles are at least one of transition metal carbide particles and boron nitride particles; and wherein
 at least 50 volume percent of the second hard particles embedded in the second continuous metallic matrix have a mesh size of −10 to +400, 
 at least 50 volume percent of the total volume of any uncoated blocky diamond particles, cubic boron nitride particles, and TSP diamond embedded in the second metallic matrix have a toughness index of at least 35, 
 the total concentration of second hard particles, blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the second layer is 10 to 50 volume percent based on the total volume of the second layer, 
 the total concentration of blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the second layer is 0.5 to 20 volume percent based on the total volume of the second layer, and 
 at least 50 volume percent of the total volume of blocky diamond particles, non-blocky diamond particles, TSP diamond, cubic boron nitride particles, and PCD compacts embedded in the second continuous metallic matrix has a size in the range of −10 mesh to 0.01 micron.