Wear resistant coating

Abstract

A wear resistant coating and a method of forming a wear resistant coating on a substrate. The method includes applying a plurality of round particles to the substrate, each of the plurality of round particles including a round outer layer encapsulating a wear resistant element. The method comprises applying a wear resistant coating binder to the substrate. The method includes heating the plurality of round particles and the wear resistant coating binder.

1 . A method of forming a wear resistant coating on a substrate, the method comprising the steps of:
 applying a plurality of round particles to the substrate, each of the plurality of round particles comprising a round outer layer encapsulating a wear resistant element;   applying a wear resistant coating binder to the substrate; and   heating the plurality of round particles and the wear resistant coating binder.   
     
     
         2 . A method defined by  claim 1 , further comprising the step of metallurgically bonding the wear resistant coating binder 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. 
     
     
         3 . A method defined by  claim 1 , wherein the wear resistant coating binder comprising metallic binding material and the metallic binding material is melted to form a monolithic matrix of metallic binding material. 
     
     
         4 . A method defined by  claim 3 , further comprising the step of the metallic binding material so melted penetrating the round outer layer of each of the plurality of round particles. 
     
     
         5 . A method defined by  claim 3 , wherein the wear resistant element of each of the plurality of round particles has a coating metallurgically bonded thereto and comprising the step of metallurgically bonding the coating of each of the plurality of round particles with the wear resistant coating binder. 
     
     
         6 . A method defined by  claim 1 , further comprising applying the plurality of round particles and a wear resistant coating binder to the substrate by introducing the plurality of round particles and the wear resistant coating binder into a plasma stream directed at the substrate, the plasma stream heating the wear resistant coating binder and the plurality of round particles. 
     
     
         7 . A method defined by  claim 6 , wherein the plasma stream heats the wear resistance coating binder to a temperature greater than at least one of a wear resistant coating binder softening temperature and a wear resistant coating binder melting temperature. 
     
     
         8 . A method defined by  claim 6 , further comprising the step of introducing a mixture comprising the plurality of round particles and the wear resistant coating binder into a plasma stream directed at the substrate. 
     
     
         9 . A method defined by  claim 6 , further comprising the step of introducing the plurality of round particles and the wear resistant coating binder separately into a plasma stream directed at the substrate. 
     
     
         10 . A method defined by  claim 1 , wherein the plurality of round particles and the wear resistant coating binder are deposited onto a melted portion of the substrate outside of a plasma stream that heated the melted portion, the melted portion of the substrate heating the plurality of round particles and the wear resistant coating binder. 
     
     
         11 . A method defined by  claim 10 , wherein the melted portion of the substrate heats the wear resistant coating binder to a temperature greater than at least one of a wear resistant coating binder softening temperature and a wear resistant coating binder melting temperature. 
     
     
         12 . A method defined by  claim 10 , wherein the plurality of round particles and the wear resistant coating binder are separated from the plasma stream by a separator. 
     
     
         13 . A method defined by  claim 10 , wherein the plasma stream is moved across a surface of the substrate and a source of the plurality of round particles and a source of the wear resistant coating binder follow the plasma stream. 
     
     
         14 . A method defined by  claim 10 , wherein the plasma stream is moved across a surface of the substrate and a source of the plurality of round particles and the wear resistant coating binder follow the plasma stream. 
     
     
         15 . A method defined by  claim 10 , further comprising the step of delivering a shielding gas around the plasma stream.