Self-organized metal alloys for wear applications

Abstract

A two-phase metallic alloy comprising precipitates of Ag possessing a volume-averaged diameter of less than about 500 nm dispersed in a matrix selected from the group consisting of Ni, Fe, combinations of Ni with Cu and combinations of Fe with Cu.

We claim: 
     
         1 . A two-phase metallic alloy comprising precipitates of Ag possessing a volume-averaged diameter of less than about 500 nm dispersed in a matrix selected from the group consisting of Ni, Fe, combinations of Ni with Cu and combinations of Fe with Cu. 
     
     
         2 . The two-phase metallic alloy of  claim 1  wherein the precipitates of Ag are immiscible in the matrix. 
     
     
         3 . The alloy of  claim 1  wherein the matrix is Ni. 
     
     
         4 . The alloy of  claim 3  wherein the Ag precipitates possess a volume-averaged diameter of from 100 to 400 nm. 
     
     
         5 . The alloy of  claim 4  wherein the Ag precipitates possess a volume-averaged diameter of from 100 to 300 nm. 
     
     
         6 . The alloy of  claim 3  wherein Ag is present in an amount ranging from about 5 to about 20 atomic percent and Ni is present in the alloy in an amount ranging from about 50 to about 95 atomic percent. 
     
     
         7 . The alloy of  claim 3  wherein the matrix further comprises Cu. 
     
     
         8 . The alloy of  claim 7  wherein Ag is present in an amount ranging from about 5 to about 20 atomic percent, Ni is present in an amount ranging from about 50 to about 90 atomic percent and Cu is present in an amount ranging from about 5 to about 45 atomic percent. 
     
     
         9 . The alloy of  claim 1  wherein the matrix is Fe. 
     
     
         10 . The alloy of  claim 9  wherein the Ag precipitates possess a volume-averaged diameter of from 100 to 400 nm. 
     
     
         11 . The alloy of  claim 10  wherein the Ag precipitates possess a volume-averaged diameter of from 100 to 300 nm. 
     
     
         12 . The alloy of  claim 9  wherein Ag is present in the alloy in an amount ranging from about 5 to about 20 atomic percent and Ni is present in the alloy in an amount ranging from about 5 to about 20. 
     
     
         13 . The alloy of  claim 9  wherein the matrix further comprises Cu. 
     
     
         14 . The alloy of  claim 13  wherein Ag is present in an amount ranging from about 5 to about 20 atomic percent, Fe is present in an amount ranging from about 50 to about 90 atomic percent and Cu is present in an amount ranging from about 5 to about 45 atomic percent. 
     
     
         15 . A method of making a two-phase metallic alloy, comprising providing a powder mixture selected from the group consisting of powder mixtures of Ag and Ni; Ag and Fe; Ag, Ni and Cu; and Ag, Fe and Cu; subjecting the powder mixture to high-energy ball milling to provide a nanocomposite; compressing the nanocomposite to provide a solid form; and optionally, annealing the solid form to provide a two-phase metallic alloy comprising precipitates of Ag possessing an average size of less than about 500 nm. 
     
     
         16 . The method of  claim 15  wherein the two-phase metallic alloy comprises a wear surface and chemical nanolayering below the wear surface. 
     
     
         17 . The method of  claim 15  wherein the powder mixture is Ag and Ni. 
     
     
         18 . The method of  claim 17  wherein the powder mixture of Ag and Ni has an atomic formula of Ni 90 Ag 10  or Ni 80 Ag 20 . 
     
     
         19 . The method of  claim 15  wherein the powder mixture is Ag and Fe. 
     
     
         20 . The method of  claim 15  wherein the powder mixture is Ag, Ni and Cu. 
     
     
         21 . The method of  claim 15  wherein the powder mixture is Ag, Fe and Cu. 
     
     
         22 . The method of  claim 21  wherein the powder mixture of Ag, Fe and Cu has an atomic formula of Ni 80 Cu 10 Ag 10  or Ni 45 Cu 45 Ag 10 . 
     
     
         23 . An article comprising the alloy of  claim 1 . 
     
     
         24 . A substrate coated with the alloy of  claim 1 . 
     
     
         25 . A method comprising coating a substrate with the alloy of  claim 1 . 
     
     
         26 . A two-phase metallic alloy comprising precipitates of Ag possessing a volume-averaged diameter of less than about 500 nm dispersed in a matrix selected from at least one of W, Mo, Cr, Ni, C, Al, Ti, Cu, Fe, Mn, S, Si, N, Co, and Nb, wherein at least one of Ni or Fe is present in an amount of at least 35 atomic percent on the basis of the metallic alloy. 
     
     
         27 . The two-phase metallic alloy of  claim 26  wherein the matrix is selected from at least one of W, Mo, Cr, Ni, C, Al, Ti, Cu, Fe, Mn, S, Si, N, Co, and Nb. 
     
     
         28 . The two-phase metallic alloy of  claim 26  wherein the matrix is selected from at least one of W, Mo, Cr, Ni, C, Al, Ti, Fe, Mn, S, Si, N, Co, and Nb. 
     
     
         29 . The two-phase metallic alloy of  claim 28  wherein the matrix is selected from at least one of Ni, Fe, Cr, Mo, Ti, and W. 
     
     
         30 . The two-phase metallic alloy of  claim 29  wherein the matrix is selected from at least one of Ni and Fe. 
     
     
         31 . The two-phase metallic alloy of  claim 26  wherein the matrix is selected from Incoloy® Alloy 330, Incoloy® Alloy 800, Incoloy® Alloy 800H, Incoloy® Alloy 800HT, Incoloy® Alloy 803, Incoloy® Alloy 840, Incoloy® Alloy 890, Inconel® Alloy 600, Inconel® Alloy 601, Inconel® Alloy 617, Nickel 200, Nickel 201, Duranickel® Alloy 301, Monel® Alloy 400, Monel® Alloy R-405, Monel® Alloy K-500, Inconel® Alloy 800, Inconel® Alloy 22, Inconel® Alloy 625, Inconel® Alloy 625SLCF®, Inconel® Alloy 686, Inconel® Alloy 690, Inconel® Alloy C-276, Inconel® Alloy G-3, Incoloy® Alloy 800, Incoloy® Alloy 825, Incoloy® Alloy 864, Incoloy® Alloy 20, or Incoloy® Alloy 25-6HN. 
     
     
         32 . The two-phase metallic alloy of  claim 28  wherein the matrix is selected from Incoloy® Alloy 330, Incoloy® Alloy 800, Incoloy® Alloy 800H, Incoloy® Alloy 800HT, Incoloy® Alloy 803, Incoloy® Alloy 840, Incoloy® Alloy 890, Inconel® Alloy 600, Inconel® Alloy 601, Inconel® Alloy 617, Nickel 200, Nickel 201, Duranickel® Alloy 301, Inconel® Alloy 800, Inconel® Alloy 22, Inconel® Alloy 625, Inconel® Alloy 625SLCF®, Inconel® Alloy 686, Inconel® Alloy 690, Inconel® Alloy C-276, Incoloy® Alloy 800, Incoloy® Alloy 864.