Composite wires for coating substrates and methods of use

Abstract

A composite wire utilized in connection with forming a resistant coating on a substrate includes a metallic outer sheath and an inner core, the inner core having a total fill weight above 15% total composite wire weight and including less than less 35% by weight of boron carbide in the inner core, and method of making the same.

What is claimed is: 
     
         1 . A method of forming a resistant coating on a substrate, the method comprising the steps of:
 providing a wire having a metallic outer sheath and an inner core;   effecting a total fill weight of the inner core to be above 15% total composite wire weight;   including less than 35% by weight of boron carbide in the inner core;   melting the wire to form a melt; and   atomizing and spraying the melt onto a substrate.   
     
     
         2 . The method of  claim 1 , wherein:
 the melt comprises the metal of the sheath and material in the inner core.   
     
     
         3 . The method of  claim 1 , the method further comprising the step of:
 forming the outer sheath of an essentially pure metal.   
     
     
         4 . The method of  claim 1 , the method further comprising the step of:
 forming the outer sheath from an alloy comprising a base metal.   
     
     
         5 . The method of  claim 4 , the method further comprising the step of:
 selecting the base metal of the alloy from the group consisting of iron, nickel, aluminum, molybdenum, tantalum, copper, cobalt, and titanium.   
     
     
         6 . The method of  claim 4 , the method further comprising the step of:
 forming the alloy to be an iron base alloy.   
     
     
         7 . The method of  claim 6 , the method further comprising the step of:
 forming the iron base alloy to further comprise chromium.   
     
     
         8 . The method of  claim 7 , the method further comprising the step of:
 forming the iron base alloy to have at least about 40% by weight of iron.   
     
     
         9 . The method of  claim 1 , the method further comprising the step of:
 forming the inner core to include chrome carbide.   
     
     
         10 . The method of  claim 9 , the method further comprising the step of:
 forming the inner core to exhibit a ratio of the chrome carbide to the boron carbide to be between about 1:4 to 4:1.   
     
     
         11 . The method of  claim 9 , the method further comprising the step of:
 forming the inner core further to comprises another carbide in addition to boron carbide and chrome carbide.   
     
     
         12 . The method of  claim 1 , the method further comprising the step of:
 forming the inner core to include at least one carbide selected from the group consisting of tungsten carbide, vanadium carbide and titanium carbide.   
     
     
         13 . A method of forming a resistant coating on a substrate, the method comprising the steps of:
 providing a wire having a metallic outer sheath and an inner core;   effecting a total fill weight of the inner core to be between 15% and 50% total composite wire weight;   including less than 35% by weight of boron carbide in the inner core;   melting the wire to form a melt; and   atomizing and spraying the melt onto a substrate.   
     
     
         14 . The method of  claim 13 , wherein the inner core includes a metal powder. 
     
     
         15 . The method of  claim 13 , wherein the inner core includes a composite powder. 
     
     
         16 . A composite wire utilized in connection with forming a resistant coating on a substrate comprising:
 a metallic outer sheath and an inner core, the inner core having a total fill weight above 15% total composite wire weight; and   wherein the inner core includes less than 35% by weight of boron carbide.   
     
     
         17 . The composite wire of  claim 16  wherein the inner core has a total fill weight to be between 15% and 50% total composite wire weight. 
     
     
         18 . The composite wire of  claim 16 , wherein the inner core includes a metal powder. 
     
     
         19 . The composite wire of  claim 16 , wherein the inner core includes a composite powder. 
     
     
         20 . A composite wire utilized in connection with forming a resistant coating on a substrate comprising:
 a metallic outer sheath and an inner core, the inner core having a total fill weight up to about 70%, and the outer sheath including one of an iron and an iron alloy;   wherein the inner core includes less than 35% by weight of boron carbide;   wherein the inner core further includes chrome carbide; and   wherein the chrome carbide and the boron carbide are present in the inner core in approximately equal weights.