Wear resistant coatings containing precipitation-hardened alloy bodies and methods for the formation thereof

Abstract

Methods for producing a coated component are provided, as are coated components having wear resistant coatings. In embodiments, the method includes the step or process of fabricating, purchasing, or otherwise obtaining a component having a component surface. An XP alloy body is formed over the component surface to yield a coated component, wherein P is phosphorus and X is cobalt, nickel, or a combination thereof. After formation of the XP alloy body, the XP alloy body is machined; and, following machining, the coated component is heat treated to precipitate harden the XP alloy body. In certain embodiments, heat treatment may be conducted to concurrently anneal the underlying component in conjunction with precipitation hardening of the XP alloy body. In other instances, the method further includes the step of forming a barrier layer over the component surface prior to deposition of the XP alloy body.

What is claimed is: 
     
         1 . A method for producing a coated component, comprising:
 obtaining a component having a component surface;   forming an XP alloy body over the component surface to yield a coated component, wherein P is phosphorus and X is cobalt, nickel, or a combination thereof;   after forming the XP alloy body, machining the XP alloy body; and   after machining the XP alloy body, heat treating the coated component to precipitate harden the XP alloy body.   
     
     
         2 . The method of  claim 1  wherein heat treating comprises heat treating the coated component to anneal the component, while concurrently precipitate hardening the XP alloy body. 
     
     
         3 . The method of  claim 1  further comprising forming a barrier layer on the component surface prior to deposition of the XP alloy body, the barrier layer containing a greater amount of X than does the XP alloy body. 
     
     
         4 . The method of  claim 3  wherein the barrier layer consists essentially of X. 
     
     
         5 . The method of  claim 3  wherein depositing comprises electroplating the XP alloy body directly onto the barrier layer. 
     
     
         6 . The method of  claim 1  wherein the component comprises a mud rotor shaft having a lobed outer surface, and wherein machining comprises machining the mud rotor shaft to impart the lobed outer surface with an average roughness equal to or less than 1 micron. 
     
     
         7 . The method of  claim 1  further comprising formulating the XP alloy body to contain:
 a majority X, by weight; and 
 about 5% to about 25% P, by weight. 
 
     
     
         8 . The method of  claim 1  further comprising formulating the XP alloy body to consist essentially of:
 about 10% to about 15% P, by weight; and 
 the remainder X. 
 
     
     
         9 . The method of  claim 1  wherein the XP alloy body is formed by successively depositing at least a first XP alloy layer and a second XP alloy layer, and wherein the method further comprises:
 depositing the first XP alloy layer; 
 machining the first XP alloy layer to remove areas of nodular growth therefrom; and 
 after machining the first XP alloy layer, depositing a second XP alloy layer over the first XP alloy layer. 
 
     
     
         10 . The method of  claim 1  wherein the XP alloy body comprises opposing inner and outer surfaces, the inner surface located closer to the component than is the outer surface; and
 wherein forming comprises forming the XP alloy body to contain a first P content adjacent the inner surface and a second P content adjacent the outer surface, the second P content at least twice the first P content. 
 
     
     
         11 . The method of  claim 1  wherein forming the XP alloy body comprises:
 depositing an XP alloy layer over the component surface utilizing an electroplating process; and 
 increasing a current density during the electroplating process to increase the P content of the XP alloy body as the XP alloy body is compiled over the component surface. 
 
     
     
         12 . A method for producing a coated component, comprising:
 obtaining a component having a component surface; and   forming a precipitation-hardened alloy body over the component surface, forming comprising:
 electrodepositing at least one alloy layer in a pre-hardened state over the component surface to yield a coated component; 
 after electrodepositing, machining the at least one alloy layer in the pre-hardened state; and 
 heat treating the coated component to anneal the component, while precipitate hardening the at least one alloy layer to yield a precipitation-hardened alloy body having a hardness at least twice that of the one or more alloy layers in the pre-hardened state. 
   
     
     
         13 . The method of  claim 12  further comprising:
 prior to electrodepositing the at least one alloy layer, forming a barrier layer over the component surface; and 
 formulating the barrier layer to be less susceptible to precipitate hardening than is the at least one alloy layer. 
 
     
     
         14 . The method of  claim 13  further comprising:
 formulating the at least one alloy layer to be composed of an XP alloy, wherein P is phosphorus and X is cobalt, nickel, or a combination thereof; and 
 formulating the barrier layer to contain an increased amount of X and a decreased amount of P as compared to the at least one alloy layer. 
 
     
     
         15 . The method of  claim 12  wherein the one or more alloy layers comprise opposing inner and outer surfaces, the inner surface located closer to the component than is the outer surface; and
 wherein the method further comprises electrodepositing the at least one alloy layer to have a P content, which decreases when moving from the outer surface toward the inner surface. 
 
     
     
         16 . A coated component, comprising:
 a component having a component surface; and   a precipitation-hardened alloy body overlying the component surface, the precipitation-hardened layer composed of an XP alloy body wherein P is phosphorus and X is cobalt, nickel, or a combination thereof.   
     
     
         17 . The coated component of  claim 16  further comprising a barrier layer disposed between the component surface and the precipitation-hardened alloy body, the barrier layer containing X in a greater amount than does the XP alloy body. 
     
     
         18 . The coated component of  claim 16  wherein the XP alloy body comprises:
 a majority X, by weight; and 
 about 5% to about 25% P, by weight. 
 
     
     
         19 . The coated component of  claim 16  wherein the XP alloy body comprises:
 opposing inner and outer surfaces, the inner surface located closer to the component than is the outer surface; 
 a first P content adjacent the inner surface; and 
 a second P content adjacent the outer surface and at least twice the first P content. 
 
     
     
         20 . The coated component of  claim 16  wherein the coated component comprises a mud rotor shaft having a lobed outer surface, and wherein the lobed outer surface has an average surface roughness equal to or less than 1 micron.