Reduced carbides ferrous alloys

Abstract

Disclosed herein are embodiments of wear resistant alloys, such as ferrous alloys, that can have reduced carbide contents. In some embodiments, the alloys may have no carbides. In some, the alloy may have boride phases, such as phases having high Mo+W content and/or high Fe+Cr content. There can be reduced hardphases levels out of the specifically disclosed boride phases in some embodiments. In some embodiments, hypereutectic chromium borides can have limited incorporation into the disclosed alloys.

1 . A feedstock material configured to form a microstructure comprising:
 Fe;   B: about 1 wt. % to about 3.6 wt. %;   C: greater than 0 wt. % and up to about 0.5 wt. %;   Cr: about 2 wt. % to about 15 wt. %;   Mo: about 4 wt. % to about 15 wt. %;   Ni: greater than 0 wt. % and up to about 3 wt. %;   Mn: greater than 0 wt. % and up to about 3 wt. %; and   Si: greater than 0 wt. % and up to about 2 wt. %;   wherein the feedstock material is configured to form the microstructure comprising a martensitic matrix characterized by having, under thermodynamic equilibrium conditions:   a mole fraction of complex borides comprising ≥30 wt. % Mo+W, wherein the mole fraction of the complex borides is between about 0.05 and about 0.50;   a mole fraction of chromium borides comprising ≥50 wt. % Fe+Cr, wherein the mole fraction of the chromium borides is between about 0.05 and about 0.50; and   a mole fraction of hard phases other than the complex borides and the chromium borides of less than about 0.10.   
     
     
         2 . The feedstock material of  claim 1 , wherein C is about 0.05 wt. % to about 0.5 wt. %. 
     
     
         3 . (canceled) 
     
     
         4 . (canceled) 
     
     
         5 . The feedstock material  claim 1 , wherein the feedstock material is configured to form the martensitic matrix comprising a mole fraction of hypereutectic hard phases of less than about 0.10. 
     
     
         6 . (canceled) 
     
     
         7 . The feedstock material of  claim 1 , wherein the feedstock material is configured to form the martensitic matrix comprising a mole fraction of all hard phases of between about 0.05 and about 0.50. 
     
     
         8 . (canceled) 
     
     
         9 . (canceled) 
     
     
         10 . The feedstock material of  claim 1 , wherein the feedstock material is configured to form the martensitic matrix comprising a mole fraction of primary carbides of less than about 0.01%. 
     
     
         11 . The feedstock material of  claim 1 , wherein the mole fraction of hard phases other than the complex borides and the chromium borides is less than about 0.01. 
     
     
         12 . The feedstock material of  claim 1 , wherein the feedstock material is configured to form the martensitic matrix which comprises Fe and a combination of elements selected from the group consisting of, in wt. %:
 B: 2.6, C: 0.2, Cr: 10, Mo: 7;   B: 2.6, Cr: 8, Mo: 7;   B: 2.6, Cr: 8, Mo: 10;   B: 2.6, Cr: 6, Mo: 10;   B: 2.6, Cr: 4, Mo: 10;   B: 2.6, Cr: 2, Mo: 10;   B: 3.4, Cr: 5, Mo: 14;   B: 2.8, C: 0.2, Cr: 8, Mo: 7, Mn: 1, Si: 0.5;   B: 3, C: 0.2, Cr: 6, Mo: 9, Mn: 1, Si: 0.5;   B: 3, C: 0.2, Cr: 8, Mo: 7;   B: 3, C: 0.2, Cr: 8.7, Mo: 8.3;   B: 3.4, C: 0.25, Cr: 9.7, Mo: 9.4;   B: 2.8, C: 0.5, Cr: 8, Mo: 7, Mn: 1, Si: 0.5;   B: 3, C: 0.5, Cr: 6, Mo: 9, Mn: 1, Si: 0.5;   B: 3, C: 0.5, Cr: 8, Mo: 7;   B: 3, C: 0.5, Cr: 8.7, Mo: 8.3;   B: 3.2, C: 0.5, Cr: 8.7, Mo: 8.3; and   B: 3.4, C: 0.5, Cr: 9.7, Mo: 9.4.   
     
     
         13 . (canceled) 
     
     
         14 . The feedstock material of  claim 1 , wherein the feedstock material is a powder. 
     
     
         15 . (canceled) 
     
     
         16 . (canceled) 
     
     
         17 . (canceled) 
     
     
         18 . (canceled) 
     
     
         19 . (canceled) 
     
     
         20 . (canceled) 
     
     
         21 . (canceled) 
     
     
         22 . (canceled) 
     
     
         23 . (canceled) 
     
     
         24 . (canceled) 
     
     
         25 . (canceled) 
     
     
         26 . (canceled) 
     
     
         27 . (canceled) 
     
     
         28 . A method of forming a hardfacing coating onto a substrate, the method comprising:
 applying a feedstock material to the substrate to form the coating, the coating comprising:
 Fe; 
 B: about 1 wt. % to about 3.6 wt. %; 
 C: greater than 0 wt. % and up to about 0.5 wt. %; 
 Cr: about 2 wt. % to about 15 wt. %; 
 Mo: about 4 wt. % to about 15 wt. %; 
 Ni: greater than 0 wt. % and up to about 3 wt. %; 
 Mn: greater than 0 wt. % and up to about 3 wt. %; and 
 Si: greater than 0 wt. % and up to about 2 wt. %; 
 wherein the feedstock material is configured to form a martensitic matrix which is characterized by having, under thermodynamic equilibrium conditions: 
 a mole fraction of complex borides comprising ≥30 wt. % Mo+W, wherein the mole fraction of the complex borides is between about 0.05 and about 0.50; 
 a mole fraction of chromium borides comprising ≥50 wt. % Fe+Cr, wherein the mole fraction of the chromium borides is between about 0.05 and about 0.50; and 
 a mole fraction of hard phases other than the complex borides and the chromium borides of less than about 0.10. 
   
     
     
         29 . The method of  claim 28 , wherein C is about 0.05 wt. % to about 0.5 wt. %. 
     
     
         30 . The method of  claim 28 , wherein the applying comprises applying a thermal spray. 
     
     
         31 . The method of  claim 28 , wherein the applying comprises applying using a bulk welding process. 
     
     
         32 . The method of  claim 28 , wherein the substrate is a wear plate. 
     
     
         33 . A wear-resistant dual-boride metallic coating comprising:
 Fe;   B: about 1 wt. % to about 3.6 wt. %;   C: greater than 0 wt. % and up to about 0.5 wt. %;   Cr: about 2 wt. % to about 15 wt. %;   Mo: about 4 wt. % to about 15 wt. %;   Ni: greater than 0 wt. % and up to about 3 wt. %;   Mn: greater than 0 wt. % and up to about 3 wt. %;   Si: greater than 0 wt. % and up to about 2 wt. %;   a martensitic matrix;   a volume fraction of complex borides comprising ≥30 wt. % Mo+W, wherein the volume fraction of the complex borides is between about 0.05 and about 0.50;   a volume fraction of chromium borides comprising ≥50 wt. % Fe+Cr, wherein the volume fraction of the chromium borides is between about 0.05 and about 0.50; and   a volume fraction of hard phases other than the complex borides and the chromium borides of less than about 0.10.   
     
     
         34 . The coating of  claim 33 , wherein C is about 0.05 wt. % to about 0.5 wt. %. 
     
     
         35 . (canceled) 
     
     
         36 . (canceled) 
     
     
         37 . The coating of  claim 33 , further comprising a volume fraction of hypereutectic hard phases is less than about 0.10. 
     
     
         38 . (canceled) 
     
     
         39 . The coating of  claim 33 , wherein a volume fraction of all hard phases is between about 0.05 and about 0.50. 
     
     
         40 . (canceled) 
     
     
         41 . (canceled) 
     
     
         42 . The coating of  claim 33 , further comprising a volume fraction of primary carbides of less than about 0.01. 
     
     
         43 . The coating of  claim 33 , further comprising a weight percent of carbon in the martensitic matrix is greater than of between about 0 and up to about 0.45 wt. %. 
     
     
         44 . (canceled) 
     
     
         45 . The coating of  claim 33 , wherein the volume fraction of hard phases other than the complex borides and the chromium borides is less than about 0.01. 
     
     
         46 . The coating of  claim 33 , wherein a percent of chromium in the martensitic matrix is between 5 wt. % and 12 wt. %. 
     
     
         47 . The coating of any one of  claim 33 , wherein the coating comprises a combination of elements selected from the group consisting of, in wt. %:
 B: 2.6, C: 0.2, Cr: 10, Mo: 7;   B: 2.6, Cr: 8, Mo: 7;   B: 2.6, Cr: 8, Mo: 10;   B: 2.6, Cr: 6, Mo: 10;   B: 2.6, Cr: 4, Mo: 10;   B: 2.6, Cr: 2, Mo: 10;   B: 3.4, Cr: 5, Mo: 14;   B: 2.8, C: 0.2, Cr: 8, Mo: 7, Mn: 1, Si: 0.5;   B: 3, C: 0.2, Cr: 6, Mo: 9, Mn: 1, Si: 0.5;   B: 3, C: 0.2, Cr: 8, Mo: 7;   B: 3, C: 0.2, Cr: 8.7, Mo: 8.3;   B: 3.4, C: 0.25, Cr: 9.7, Mo: 9.4;   B: 2.8, C: 0.5, Cr: 8, Mo: 7, Mn: 1, Si: 0.5;   B: 3, C: 0.5, Cr: 6, Mo: 9, Mn: 1, Si: 0.5;   B: 3, C: 0.5, Cr: 8, Mo: 7;   B: 3, C: 0.5, Cr: 8.7, Mo: 8.3;   B: 3.2, C: 0.5, Cr: 8.7, Mo: 8.3; and   B: 3.4, C: 0.5, Cr: 9.7, Mo: 9.4.   
     
     
         48 . (canceled) 
     
     
         49 . The coating of  claim 33 , wherein the coating has a hardness of at least 60HRC. 
     
     
         50 . (canceled) 
     
     
         51 . The coating of  claim 33 , wherein the coating is a hardfacing overlay. 
     
     
         52 . A powder configured to form the coating of  claim 33 . 
     
     
         53 . (canceled)