Structured amorphous metals (sam) feedstock and products thereof

Abstract

Embodiments disclosed herein relate to the production of bulk amorphous metal (BAM) alloys comprising chromium, manganese, molybdenum, tungsten, silicon, carbon, boron, and the balance of iron to replace tungsten carbide-based welded material. The BAM alloy embodied herein can be applied through PTA welding, HVOF, TWAS, flame spraying, plasma spraying, laser, their combinations, and other coating and welding processes. When used as welded material, the density of the embodiment of around 7 grams per CC, which is less dense than the tungsten carbide customarily used, resulting in even hard faces during welding spread uniformly across the weld, therefore creating a harder and more wear-resistant weld.

What is claimed is: 
     
         1 . A coating comprising a bulk amorphous alloy comprising Fe 100−(a+b+c+d) (Cr a (Mn+Mo) b (W+Si) c (C+B) d ) wherein: B from 0 wt. % to about 5 wt. %, C from 0 wt. % to about 2 wt. %, Si from 0 wt. % to about 2, Mn from 0 wt. % to about 5 wt. %, Mo is 0 to about 20 wt. %, W is 0 wt. % to about 10 wt. %, and balance is Fe; and wherein C+B is about 2 to about 10 in wt. %. 
     
     
         2 . The coating of  claim 1 , wherein a ratio Mo/(Mn+W+Si) is about 5 to 3. 
     
     
         3 . The coating of  claim 1 , wherein a ratio Mo/(Mn+W+Si) is about 2 to about 1. 
     
     
         4 . The coating of  claim 1 , wherein a ratio Mo/(Mn+W+Si) is about is about 1 to about 2. 
     
     
         5 . The coating of  claim 1 , wherein the bulk amorphous alloy is partially to fully amorphous. 
     
     
         6 . The coating of  claim 1 , wherein a thickness of the bulk amorphous alloy is about 0.001 inch to inch. 
     
     
         7 . The coating of  claim 1 , wherein an amount of C+B is about 2 wt. % to about 3.5 wt. %. 
     
     
         8 . The coating of  claim 1 , wherein the coating has Vicker hardness of at least about 800. 
     
     
         9 . The coating of  claim 1 , wherein the coating has an abrasion resistance as measured via ASTM G65 is less than 1 gram. 
     
     
         10 . The coating of  claim 9 , wherein the abrasion resistance is less than 0.6 gram. 
     
     
         11 . The coating of  claim 1 , wherein the bulk amorphous alloy has a density in a range of about 7 gm/cc to about 8 gm/cc. 
     
     
         12 . The coating of the  claim 1 , wherein the coating is crack-free. 
     
     
         13 . The coating of the  claim 1 , wherein the coating has a shrinkage less than 5%. 
     
     
         14 . The coating of the  claim 13 , wherein the coating has a shrinkage less than 0.5%. 
     
     
         15 . The coating of the  claim 1 , wherein the bulk amorphous alloy has a wear resistance as measured by ASTM G65 that is equal to or more than that of a material consisting of NiCrFeSiBC and 60 wt. % WC. 
     
     
         16 . The coating of the  claim 1 , wherein the bulk amorphous alloy has a density less than that of the tungsten carbide or 13 g/cc. 
     
     
         17 . The coating of the  claim 1 , wherein the bulk amorphous alloy has a grain size about 100 micron or less. 
     
     
         18 . A method comprising:
 obtaining a feedstock comprising Fe 100−(a+b+c+d) (Cr a (Mn+Mo) b (W+Si) c (C+B) d ), wherein: a is from 10 to 30 at. %, b is from 10 to 20 at. %, c is from 2 to 10 at. %, and d is from 2 to 10 at. %,   wherein in the feedstock in weight percent, B is greater than 0 to about 5, C is greater than to about 2, Si is greater than 0 to about 2, Mn is greater than 0 to about 5, Mo is greater than 0 to about 20, W is greater than 0 to about 10, wherein B+C is about 2 to about 10, and wherein a ratio Mo/(Mn+W+Si) is about 1 to about 5; wherein the feedstock is free of tungsten carbide;   performing welding; and   forming a weld.   
     
     
         19 . The method of  claim 19 , wherein the feedstock is a wire feedstock or a powder feedstock. 
     
     
         20 . The method of  claim 19 , further comprising performing thermal spraying; and forming a hard surface.