Non-magnetic metal matrix composites

Abstract

Metal matrix composites for use in oilfield applications are disclosed herein. The metal matrix composites comprise a metallic matrix comprising nickel in an amount of from 10 percent to 80 percent by weight based on total weight of the metallic matrix; chromium in an amount of from 10 percent to 45 percent by weight based on total weight of the metallic matrix; and molybdenum in an amount of from 10 percent to 45 percent by weight based on total weight of the metallic matrix. The metal matrix composite further comprises a particulate phase comprising tungsten carbide particles. The metal matrix composite exhibits desirable physical properties, including low relative magnetic permeability, high hardness, and high abrasion resistance. Articles comprising the metal matrix composites disclosed herein and methods of making the articles are also disclosed.

1 . A metal matrix composite comprising:
 a metallic matrix comprising:
 nickel in an amount of from 10 percent to 80 percent by weight based on total weight of the metallic matrix; 
 chromium in an amount of from 10 percent to 45 percent by weight based on total weight of the metallic matrix; and 
 molybdenum in an amount of from 10 percent to 45 percent by weight based on total weight of the metallic matrix; and 
   particulate carbide.   
     
     
         2 . The metal matrix composite of  claim 1 , wherein the nickel and molybdenum are present in a weight ratio of less than 6:1. 
     
     
         3 . The metal matrix composite of  claim 1 , wherein the chromium and molybdenum are present in a weight ratio of less than 2:1. 
     
     
         4 . The metal matrix composite of  claim 1 , wherein the nickel and chromium are present in a weight ratio of less than 3:1. 
     
     
         5 . The metal matrix composite of  claim 1 , wherein the chromium is present in an amount greater than 22 percent by weight based on total weight of the metallic matrix. 
     
     
         6 . The metal matrix composite of  claim 1 , wherein the particulate carbide comprises tungsten carbide particles. 
     
     
         7 . The metal matrix composite of  claim 1 , wherein the metallic matrix further comprises silicon. 
     
     
         8 . The metal matrix composite of  claim 7 , wherein the silicon is present in an amount of from 0.05 percent by weight to 5 percent by weight based on total weight of the metallic matrix. 
     
     
         9 . The metal matrix composite of  claim 1 , wherein the metal matrix composite is substantially free of iron and/or niobium. 
     
     
         10 . The metal matrix composite of  claim 1 , wherein the metallic matrix comprises a Laves phase. 
     
     
         11 . The metal matrix composite of  claim 10 , wherein the Laves phase comprises an MoNi 2  structure, an NiMo 2  structure, and/or an (Mo,Cr) 1 Ni 2  structure; wherein the Laves phase is present in an amount of at least 0.1 percent by volume based on total volume of the metallic matrix; and/or wherein the Laves phase comprises particles having an average diameter of from 0.02 microns to 5 microns. 
     
     
         12 . The metal matrix composite of  claim 1 , wherein the metal matrix composite has:
 (a) a relative magnetic permeability of less than 1.01 μr, as measured by ASTM A342;   (b) a Rockwell scale hardness of at least 35 HRC, as measured by ASTM E18; and/or   (c) a volume loss of no more than 33 mm 3  as measured by ASTM G65 Procedure A.   
     
     
         13 . An article comprising:
 a substrate; and   the metal matrix composite of  claim 1  deposited onto at least a portion of a surface of the substrate.   
     
     
         14 . A powder composition comprising:
 metal particles comprising:
 nickel in an amount of from 10 percent to 80 percent by weight based on total weight of the metal particles; 
 chromium in an amount of from 10 percent to 45 percent by weight based on total weight of the metal particles; and 
 molybdenum in an amount of from 10 percent to 45 percent by weight based on total weight of the metal particles; and 
   carbide particles.   
     
     
         15 . The powder composition of  claim 14 , wherein the nickel and molybdenum are present in a weight ratio of less than 6:1. 
     
     
         16 . The powder composition of  claim 14 , wherein the chromium and molybdenum are present in a weight ratio of less than 2:1. 
     
     
         17 . The powder composition of  claim 14 , wherein the nickel and chromium are present in a weight ratio of less than 3:1. 
     
     
         18 . The powder composition of  claim 14 , further comprising silicon. 
     
     
         19 . The powder composition of  claim 14 , wherein the carbide particles comprise tungsten carbide particles. 
     
     
         20 . A method of applying a coating comprising a metal matrix composite on a metal substrate comprising:
 applying the powder composition of  claim 14  to at least a portion of a surface of the substrate;   heating to at least partially melt the powder composition; and   cooling the portion of the surface of the substrate.