An iron-based welding and forging alloy with a complex chemistry produces a dense, homogenous weld deposit that is resistant to hardness loss at elevated temperatures with less reliance on cobalt content. Such an alloy may comprise, in approximate percentages by weight: cobalt: 5-25; chromium: 7-14; tungsten: 2.5-10; molybdenum: 2-9; nickel: 1-6; carbon: 0.01-5; manganese: 0.01-3; with iron and residual elements comprising the balance. The residual elements may include one or more of the following: silicon, vanadium, phosphorus, and sulfur. The amounts of the residual elements may be up to 1% by weight. The inventive alloys may be provided in any suitable form for welding purposes, including metal-core TIG (GTAW), coated electrode (SMAW) and metal-core-wire (MCAW). The inventive alloy combinations may be fabricated as welding filler, providing resistance to high temperature softening, facilitating use in applications that previously dictated a specific cobalt-based material.

The present invention relates to granular composite density enhancement, and related methods and compositions. The applications where these properties are valuable include but are not limited to: 1) additive manufacturing (“3D printing”) involving metallic, ceramic, cermet, polymer, plastic, or other dry or solvent-suspended powders or gels, 2) concrete materials, 3) solid propellant materials, 4) cermet materials, 5) granular armors, 6) glass-metal and glass-plastic mixtures, and 7) ceramics comprising (or manufactured using) granular composites.

The present invention relates to granular composite density enhancement, and related methods and compositions. The applications where these properties are valuable include but are not limited to: 1) additive manufacturing (“3D printing”) involving metallic, ceramic, cermet, polymer, plastic, or other dry or solvent-suspended powders or gels, 2) concrete materials, 3) solid propellant materials, 4) cermet materials, 5) granular armors, 6) glass-metal and glass-plastic mixtures, and 7) ceramics comprising (or manufactured using) granular composites.

The invention consists of a gray cast iron comprising carbon, silicon, vanadium, manganese, nickel, chromium, molybdenum, copper, sulfur, phosphorous, tin and titanium, wherein: the percentage by weight of carbon is from 3.70 to 3.90%; the percentage by weight of silicon is from 1.30 to 2.10%; the percentage by weight of vanadium is from 0.10 to 0.15%; the percentage by weight of manganese is from 0.60 to 0.90%; the percentage by weight of nickel is from 0.05 to 0.50%; the percentage by weight of chromium is from 0.20 to 0.35%; the percentage by weight of molybdenum is no more than 0.10%; the percentage by weight of copper is no more than 0.35%; the percentage by weight of sulfur is less than 0.10%; the percentage by weight of phosphorous is less than 0.10%; the percentage by weight of tin is less than 0.10%; the percentage by weight of titanium is no more than 0.01%; the remainder by weight being iron.

A centrifugally cast composite roll for rolling comprising an outer layer and an inner layer, which are integrally fused to each other, the outer layer being made of an Fe-based alloy comprising by mass 1.70-2.70% of C, 0.3-3% of Si, 0.1-3% of Mn, 1.1-3.0% of Ni, 4.0-10% of Cr, 2.0-7.5% of Mo, 3-6.0% of V, 0.1-2% of W, 0.2-2% of Nb, 0.01-0.2% of B, and 0.01-0.1% of N, the balance being Fe and inevitable impurities, and the inner layer being made of ductile cast iron.

Embodiments of an iron-based coating configured to be thermally sprayed are disclosed. The iron-based coatings can be fully readable, thus allowing for thickness measurements to be performed on the coating with standard magnetic measuring equipment. Further, the iron-based coating can have advantageous properties, such as high hardness, high wear resistance, and high adhesion strength.

Embodiments of an iron-based coating configured to be thermally sprayed are disclosed. The iron-based coatings can be fully readable, thus allowing for thickness measurements to be performed on the coating with standard magnetic measuring equipment. Further, the iron-based coating can have advantageous properties, such as high hardness, high wear resistance, and high adhesion strength.

An iron-based alloy composition including: boron (B): 1. 6-2.4 wt. %; carbon (C): 2.2-3.0 wt. %; chromium (Cr): 3.5-5.0 wt. %; manganese (Mn): below 0.8 wt. %; molybdenum (Mo): 16.0-19.5 wt. %; nickel (Ni): 1.0-2.0 wt. %; silicon (Si): 0.2-2.0 wt. %; vanadium (V): 10.8-13.2 wt. %; and balanced with iron (Fe). Further, an item including a substrate portion and a hardfacing coating bonded to the substrate portion, wherein the hardfacing coating is made by an overlay welding process using the iron-based alloy composition.

A cast steel alloy comprising carbon (0.8 to 2.0%), chromium (4 to 15%), silicon (0.68 to 2.0%), manganese (0.6 to 1.2%) and nickel (1.5 to 4%) that exhibits exceptional hardness and tensile strength and is useful for a wide range of high wear resistance applications including in the mining, excavation and agriculture industries.

The present invention relates to an iron-based alloy that is able to provide a coating on a substrate, the coating having simultaneously high hardness and wear resistance. The iron-based alloy consists of 3.0-7.0% by weight Cr; 1.3-3.0% by weight C; 0.2-2.0% by weight B; 2.0-10.0% by weight V; optionally 1.5% by weight or less Si; optionally 1.0% by weight or less Mn, optionally 2.0% by weight or less Mo; optionally 1.5% by weight or less Ni; the balance being Fe and unavoidable impurities.

The present invention further relates to an article comprising a substrate and coating formed thereon, the coating being formed from the alloy, and to a method for forming a coated article. The method preferably employs HVOF, laser cladding or plasma cladding.