A composite structure with an aluminum-based alloy layer containing boron carbide and a manufacturing method thereof are provided. The composite structure includes a substrate with an open hole in that surface and the aluminum-based alloy layer containing boron carbide. The aluminum-based alloy layer is disposed in the open hole and contains aluminum, boron, carbon, and oxygen, wherein the content of aluminum is between 4 at. % and 55 at. %, the content of boron is between 9 at. % and 32 at. %, the content of carbon is between 13 at. % and 32 at. %, the content of oxygen is between 2 at. % and 38 at. %, and the ratio of the content of boron to carbon is between 0.3 and 2.7.

There are provided a Ni-based thermal spraying alloy powder having excellent corrosion resistance and erosion-corrosion resistance even in an environment in which corrosion acts or corrosion and erosion act simultaneously, and a method for manufacturing an alloy coating. A Ni-based thermal spraying alloy powder comprising Cr: 15 wt % or more and 25 wt % or less, Mo: 0 wt % or more and 5 wt % or less, Si: 0.5 wt % or more and less than 2 wt %, Fe: 5 wt % or less, C: 0.3 wt % or more and 0.7 wt % or less, and B: 4 wt % or more and 7 wt % or less, with the balance being Ni and incidental impurities.

There are provided a Ni-based thermal spraying alloy powder having excellent corrosion resistance and erosion-corrosion resistance even in an environment in which corrosion acts or corrosion and erosion act simultaneously, and a method for manufacturing an alloy coating. A Ni-based thermal spraying alloy powder comprising Cr: 15 wt % or more and 25 wt % or less, Mo: 0 wt % or more and 5 wt % or less, Si: 0.5 wt % or more and less than 2 wt %, Fe: 5 wt % or less, C: 0.3 wt % or more and 0.7 wt % or less, and B: 4 wt % or more and 7 wt % or less, with the balance being Ni and incidental impurities.

A bearing component such as a bearing ring includes a metallic base body and at least one alloy steel coating on the base body, the coating being applied to the base body by deposition welding. The base body is preferably non-alloy steel or cast iron, and the alloy includes at least one carbide-forming transition metal such as niobium, tantalum, zirconium, titanium, hafnium, tungsten, molybdenum, vanadium, or manganese. The coating can form a raceway of the bearing component or a structural element such as a flange. Also a method of forming such a bearing component is provided.

A bearing component such as a bearing ring includes a metallic base body and at least one alloy steel coating on the base body, the coating being applied to the base body by deposition welding. The base body is preferably non-alloy steel or cast iron, and the alloy includes at least one carbide-forming transition metal such as niobium, tantalum, zirconium, titanium, hafnium, tungsten, molybdenum, vanadium, or manganese. The coating can form a raceway of the bearing component or a structural element such as a flange. Also a method of forming such a bearing component is provided.

A method of applying a long lasting wear-resistant coating on a Yankee drying cylinder is described, whereby the method includes: providing a Yankee drying cylinder having a cylindrical shell with a circular cross-section and an outer surface; and performing a thermal spray operation to form a wear-resistant coating layer on the outer surface of the Yankee drying cylinder during which thermal spray operation coating feedstock is fed to at least one spray device, heated to become plastic and/or semi-molten and/or molten and sprayed onto the outer surface of the Yankee drying cylinder to form the wear-resistant coating layer. The coating feedstock for the thermal spray operation consists of a specific set of elements, by percent weight, with the remainder being iron and impurities. Coatings and Yankee cylinders with such coatings are also disclosed.

A method of applying a long lasting wear-resistant coating on a Yankee drying cylinder (1), the method comprises: the step of providing a Yankee drying cylinder (1) having a cylindrical shell (2) with a circular cross-section and an outer surface (3); the step of performing a thermal spray operation to form a wear-resistant coating layer (4) on the outer surface of the Yankee drying cylinder (1) during which thermal spray operation coating feedstock (6) is fed to at least one spray device (5), heated to become plastic and/or semi-molten and/or molten and sprayed onto the outer surface (3) of the Yankee drying cylinder (1) to form the wear-resistant coating layer (4), the coating feedstock (6) for the thermal spray operation consisting of: 1.5 to 2.5 weight percent Al 0.0 to 0.2 weight percent Ti, 9.5 to 10.5 weight percent Si, 0.0 to 0.2 weight percent B, 12.5 to 14.2 weight percent Mo, 0.0 to 0.2 weight percent V, 0.0 to 0.2 weight percent C, 0.000 to 0.020 weight percent Cr, 4.5 to 6.0 weight percent Mn, 0.0 to 0.2 weight percent Mg, 0.0 to 0.2 weight percent Ni, 0.0 to 0.2 weight percent Nb, the remainder being iron and impurities.

Coatings and Yankee cylinders with such coatings are also disclosed.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

An embodiment relates to an ultrasonic additive manufacturing process, comprising joining a foil comprising a bulk metallic glass to a substrate; and forming a cladded composite comprising the foil and the substrate; wherein a thickness of the cladded composite is greater than a critical casting thickness of the bulk metallic glass, wherein the cladded composite comprises a cladding layer of the bulk metallic glass on the substrate and the bulk metallic glass comprises approximately 0% crystallinity, approximately 0% porosity, less than 50 MPa thermal stress, approximately 0% distortion, approximately 0 inch heat affected zone, approximately 0% dilution, and a strength of about 2,000-3,500 MPa.

A multicomponent alloy coating is provided. The multicomponent alloy coating includes a hard layer and a plurality of nickel-based particles dispersed in the hard layer. The composition of the multicomponent alloy coating is represented by the following formula (I):
Al.sub.dCo.sub.eCr.sub.gFe.sub.hNi.sub.iSi.sub.jC.sub.kO.sub.m  formula (I), wherein 1<d<2, 0.5<e<0.8, 2<g<3.2, 0.05<h<0.3, 2<i<3, j=1, k≥0, m≥0, and iron is present in the amount of less than 3 wt % of the composition of the multicomponent alloy coating.