Multi-part abrasive tools are disclosed herein. In one embodiment, an abrasive tool includes a first body, a second body, and a braze layer that couples the first body to the second body. The braze layer includes a braze alloy having a liquidus temperature and insoluble particles at least partially surrounded by the braze alloy. The insoluble particles are insoluble with the braze alloy at temperatures at least 100° C. above the liquidus temperature of the braze alloy.

A composite hard-surface material preparation method and a composite hard-surface material prepared thereby, the preparation method comprising: dispersedly fixing a plurality of cemented carbide sheets (2) to a surface of a metal substrate (1); and surfacing the cemented carbide sheets (2) and the metal substrate (1) with a solder (3) to obtain a composite hard-surface material, the solder (3) comprising nickel-based alloy powder, tungsten carbide particles and boron nitride powder. The solder (3) used in the preparation of the composite hard-surface material comprises nickel-based alloy powder, tungsten carbide particles and boron nitride powder, wherein the nickel-based alloy powder can increase fluidity and corrosion resistance, the tungsten carbide particle can improve hardness, and the boron nitride powder can effectively reduce friction coefficient. The present solder has good fluidity, high hardness and good solderability, using said solder, the obtained composite hard-surface material may enjoy good wear resistance.

A composite wear pad includes a substrate that is selected from the group of iron based alloys, steel, nickel based alloys, and cobalt based alloys. A hard particle-matrix alloy layer is bonded at a surface to the substrate. The hard particle-matrix alloy layer has a plurality of hard particles dispersed in a matrix alloy. The hard particle-matrix alloy layer has a thickness ranging between greater than about 13 millimeters and about 20 millimeters.

The present disclosure is directed, in certain embodiments, a system for depositing material from a metal feedstock. The system includes a feedstock guide configured to guide a metal feedstock from a material feeder to extend beyond a terminal end of the feedstock guide. The system includes a ceramic collar disposed at the terminal end of the feedstock guide and configured to guide the metal feedstock extending from the terminal end of the feedstock guide to a deposition outlet of the ceramic collar. An induction coil disposed adjacent to the ceramic collar and configured to heat a portion of the metal feedstock within the ceramic collar, such that material of the metal feedstock can be deposited on a surface from the deposition end of the ceramic collar.

A subject of the invention is a process for surfacing or resurfacing a metal part by laser-assisted deposition of a filler material in order to produce an abradable coating of the part, the process being characterized in that the filler material is an iron-based powder comprising vanadium, chromium, nickel, boron, silicon and carbon, in that the laser has an operational wavelength ranging from 900 nm to 1100 nm and in that it comprises the irradiation of the part by a laser beam such that the specific energy (SE) varies from 5 J/mg to 10 J/mg and such that the linear density (LD) varies from 25 mg/mm to 55 mg/mm. Another subject of the invention is the surfaced or resurfaced metal part. Another subject of the invention is a pre-alloy in iron-based powder form, comprising vanadium, chromium, nickel, boron, silicon and carbon.

An electrode (10) is presented including a sheath (14) formed of a ductile material, an outer coating (16) including a flux material, and a core (12) including at least one of flux material and alloying material. The ductile material may be an extrudable subset of elements of a desired superalloy material and the alloying material may include elements that complement the ductile material to form a desired superalloy material when the electrode is melted. The outer coating may be formed of a flexible bonding material or it may be segmented (18, 20) to facilitate bending the electrode onto a spool. Any hygroscopic material of the electrode may be included in the core to protect it from exposure to atmospheric moisture.

A chromium-free, distributed hardfacing disposable on a surface of a wellsite component is disclosed. The hardfacing includes a metal filler (e.g., nickel) and particles distributed about the filler. The particles include pellets made of tungsten carbide and pieces made of angular molybdenum carbide. The pieces are smaller than the pellets for distribution in the filler between the pellets whereby a uniform distribution of particles is provided about the filler.

A sprocket wheel, which is an example of the machine component, includes a base made of a first metal, and an overlay disposed in contact with the base to cover at least a part of a surface of the base. The overlay includes a matrix made of a second metal, and hard particles dispersed in the matrix. The overlay includes a protrusion that protrudes toward the base in a region including the interface between the overlay and the base.

Methods for welding a particle-matrix composite body to another body and repairing particle-matrix composite bodies are disclosed. Additionally, earth-boring tools having a joint that includes an overlapping root portion and a weld groove having a face portion with a first bevel portion and a second bevel portion are disclosed. In some embodiments, a particle-matrix bit body of an earth-boring tool may be repaired by removing a damaged portion, heating the particle-matrix composite bit body, and forming a built-up metallic structure thereon. In other embodiments, a particle-matrix composite body may be welded to a metallic body by forming a joint, heating the particle-matrix composite body, melting a metallic filler material forming a weld bead and cooling the welded particle-matrix composite body, metallic filler material and metallic body at a controlled rate.

A method for preparing powders of hard alloys, such as Ti and Ti—Zr alloys, using a hydride-dehydride process, and powders produced by the process, are disclosed. The method can be used to manufacture brazing powders. The method is less hazardous and more cost effective than current methods, such as gas atomization, of preparing such braze materials.