THERMAL SPRAY COMPOSITION AND COMPONENT MADE THEREWITH

Abstract

Thermal spray coating compositions, methods of using thermal spray coating compositions, and remanufactured components are disclosed herein. A thermal spray coating composition can include about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron. The thermal spray coating composition can include about 2% to about 12% by weight copper.

Claims

1. A thermal spray coating composition comprising about 7% to about 9% by weight aluminum, about 5% to about 7% by weight silicon, about 1% to about 3% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron.

2. The thermal spray coating composition of claim 1, wherein the copper is about 2% to about 12% by weight.

3. The thermal spray coating composition of claim 1, wherein the aluminum is about 8% by weight.

4. The thermal spray coating composition of claim 1, wherein the silicon is about 6% by weight silicon.

5. The thermal spray coating composition of claim 1, wherein the manganese is about 2% by weight.

6. The thermal spray coating composition of claim 1, wherein the copper is about 2% by weight.

7. The thermal spray coating composition of claim 1, wherein the copper is about 6% by weight.

8. The thermal spray coating composition of claim 1, wherein the copper is about 12% by weight.

9. The thermal spray coating composition of claim 1, wherein the thermal spray coating can be used in one or more of the following processes: plasma spraying, detonation spraying, twin wire arc spraying, flame spraying, or high velocity oxy-fuel coating spraying.

10. The thermal spray coating composition of claim 1, wherein the thermal spray coating composition is a wire.

11. The thermal spray coating composition of claim 9, wherein the wire is a cored wire.

12. The thermal spray coating composition of claim 1, wherein the thermal spray coating composition is gas atomized powder.

13. A method of remanufacturing a component comprising: applying a thermal spray coating composition to a substrate, wherein the thermal spray coating composition comprises about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 1% to about 14% by weight copper, with a remaining balance of iron; and cooling the thermal spray coating composition rapidly.

14. The method of claim 13, wherein the copper is about 2% to about 12% by weight.

15. The method of claim 13, wherein the thermal spray coating composition is applied by a process selected from the following: plasma spraying, detonation spraying, twin wire arc spraying, flame spraying, or high velocity oxy-fuel coating spraying.

16. The method of claim 13, wherein the thermal spray coating composition is a wire.

17. The method of claim 16, wherein the wire is a cored wire.

18. The method of claim 13, wherein the thermal spray coating composition is gas atomized powder.

19. A remanufactured component comprising a substrate and a thermal spray coating composition comprising about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 2% to about 12% copper, with a remaining balance of iron.

20. The remanufactured component of claim 19, wherein the thermal spray coating composition is a wire.

Description

EXAMPLE

[0025] The following example is for illustrative purposes only. The following compositions were deposited onto a substrate using a thermal spray process. Each of the compositions was machined using the same tools and the surface roughness was measured. Surface roughness is highly dependent upon the particular technique and machine used. It is believed that surface roughness may correlate to machinability of the composition.

TABLE-US-00001 Compo- Compo- Compo- Compo- Element sition 1 sition 2 sition 3 sition 4 Aluminum 8% 8% 8% 8% Silicon 6% 6% 6% 6% Manganese 0% 2% 2% 2% Copper 0% 2% 6% 12%  Iron Balance Balance Balance Balance

[0026] The surface roughness of the composition 1 was 2.4 microns, composition 2 was 1.6 microns, composition 3 was 1.0 microns, and composition 4 was about 0.7 microns. A lower surface roughness generally correlates to a higher machinability. Accordingly, the increased copper concentrations showed increased machinability.

[0027] It is believed that adding face-centered cubic (fcc) transition metal elements, such as copper, that are insoluble in a body-centered cubic (bcc) iron matrix increases the machinability of the composition due to the uniform distribution of the fcc crystal structure phase. Moreover, it is believed that the rapid solidification that occurs during thermal spray deposition unexpectedly aided in achieving a very uniform distribution of copper within the iron matrix. In other words, it is believed that the molten droplets formed during thermal spraying solidified so quickly upon impact that the insoluble copper does not have time to segregate to their thermodynamically-stable condition as coarser, separate phases.

INDUSTRIAL APPLICABILITY

[0028] The present disclosure finds potential applicability in any remanufacture strategy where there is a desire for at least one of reducing cost of the coating material or improving efficiency with regard to the application and machining of the coating. The present disclosure finds specific application in substituting the disclosed thermal spray coating composition of the present disclosure in place of the material used in the past to remanufacture components.

[0029] The thermal spray coating composition of the present disclosure can be applied to a new part to increase wear and corrosion resistance or to a used part to bring the used part into specification for reuse. The used part may have a wear area that requires additional material, such as the disclosed thermal spray coating composition. The used part, or a remanufactured component, can include a substrate and a thermal spray coating composition including about 8% by weight aluminum, about 6% by weight silicon, about 2% by weight manganese, about 2% to about 12% copper, with a remaining balance of iron. The substrate is usually the original material that has worn away during use of the component. The thermal spray coating composition provides the remanufactured component with the material to restore the worn area.

[0030] For example, the thermal spray coating composition can be applied to a worn component to return the component to its original dimensions. The thermal spray coating composition can be applied repeatedly to build up the wear area, depending on the level of wear. The thermal spray coating composition, therefore, can restore the remanufactured component to the same dimensions as the original component.

[0031] It will be apparent to those skilled in the art that various modification and variations can be made to the disclosed composition, method, and remanufactured component. Other embodiments will be apparent to those skilled in the art from consideration of the specification and practice of the disclosed composition. It is intended that the specification and example be considered as exemplary only, with a true scope being indicated by the following claims and their equivalents.