Kennametal Inc.

Qingjun Zheng

Yixiong Liu

Michael J Meyer

James A Faust

Mark J Rowe

Danie J De Wet

Sudharsan Subbaiyan

Piyamanee Komolwit

Robert J Vasinko

Abdelhakim Belhadjhamida

Debangshu Banerjee

Xin Deng

Martin G Perez

Terry Wayne Kirk

Hongbo Tian

Peter Rudolf Leicht

Zhenyu Liu

Matthew Yao

Jonathan Bitler

Joern Kohlscheen

Danie DeWet

Jacob Poremski

Andrew Ruminski

David A Lee

Joel T Dawson

Jim Faust

Srinivasarao Boddapati

Corinne Charlton

Daniel Bourlotos

Jerry Dean

Daniel J De Wet

Danie J Dewet

In one aspect, nozzles for arc torches are described herein comprising refractory coatings for increasing nozzle operational lifetimes via resistance to weld splatter and the associated accumulation of molten metal deposits. In one aspect, a nozzle for an arc torch comprises a first body including a central bore and an exterior surface. A coating is adhered to the exterior surface by thermal spray, physical vapor deposition (PVD), or chemical vapor deposition (CVD), the coating comprising a refractory layer including one or more metallic elements selected from the group consisting of aluminum, silicon and metallic elements of Groups IIIB-VIIIB of the Periodic Table and one or more non-metallic elements selected from Groups IIIA, IVA, VA, and VIA of the Periodic Table.

Coated nozzles for arc torches

A multi-component electro-mechanical flame spray deposition system is disclosed having a first electro-mechanical feeder and a second electro-mechanical feeder, each in communication with a mixing hopper, and wherein the mixing hopper is in communication with a powder nozzle having an orifice, and a combustion torch having an orifice, wherein the orifice of the powder nozzle is in juxtaposition to the orifice of the combustion torch. A method of using the multi-component electro-mechanical flame spray deposition system is provided for depositing substrates on or to articles of manufacture.

Multi-component electro-mechanical flame spray deposition system

Wear resistant articles are described herein which, in some embodiments, mitigate CTE differences between wear resistant components and metallic substrates. In one aspect, an article comprises a layer of sintered cemented carbide bonded to a layer of iron-based alloy via a metal-matrix composite bonding layer, wherein coefficients of thermal expansion (CTE) of the sintered cemented carbide layer, metal matrix composite bonding layer, and iron-based alloy layer satisfy the relation: wherein 0.5&#x2264;x&#x2264;2 and CTE WC, CTE MMC and CTE Fe are the CTE values for the sintered cemented carbide, metal matrix composite, and iron-based alloy in 1/K respectively at 900&#xb0; C. to 1100&#xb0; C.

Wear resistant articles and applications thereof

In one aspect, methods of making freestanding metal matrix composite articles and alloy articles are described. A method of making a freestanding composite article described herein comprises disposing over a surface of the temporary substrate a layered assembly comprising a layer of infiltration metal or alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. The layered assembly is heated to infiltrate the hard particle layer with metal or alloy providing a metal matrix composite, and the metal matrix composite is separated from the temporary substrate. Further, a method of making a freestanding alloy article described herein comprises disposing over the surface of a temporary substrate a flexible sheet comprising organic binder and powder alloy and heating the sheet to provide a sintered alloy article. The sintered alloy article is then separated from the temporary substrate.

Methods of making metal matrix composite and alloy articles

Welding rods and associated cladded articles are described herein. Briefly, a welding rod comprises a hard particle component dispersed in a nickel-based alloy matrix or cobalt-based alloy matrix, the hard particle component comprising tungsten carbide particles having an average size of less than 45 &#x3bc;m, and the nickel-based alloy matrix or the cobalt-based alloy matrix comprising at least one metal carbide forming element.

Composite welding rods and associated cladded articles

Methods of superalloy article repair are provided. In some embodiments, a method for repairing a nickel-based superalloy article comprises providing a layered assembly over a damaged region of the nickel-based superalloy article, the layered assembly comprising a nickel-based superalloy preform, an infiltration alloy preform and a melting point depressant component. The layered assembly is heated to form a nickel-based filler alloy metallurgically bonded to the damaged region, wherein primary carbide and secondary carbide phases are present in the nickel-based filler alloy in a combined amount of 0.5 to 10 vol. %.

Layered assemblies for superalloy article repair

Cobalt-based alloy compositions are described herein having properties compatible with thermal spray and sintering techniques. Such alloy compositions can provide claddings to a variety of metallic substrates having complex geometries, wherein the claddings exhibit desirable density, hardness, wear resistance and corrosion resistance. Briefly, an alloy composition described herein comprises 15-25 wt. % chromium, 15-20 wt. % molybdenum, 0-15 wt. % tungsten, 10-20 wt. % nickel, 2.5-3.5 wt. % boron, 2.5-4.5 wt. % silicon, 1-2 wt. % carbon and the balance cobalt, wherein a ratio of boron to silicon (B/Si) in the alloy composition ranges from 0.5 to 1.0.

Wear resistant and corrosion resistant cobalt-based alloy powders and applications thereof

In one aspect, composite articles are described herein employing cobalt-based alloy claddings exhibiting high hardness and wear resistance while maintaining desirable integrity and adhesion to surfaces of metallic substrates. A composite article, in some embodiments, comprises a metallic substrate and a composite cladding metallurgically bonded to one or more surfaces of the metallic substrate, the composite cladding including cobalt-based alloy having a chromium gradient, wherein chromium content increases in a direction from the composite cladding surface to an interface of the composite cladding with the metallic substrate.

Cladded articles and applications thereof

In one aspect, methods of making cladded articles are described herein. A method of making a cladded article, in some embodiments, comprises disposing over a surface of a metallic substrate a sheet comprising organic binder and powder metal or powder alloy having a solidus temperature at least 100&#xb0; C. less than the metallic substrate and heating the powder metal or powder alloy to provide a sintered metal or sintered alloy cladding metallurgically bonded to the metallic substrate.

Cladded articles and methods of making the same

A method of imparting wear-resistance to a contact face of a turbine blade Z-notch comprising applying a flexible cladding sheet comprising a Co-based cladding alloy and an organic binder to the contact face of the Z-notch, heating the turbine blade Z-notch with flexible cladding sheet thereon to volatilize the organic binder and remove it from the cladding sheet, and further heating the turbine blade Z-notch with flexible cladding sheet thereon to sinter the cladding sheet by liquid phase sintering, thereby cladding the cladding sheet to the contact face to produce a wear-resistant layer thereon.

Imparting high-temperature wear resistance to turbine blade Z-notches

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.

Composite wear pad and methods of making the same

In one aspect, articles employing CVD coatings deposited at low temperatures are described herein. Briefly, a coated article described herein comprises a substrate and a refractory coating adhered to the substrate, the refractory coating including a layer of TiN deposited by thermal CVD, the layer of TiN having an average crystallite size of 0.05 &#x3bc;m to 0.5 &#x3bc;m and residual tensile stress of 100 MPa to 700 MPa.

Low temperature CVD coatings and applications thereof

Carbide pellets including relatively small amounts of metallic binder are produced by steps of pressing, comminuting, shaping and sintering. The carbide pellets may be used as wear resistant hard facing materials that are applied to various types of tools. The carbide pellets provide improved mechanical properties such as hardness and abrasiveness while maintaining required levels of toughness and strength.

Growing community of inventors

Export, PA, United States of America

Qingjun Zheng