Using computational metallurgy to design nanostructured and amorphous thermal spray coatings for wear and corrosion resistance

Computational metallurgy is a technique being used and developed in the field of bulk alloys to design and develop novel amorphous and nanocrystalline materials.  This technology can be easily transitioned to develop chemistries for both wear and corrosion resistant thermal spray coatings.  Thus, nanostructured and amorphous chemistries can be designed to specifically accommodate one of the many environmental conditions experienced by the oil and gas industry.  This study reviews the design procedures behind developing three unique chemistries intended to function in different environments: 1) a Nickel-based chemistry similar to Alloy C276 for high temperature corrosion resistance, 2) an Fe-based chemistry containing elevated refractory content intended specifically for spray and fuse applications to resist sulfur-related corrosion, and 3) an Fe-based chemistry designed to resist high temperature erosion.  All three alloys were initially produced for the twin wire arc process in the form of cored wires.  In general, nanomaterials are uniquely beneficial to each application in their 1) ability to rapidly form protective scale in corrosive environments, 2) inherently low melting temperature allowing for effective spray and fuse processing, and 3) high hardness due to the decreased grain size.