Nickel based thermal spray powder and coating, and method for making the same

A coating comprising:

• an alloy, the alloy comprising a solid solution and a first component, wherein:
• the solid solution comprises nickel and chromium,
• the first component comprises a binary compound, a ternary compound, or both comprising at least one transition metal element and at least one nonmetal element;
• and
• the alloy is represented by the formula:
• (NixCry)a(MbNc)
• wherein:
• M represents the transition metal element in the first component;
• N represents the nonmetal element in the first component;
• a, b, and c each is greater than 0 and independently represents a weight percentage;
• x and y each is greater than 0 and independently represents a weight percentage of the Ni-containing solid solution;
• a is from 85 to 95, b is from 0.1 to 10, c is from 5 to 10, a ratio of x to y is between 0.5 to 1.9, and y is 33-35;
• wherein the alloy comprises:
• 48 to 54 wt. % Ni,
• 33 to 35 wt. % Cr,
• 3.3 to 3.5 wt. % Si,
• 4 to 4.5 wt. % B,
• about 1 wt. % C,
• 1-2 wt. % Ti,
• and a balance of Fe;
• and
• wherein the coating is substantially amorphous.