# US 10,308,999 B2 · Iron-based alloy coating and method for manufacturing the same

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- Number: US 10,308,999 B2
- Document ID: US10308999B2
- Status: Granted
- Kind: B2
- Application number: 14/974,127
- Filed: 2015-12-18
- Published: 2017-06-08
- Granted: 2019-06-04
- Earliest claimed: 2015-12-03
- Assignees: Industrial Technology Research Institute
- Applicants: Industrial Technology Research Institute
- Inventors: Li-Shing Chou; Yen-Yu Hou; Chih-Chao Yang; Yi-Tsung Pan
- Web page: https://patentgrep.com/patent/US10308999B2

## CPC

- C22C 33/003: {making amorphous alloys}
- B23K 26/0006: {taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence)}
- B23K 26/354: by melting
- C22C 33/0207: {Using a mixture of pre-alloyed powders or a master alloy}
- C22C 33/0285: {with Cr, Co, or Ni having a minimum content higher than 5%}
- C22C 38/005: {containing rare earths, i.e. Sc, Y, Lanthanides}
- C22C 38/02: containing silicon
- C22C 38/22: with molybdenum or tungsten
- C22C 38/32: with boron
- C23C 4/06: Metallic material
- C23C 4/08: containing only metal elements (C23C4/073 takes precedence)
- C23C 4/131: Wire arc spraying
- C23C 4/134: Plasma spraying
- C23C 4/137: Spraying in vacuum or in an inert atmosphere
- C23C 4/18: After-treatment
- B23K 2101/34: Coated articles {; Surface treated articles}
- B23K 2103/04: Steel {or steel} alloys
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B23K: SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04)

## Abstract

A method of manufacturing an iron-based alloy coating is provided, which includes (a) providing an iron-based alloy powder having a chemical formula of FeaCrbMocSidBeYf, wherein 48≤a≤50; 21≤b≤23; 18≤c≤20; 2≤d≤3; 2≤e≤4; and 0<f≤2. The method also includes step (b) thermal spraying the iron-based alloy powder to form an amorphous iron-based alloy coating, and step (c) laser re-melting the amorphous iron-based alloy coating, wherein the iron-based alloy coating is densified and remains amorphous.

## Claims

### Claim 1

An iron-based alloy coating, having a composition of:
FeaCrbMocSidBeYf,
wherein 48≤a≤50;
21≤b≤23;
18≤c≤20;
2≤d≤3;
2≤e≤4; and
0<f≤2,
wherein the iron-based alloy coating is amorphous and has a porosity of less than 0.5%.

### Claim 2 (depends on 1)

The iron-based alloy coating as claimed in claim 1, having a thickness of 30 μm to 300 μm.

### Claim 3 (depends on 1)

The iron-based alloy coating as claimed in claim 1, having a pore size less than 2 μm.

### Claim 4

A method of manufacturing an iron-based alloy coating, comprising:
(a) providing an iron-based alloy powder having a chemical formula of FeaCrbMocSidBeYf, wherein 48≤a≤50; 21≤b≤23; 18≤c≤20; 2≤d≤3; 2≤e≤4; and 0<f≤2;
(b) thermal spraying the iron-based alloy powder to form an amorphous iron-based alloy coating; and
(c) laser re-melting the amorphous iron-based alloy coating, wherein the iron-based alloy coating is densified and remains amorphous.

### Claim 5 (depends on 4)

The method as claimed in claim 4, wherein the iron-based alloy coating has a thickness of 30 μm to 300 μm after step (c).

### Claim 6 (depends on 4)

The method as claimed in claim 4, wherein the iron-based alloy coating has a pore size less than 2 μm and a porosity of less than 0.5% after step (c).

### Claim 7 (depends on 4)

The method as claimed in claim 4, wherein the iron-based alloy powder in step (a) has a diameter of 25 μm to 60 μm.

### Claim 8 (depends on 4)

The method as claimed in claim 4, wherein thermal spraying the iron-based alloy powder in step (b) comprises melting the iron-based alloy powder using an electric arc, and then spraying the melted iron-based alloy powder onto a substrate using a gas mixture of argon and hydrogen.

### Claim 9 (depends on 4)

The method as claimed in claim 4, wherein laser re-melting the amorphous iron-based alloy coating in step (c) utilizes a laser power of 80 W to 150 W, and a depth of the amorphous iron-based alloy coating scanned by a laser is between 30 μm and 300 μm.