# US 12,000,027 B2 · Bimetallic materials comprising cermets with improved metal dusting corrosion and abrasion/erosion resistance

> Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt

- Number: US 12,000,027 B2
- Document ID: US12000027B2
- Status: Granted
- Kind: B2
- Application number: 17/772,077
- Filed: 2020-10-29
- Published: 2022-12-01
- Granted: 2024-06-04
- Earliest claimed: 2019-11-01
- Assignees: ExxonMobil Chemical Patents Inc.
- Applicants: ExxonMobil Chemical Patents Inc.
- Inventors: Changmin Chun; Ning Ma; Jorge J. Perdomo; John S. Coleman; Larry L. Iaccino
- Web page: https://patentgrep.com/patent/US12000027B2

## CPC

- C22C 29/005: {comprising a particular metallic binder}
- C23C 26/00: Coating not provided for in groups C23C2/00 - C23C24/00
- B22F 7/08: with one or more parts not made from powder {(B22F7/062 takes precedence)}
- B23K 26/0006: {taking account of the properties of the material involved (B23K26/32, B23K26/40 take precedence)}
- B23K 26/34: Laser welding for purposes other than joining
- B23K 35/304: {with Cr as the next major constituent}
- C22C 19/05: with chromium
- C22C 19/053: {with the maximum Cr content being at least 30% but less than 40%}
- C22C 19/055: {with the maximum Cr content being at least 20% but less than 30%}
- C22C 19/058: {without Mo and W}
- C22C 19/07: based on cobalt
- C22C 27/06: Alloys based on chromium
- C22C 29/04: based on carbonitrides
- C22C 29/06: based on carbides, but not containing other metal compounds
- C22C 29/067: {comprising a particular metallic binder}
- C22C 29/12: based on oxides
- C22C 29/14: based on borides
- C22C 30/00: Alloys containing less than 50% by weight of each constituent
- C22C 30/02: containing copper
- C22C 38/001: {containing N}
- C22C 38/005: {containing rare earths, i.e. Sc, Y, Lanthanides}
- C22C 38/04: containing manganese
- C22C 38/06: containing aluminium
- C22C 38/34: with more than 1.5% by weight of silicon
- C22C 38/40: with nickel
- C22C 38/44: with molybdenum or tungsten
- C22C 38/48: with niobium or tantalum
- C22C 38/50: with titanium or zirconium
- C22C 38/52: with cobalt
- C23C 26/02: applying molten material to the substrate
- B22F 2998/10: Processes characterised by the sequence of their steps
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- B23K 2101/35: {Surface treated articles}
- B23K 2103/166: {Multilayered materials}
- B23K 2103/18: Dissimilar materials
- B23K 2103/26: {Alloys of Nickel and Cobalt and Chromium}
- B23K 2103/52: {Ceramics}
- C22C 2204/00: End product comprising different layers, coatings or parts of cermet
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- 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)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- 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

## Abstract

Methods and compositions are provided for improving metal dusting corrosion, abrasion resistance and/or erosion resistance for various materials, preferably for applications relating to high-temperature reactors, including dense fluidized bed reactor components. In particular, cermets comprising (a) at least one ceramic phase selected from the group consisting of metal carbides, metal nitrides, metal borides, metal oxides, metal carbonitrides, and mixtures of thereof and (b) at least one metal alloy binder phase are provided. Ceramic phase materials include chromium carbide (Cr23C6). Metal alloy binder phase materials include β-NiAl intermetallic alloys and Ni3Sn2 intermetallic alloys, as well as alloys that contain α-Cr and/or γ′-Ni3Al hard phases. Preferably, bimetallic materials are provided when the cermet compositions are applied using a laser, e.g., a laser cladding method such as high power direct diode (HPDD) laser, or by plasma-based methods such as plasma transfer arc (PTA) welding and powder plasma welding (PPW).

## Claims

### Claim 1

A laser cladded bimetallic material, comprising:
(i) a high temperature alloy substrate, and (ii) a precipitated cermet composition comprising one or more metals, M, from a metal alloy binder,
wherein the high temperature alloy substrate comprises a high temperature alloy substrate selected from the group consisting of (i) Ni-based, high Cr alloys, (ii) FeNi-based alloys, (iii) FeNiCo-based alloys, (iv) NiCo-based alloys, (v) Ni-based alloys, (vi) Steam Cracker Alloys, (vii) Austenitic Stainless Steels and mixtures thereof; wherein the precipitated cermet composition comprises:
(a) at least one ceramic phase material selected from the group consisting of metal carbides (MxCy), metal nitrides (MxNy), metal borides (MxBy), metal oxides (MxOy), metal carbonitrides (MxCNy), and mixtures of thereof; wherein:
wherein the one or more metals, M, is at least one element selected from a group consisting of titanium (Ti), Zirconium (Zr), Hafnium (Hf), Vanadium (V), Niobium (Nb), Tantalum (Ta), Molybdenum (Mo), Tungsten (W), Iron (Fe), Nickel (Ni), Cobalt (Co), Chromium (Cr), Aluminium (Al), Silicon (Si), Manganese (Mn), and mixtures of thereof;
x is a whole or fractional numerical value ranging from 1 to 26; and
y is a whole or fractional numerical value ranging from 1 to 6; and
(b) at least one metal alloy binder phase corresponding to the metal alloy binder, wherein the at least one metal alloy binder phase comprising
(i) about 28.0 to about 33.0 wt. % chromium (Cr);
(ii) about 0.5 to about 2.9 wt. % carbon (C);
(iii) about 4.1 to about 30.0 wt. % of an alloying element selected from the group consisting of Iron (Fe), Cobalt (Co), Aluminum (Al), Silicon (Si), Manganese (Mn), Copper (Cu), Titanium (Ti), Zirconium (Zr), Hafnium (Hf), Vanadium (V), Niobium (Nb), Tantalum (Ta), Molybdenum (Mo), Tungsten (W), and mixtures of thereof; and
(iv) the balance being nickel (Ni),
wherein the wt. % is based on the total weight of the alloy.

### Claim 2 (depends on 1)

The laser cladded bimetallic material of claim 1, wherein the at least one metal alloy binder phase comprises from about 4.1 to about 18.0 wt. % of the alloying element.

### Claim 3 (depends on 1)

The laser cladded bimetallic material of claim 1, wherein the ceramic phase comprises a metal carbide (MxCy).

### Claim 4 (depends on 1)

The laser cladded bimetallic material of claim 1, wherein the ceramic phase of the precipitated cermet composition in the laser cladded bimetallic material constitutes about 5 vol. % to about 80 vol. % of the total volume of the precipitated cermet composition.

### Claim 5 (depends on 4)

The laser cladded bimetallic material of claim 4, wherein the ceramic phase of the precipitated cermet composition in the laser cladded bimetallic material constitutes about 20 vol. % to about 60 vol. % of the total volume of the precipitated cermet composition.

### Claim 6 (depends on 1)

The laser cladded bimetallic material of claim 1, wherein the laser cladded bimetallic material is a layer or insert of a dense fluidized bed (DFB) reactor component.

### Claim 7 (depends on 1)

The laser cladded bimetallic material of claim 1, wherein M is selected from the group consisting of Tungsten (W), Molybdenum (Mo), Titanium (Ti), Chromium (Cr), and mixtures of thereof.

### Claim 8 (depends on 1)

The laser cladded bimetallic material of claim 1, wherein the ceramic phase material constitutes about 5 vol. % to about 80 vol. % of the total volume of the precipitated cermet composition.

### Claim 9 (depends on 1)

The laser cladded bimetallic material of claim 1, wherein the at least one metal alloy binder phase has a nominal composition (wt. %) selected from the group consisting of:
Bal.Ni:28Cr:7W:3.5Ta:0.3Ti:0.5Zr:0.6C
Bal.Ni:30Cr:13W:2.5C
Bal.Ni:28.5Cr:4.6W:1.2C
Bal.Ni:30Cr:8.5W:1.45C
Bal.Ni:30Cr:17.0W:1.0C
Bal.Ni:32.5Cr:17.5W:2.55C
Bal.Ni:32Cr:13.0W:2.5C; and
Bal.Ni:29Cr:7.5W:2.4Si: 1.2C.

### Claim 10 (depends on 1)

The method of claim 1, wherein the precipitated cermet composition of the laser cladded bimetallic material comprise less than 3 volume (vol.) % porosity.

### Claim 11 (depends on 1)

The method of claim 1, wherein the precipitated cermet composition of the laser cladded bimetallic material comprise less than 1 volume (vol.) % porosity.

### Claim 12 (depends on 1)

The method of claim 1, wherein the precipitated cermet composition comprises metal carbides (MxCy).

### Claim 13 (depends on 1)

The method of claim 1, wherein the precipitated cermet composition comprises metal nitrides (MxNy).

### Claim 14 (depends on 1)

The method of claim 1, wherein the precipitated cermet composition comprises metal borides (MxBy).