Erosion resistant cermet linings for oil and gas exploration, refining and petrochemical processing applications

A method for protecting metal surfaces in oil & gas exploration and production, refinery and petrochemical process applications subject to solid particulate erosion at temperatures of up to 1000° C., the method comprising the step of providing said metal surfaces with a hot erosion resistant cermet lining or insert, wherein said cermet lining or insert comprises:

• a) a ceramic phase, and b) a metal binder phase,
• wherein said ceramic phase is (PQ) and said metal binder phase is (RS) wherein,
• P is at least one metal selected from the group consisting of Group IV, Group V, Group VI elements,
• Q is boride,
• R is selected from the group consisting of Fe, Ni, Co, Mn and mixtures thereof, and
• S comprises at least one element selected from the group consisting of Cr, Al, Si and Y
• wherein said ceramic phase comprises from about 30 to about 95 vol % of the volume of said cermet lining or insert, and
• wherein said cermet lining or insert has a HEAT erosion resistance index of at least about 5.0 and a K1C fracture toughness of at least about 7.0 MPa·m1/2,
• wherein said cermet lining or insert is a composition gradient cermet material produced by the method comprising the steps of:
• heating a metal alloy containing at least one of chromium and titanium at a temperature in the range of about 600° C. to about 1150° C. to form a heated metal alloy;
• exposing said heated metal alloy to a reactive environment comprising at least one member selected from the group consisting of reactive carbon, reactive nitrogen, reactive boron, reactive oxygen and mixtures thereof in the range of about 600° C. to about 1150° C. for a time sufficient to provide a reacted alloy;
• and
• cooling said reacted alloy to a temperature below about 40° C. to provide a composition gradient cermet material.