Compositions of corrosion-resistant Fe-based amorphous metals suitable for producing thermal spray coatings

An apparatus for producing a graded corrosion-resistant amorphous-metal coating including layers on a structure, comprising:

• a deposition chamber,
• a deposition system in said deposition chamber that produces two deposition sprays,
• wherein said two deposition sprays include a first amorphous metal and a second amorphous metal,
• wherein said first amorphous metal is a first amorphous metal containing a composite material made of amorphous metal that contains manganese (1 to 3 atomic %), yttrium (0.1 to 10 atomic %), and silicon (0.3 to 3.1 atomic %) in the range of composition given in parentheses;
• and that contains the following elements in the specified range of composition given in parentheses:
• chromium (15 to 20 atomic %), molybdenum (2 to 15 atomic %), tungsten (1 to 3 atomic %), boron (5 to 16 atomic %),
• carbon (3 to 16 atomic %), and
• the balance iron;
• and
• wherein said second amorphous metal is an amorphous metal that is different from said first amorphous metal, wherein said second amorphous metal is a composite material made of amorphous metal that contains manganese (1 to 3 atomic %), yttrium (0.1 to 10 atomic %), and silicon (0.3 to 3.1 atomic %) in the range of composition given in parentheses;
• and that contains the following elements in the specified range of composition given in parentheses:
• chromium (15 to 20 atomic %), molybdenum (2 to 15 atomic %), tungsten (1 to 3 atomic %), boron (5 to 16 atomic %), carbon (3 to 16 atomic %), and the balance iron, and
• wherein said deposition system directs said two deposition sprays onto the structure, wherein said deposition system includes
• an amorphous metal application system
• for applying said first amorphous metal to the structure by sputter deposition to form a first layer, and
• for applying said second amorphous metal to the structure by sputter deposition to form a second layer producing the graded corrosion-resistant amorphous-metal coating on the structure.