Advances in Wear Resistant Alloys and
Products
Jim Wu, Ph.D.
CTO
Deloro Stellite Group
Outline
Types of Corrosion and Wear Resistant Alloys (Co and Ni
Alloys)
Newly Developed Alloys
Applications
Wear and Corrosion Resistant Alloys
Cobalt based alloys
Nickel based alloys
Alloy Composites
Cobalt Alloys Type 1
Type 1 Carbide Alloys
High carbon ( > 0.8% )
Carbide particles: M7C3 and M23C6
Resistant to wear and corrosion at temperatures below 600 C.
Alloy Nominal Composition HRC
6 29Cr-4.5W-1.2C 42
706 29Cr-4.5Mo-1.2C 42
712 29Cr-8.5Mo-1.6C 46
Powder, Rod, Wire, P/M and Casting
Wrought Products 6B, 6K, 706K
Microstructures
Type 1 Cobalt Alloys
Hypo-eutectic Hyper-eutectic
Carbide Shapes in Hyper-eutectic Stellite Alloy
30
Longitudinal Transverse
SEM Micrograph (BEI)
Type 1 Alloy 712 (Mo-Containing)
Cr in dark areas (M23C6) and Mo in light areas (Mo6C)
Corrosion Test Results in 10% H2SO4 @ 66 C
50
Corrosion Rate in m m /year
X=W
45
40
35
30 X=W
25
20
15 X=Mo
10 X=Mo
5
0
29Cr-1.2C-4.5X 29Cr-2.4C-12X
W-Containing Alloy Mo-Containing Alloy
ASTM G65 Wear Test Results
Stellite-712
Stellite-12
0 10 20 30 40 50 60
Volume Loss in mm3
Piston for Downhole Drilling
Stellite 712 Overlay
Oil Drilling Piston
Stellite 706 PTA
Valves
Stellite 6 Overlay
Gas Turbine Blades
Stellite 694 Overlay on Z-Notch
Z-Notch
Fretting Wear
PTA Hardfaced Extrusion Screws
Tri-Cone Drill Bits
Journal
Thrust Face
Pilot Pin
(Hardfaced with Type 1 Co Alloy)
Cobalt Alloys Type 2
Type 2 Intermetallic Alloys (Originally developed by DuPont)
Hard Laves phase: Co3Mo2Si and CoMoSi, low carbon content
Stable up to 800 C
For high temperature wear and highly corrosive wear
Tribaloy Nominal Composition HRC
T-400 28Mo-9Cr-2.6Si-0.04C 55
T-400C 27Mo-14Cr-2.6Si-0.1C 54
T-800 28Mo-17Cr-3.4Si-0.04C 58
T-900 23Mo-17Cr-16Ni-2.7Si-0.04C 54
T-401* Hypo-eutectic (most ductile) 48
* Patent pending
Powder, Rod, Wire, P/M and Casting
SEM Micrograph (BEI)
Type 2 Cobalt Alloy (T-400C) - Casting
Primary Laves Phase
SEM Micrograph (BEI)
Type 2 Cobalt Alloy (T-900) PTA Weld
SEM Micrograph (BEI)
Type 2 Hypo-eutectic (T-401) - Casting
Secondary Laves Phase
Hot Hardness
800
700 T400
440C
712
600
Stellite 6
Hot hardness, HV
500
400
300
200
100
0
0 250 500 750 1000 1250 1500
Test Temperature, F
Cast Tribaloy T-400 Actuator for Turbochargers
Kocks mill rolls
Hardfaced with T-900 for rolling W rods
Corrosion Test Results by Teck Cominco
GI Bath 0.22%Al, saturated with Fe, at 470C
T-401 or T-800 Galvanizing Bushing
Cobalt Alloys Type 3
Type 3 - Solid Solution Alloys
Solid solution strengthened with a few carbide particles
Strong work hardening
High corrosion resistance
Alloy Nominal Composition HRC
21 28Cr-5Mo-0.25C 28
Ultimet 25Cr-9Ni-5Mo-2W-0.05C 27
31 (X40) 26Cr-11Ni-7.5W-0.5C 32
28* CoCr-12Mo 38
* Patent pending
Powder, Rod, Wire and Casting
Phase Transformation
BSED Pattern
Phase Transformation of a Type 3 Alloy under Stress
Valve Stem
Stellite 21 PTA
Stellite 21 Forging Dies (HIPed)
Application: Automotive
torsion bars
Previous Die Material: H13
Previous Life: 2000 hits
Current Material: Stellite 21
HIP
Current Life: 38,000 hits
(Coated with TiN but
not necessary)
Ultimet
Thick PTA Overlay
Ultimet Overlay by Laser Cladding on Offshore Drilling Platform
Tensioners
Stellite 28 Laser Clad (0.5 thick)
Hardness: HRC 47-48
Comparison between Stellite 28 and 21
Stellite 28 Stellite 21
Mo Content 12% 5.5%
PTA Overlay Hardness at Room Temp HRC 38 HRC 33
Abrasion G65 Vol Loss in mm3 60 76
Critical Pitting Temperature (ASTM G48C) 70-75 C <45 C
Weld Repair of Stellite 28 PTA Overlay
No Preheat, Stellite 6 rod
150C Preheat, Stellite 6 rod
No Preheat, No Filler
Rod Dia: 3.2 mm
Other Co Alloys under Development
Stellite 6A Anti-aging
Stellite 21LA Very tough laser clad and PTA overlay
Laser - 6.5 times as Stellite 21
PTA -1.5 times as Stellite 21
Stellite 24 Hot Metal-working
Stellite 300 High abrasion resistance at HRC 62, designed for hot dip
coating applications.
Tribaloy SF T-400 Spray and fuse version of T-400
Abrasion Test Results of Investment Cast Samples
ASTM G65 Procedure B Abrasion Test
Hardness HRC or Volume Loss mm3
70
60
50
Hardness
40 Volume Loss
30
20
10
0
Stellite Stellite
Stellite 6 T-800
80 300
Hardness 39 55 61 62
Volume Loss 19.6 18.1 5.1 4.9
Nickel Alloys
Boride Alloys: 1-4% B
Deloro Alloys Rod and Powder
Silicide Alloys: 5-7% Si
Nucalloy Alloys Rod and Powder
Intermetallic Alloys: C+B < 0.1%
Tribaloy T-700 - Powder
Solid Solution Alloys: C+B < 0.4%
Ni-Cr Alloys
Castings can be made with most of these alloys.
Solid Solution Ni Alloys
Nistelle (Hastelloy) alloys
B, C, 625 and others Powder and Wire
Nistelle Super C
Ni-23Cr-18Mo - Powder
Castings can be made with most of these alloys.
Corrosion Resistance
PTA All-Weld Specimens
1.200
Corrosion Rate in mm/year
0.975
1.000
0.800 0.668
0.600 0.521
0.400
0.224
0.200 0.127
0.005
0.000
10% H2SO4 @ 5% HCl @ 66C 65% HNO3 @ 66C
boiling
Nistelle C Nistelle Super C
Ni-Cr Alloys
Contain 45-50% Cr.
Highly corrosion resistant.
Used successfully in handling black liquor in pulp mills.
(cast pipes)
Used successfully with thermal spraying in preventing fire-
side corrosion in power gen boilers.
Powder, Wire and Casting
Alloy Matrix Composites (AMC)
Alloy Matrix
Co, Co+Cr, Ni, Ni+Cr, and Other Alloys
Hard Particles
Carbides
Product Forms
Powders and tube wires
Wear Resistant Carbide Overlays/Coatings
PTA Overlays
Carbides in Ni or Co alloys
HVOF Coatings
Carbides in Co or Ni or their alloys
GTAW (MIG) Overlays
Carbides in Ni or Co alloys
Carbides
TUNGSTEN CARBIDE - WC:
6.1% C - WC+W2C: 3.9% C
VANADIUM/TUNGSTEN CARBIDE - (V,W)C: 13%
C, 57% V, 23% W
CHROMIUM CARBIDE
- Cr3C2: 10% C
Hardness of Carbides
W2C 3000 DPH
WC 2400 DPH
VC 2800 DPH
TiC 2800 DPH
Cr7C3 2100 DPH
M7C3 (Co) 1600 DPH
M7C3 (Fe) 1500 DPH
Characteristics of AMC
Excellent abrasion resistance
Bonding between matrix and carbide important to wear
resistance
Carbide integrity important too
Precipitation of WC very sluggish
TiC easy to oxidize
Erosion Test Data at 700 C (Solid Particle Erosion)
Erosion Testing, 700 deg.C, 60-deg
Stellite + 20%TiC
Stellite 720
Tribaloy T800
Stellite+ 50%CrC
Stellite 712
Stellite 1
Stellite 6
Stellite 12
Stellite + 70%CrC
Super Stelcar 50
902
304H+TMT coating
AISI 304H
410 + TMT Coating
AISI 410
0 0.01 0.02 0.03 0.04 0.05 0.06 0.07
Weight loss mg/g of erodant
Thermocouple Sheath
Stellite 712 TiC Composite
PTA Weld Overlay of WC in NiSiB
Equipment for Tarsand Excavation
AMC PTA Overlay
Screens for Tar Sand Processing
AMC PTA Overlay
Product Forms of Wear Resistant Alloys
Components
Castings
Powder Metallurgy Parts
Wrought Products (Stellite 6B, 6K, 706K)
Hardfacing Consumables
Hardfacing Consumables
Cast rods for GTAW (TIG) or Oxyacetylene weld overlaying.
Coated Electrodes for SMAW.
Tubular or solid wires for GMAW (MIG) or GTAW overlaying.
Powders
Flame spray and fuse.
Plasma transfer arc (PTA) weld overlays.
HVOF thermal spray.
Laser cladding.
HIP cladding or HIPing.
Effect of Different Overlaying Process
60
50
40
Fe %
30
20
10
0
0 0.1 0.2 0.3 0.4 0.5
Distance from bond line
PTA Weld GTA (TIG) Weld
Effect of Dilution on Hardness at Various Temperatures
As temp increases, effect of Fe dilution increases.
50
45 Temp C
40 22
Hardness Rc
35
204
30
427
25
538
20
15 649
10 760
5
0
Stellite-6 6% Fe 10% Fe 20% Fe
Surfacing Equipment
Plasma Transferred Arc Welding
High Velocity Oxyfuel (HVOF) Thermal Spraying
Industries Served
Automotive Power Generation
Chemical Processing Fossil fuel
Food Coal fired
Wood Cutting Nuclear
Waste Incineration Hydropower
Glass Oil Drilling and Refining
Pulp and Paper Medical and Dental
Steel Mills
Concluding Remarks
Deloro Stellite has a large portfolio of alloys in components and
hardfacing consumables.
Deloro Stellite is capable of providing alloy solutions for most of
wear/corrosion problems.
