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 600º 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 µ

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 @ 66º 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 800º 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 470°C

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 (HIP’ed)

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

150°C 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 HIP’ing.
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.