Ni- and Fe-Based Heat-Resistant Alloys for Coatings
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Ni- and Fe-Based Heat-Resistant Alloys for Coatings

01
Description
JSC POLEMA, Russia's largest manufacturer of metal powders, offers a diverse range of powder alloys and pure metals produced by various methods, including high-pressure gas and water atomizing, oxide reduction, and mechanical grinding.


Recently, the company has been actively implementing new technical solutions for gas atomizing, which significantly improve the morphology of particles, reduce the number of satellites, and increase the fluidity of powders and the quality of weld coatings.


Atomized powders produced by JSC POLEMA are classified into two groups: powders for coatings and structural powders.


The first group includes over 200 types of powders for coatings using various methods, including self-fluxing nickel, iron, and copper alloys, tool steels, high-carbon and low-carbon steels and alloys, corrosion-resistant and heat-resistant steels and alloys, as well as tin- and zinc-based composite powders and alloys.


The variety of available powders for coatings, used in high-speed, detonation, gas-flame, and plasma spraying, gas-powder, plasma, induction, and laser welding, allows to solve specific problems of surface hardening and effective protection against wear and corrosion of machines and equipment parts operating under elevated temperatures, high mechanical stress, and with abrasive substances and in aggressive environments.


The second group includes structural powders, such as pressed powders of pure metals (chromium, molybdenum, tungsten, nickel, and titanium), copper-based alloys (bronze and brass), stainless steels, special alloys with high magnetic permeability (permalloys), and materials for shot jet processing of parts (tool steels).


Powders of this group are used for making sheet rolled products, bars, and non-ferrous and refractory metal forgings, tools, sintered and deformed parts, composite materials used in electrical engineering, electronics, tool engineering, machine engineering, aerospace industry, nuclear power engineering, vehicles, filters, gas absorbers, and other engineering areas.
02
specifications

VKNA, RP-NiCr16Al6Y, AP-Cr20Ni80, RP-Cr20Ni80, RP-NiCr20Co20Al13, RP-FeCr20Al6Y and others. 


Me (Fe, Ni, Co)-Cr-Al alloys provide heat-resistant coatings for gas turbine engines and energy equipment. 


Reduced and water-atomized powders may be used to make structural parts by sintering method.


RP-Ni85Al15 is gas-thermal and flame-resistant, durable in water and coating alkali, and can be used as substrate for oxide and carbide coatings.


RP-Ni70Al30 ensures flame-resistant and heat-resistant coatings at temperatures of up to 1200 0С, can be used for structural parts made by sintering.


RP-Ni55Ti45 provide wear-resistant coatings durable in coating alkali, seawater, in open air at temperatures of up to 600 0С, can be used for structural parts with shape-memory effects made by sintering.



Coating methods include: 

--plasma spraying,

--plasma-jet hard-facing (PTA),

--gas-flame spraying,

--detonation spraying,

--and high-speed spraying (HVOF).

Choice of material is related to the application of coating, and to the method of depositing strengthening coatings, it aims at acheiving special properties of the surface of machines and equipment parts.


Atomized powders may be delivered with other particle sizes not shown in the table, in microns: 45-125, -125, 100-140, 100-280, 160-280, 280-400.



*New materials: Ni-Cr-Al-Y alloys for coatings in the aerospace industry.


Ni-Cr-Al-Y alloys are widely used for coatings on blades that operate at high temperatures and thermal stresses.


Properties of NiAl Metallides


The main phase in the structure of PW-Ni70Al30 material is NiAl metalide (β` phase >95%), in PW-Ni85Al15 – Ni3Al metalide (γ`- phase >95%), in VKNA – Ni3Al metalide (γ`- phase). The structure of the materials in the coating is characterized by high resistance to recrystallization during their operation at elevated temperatures.


Particle size


The main cut is 20-63 μm, VKNA powder – 56 μm. The typical average size (nominal diameter) of powder particles is 30-40 microns.


Physical and Mechanical Properties of Powders and Coatings


VKNA is a heat-resistant superalloy based on Ni3Al metalide, phase-strengthened with refractory metal additives and characterized by excellent physical and mechanical properties of plasma coatings - structural thermostability, heat resistance and wear resistance in the conditions of GTE parts operating at 1150-12000 C.


PW-Ni70Al30 has a melting point of 1640 0C. It's characterized with exceptionally high heat resistance when heated in air, three times the corrosion resistance of the well-known heat-resistant alloy CrNi77TiAlB.


Material

Weight gain in air, g/m2, at T 0C for 100 hours

1000 1100 1200

RP-Ni70Al30 (Ni70Al30)

0.06 0.1 0.2

CrNi77TiAlB (NiCr20Ti2,5Al)

0.14 0.36 0.65


RP-Ni70Al30 in plasma coatings is corrosion-resistant in atmosphere, water and in alkalis (NaOH and KOH solutions).
Surface hardness is approximately 40 HRC; the material forms durable coatings with steel and copper and presses and sinters well in vacuum.


RP-Ni85Al15 has a melting point of of 1400 0С; excellent heat-resistance of coatings when heated in open air to 1150 0С; the material and coatings are durable in the atmosphere, water and alkalis.

Hardness of plasma coatings is approximately 300 HB; the material forms durable coatings with steel and copper.

03
advantages
—
Profound production experience
—
Strict quality control of all produced materials
—
In-house research laboratory
—
Flexible discount system
04
Product names
Below are examples of product names:



AP-NiAl5, 

AP-Cr20Ni80, 

AP-Cr20Ni80, 

RP-Cr20Ni80, 

RP-FeCr25Al6, 

RP-FeCr20Al6Y, 

RP-FeCr25Al10, 

RP-Ni70Al30, 

RP-Ni85Al15, 

RP-Ni55Ti45, 

RP-Ni75Al23W (VKNA), 

RP-NiCr20Al10, 

RP-NiCr16Al6Y, 

RP-NiCr20Co20Al13, 

AP-NiCr22Al10Y, 

AP-NiCr67Al12, 

RP-NiCr20Si.





You can contact our sales managers for more details at:

export_polema@metholding.com,

tel.: +7(4872)25-06-76.
05
chemical composition

Powder name
Particle shape
Cut

Nominal chemical composition, %

Main components and impurities

Fе

Сr

Ni

Co

Мо

Al

Others

AP-NiAl5 

gas-atomized, spheroidal

<1

-

base

-

-

5

С <0.1, Si, Fe, Mn <1

AP-Cr20Ni80 

gas-atomized with Ni, spheroidal

AP-Cr20Ni80 

water-atomized, round 

-40, 20-63, 40-100, 80-160 microns

<1

20.5

base

-

-

-

С, Mn <0.1
Si <0.5 О<0.05

RP-Cr20Ni80 

reduced, irregular
-40, 40-100, 40-160 microns

<0.3

20

base

-

-

-

С <0.06 S <0.01 Si <0.1 O <0.3

RP-FeCr25Al6 

reduced, irregular
-45, -63, -280 microns

base

25

--

--

--

6

С<0.2  Са, С <0.2

RP-FeCr20Al6Y 

reduced, irregular
-45, -63, -280 microns

base

26

-

-

-

6

С <0.2
Y

RP-FeCr25Al10 

reduced, irregular
-45, -63, -280 microns

base

25

-

-

-

10

С <0.2

RP-Ni70Al30 

reduced, irregular
20-63 microns

<0.2

-

base

-

-

30.5

С <0.07

RP-Ni85Al15 

reduced, irregular
20-63, 40-100 microns

<0.2

-

base

-

-

18.5

С <0.07

RP-Ni55Ti45 

reduced, irregular
20-63, 40-100 microns

<0.6

-

base

-

-

-

Ti 45
С <0.07

RP-Ni75Al23W (VKNA) 

reduced, irregular 

-56 microns

0.2

+

base

+

+

23

chem. comp. by request

RP-NiCr20Al10 

reduced, irregular
-45, -63, -280 microns

base

20

-

-

-

10

С <0.2

RP-NiCr16Al6Y 

reduced, irregular
-45, -63, -280 microns

-

16

base

-

-

6

Y 0.5
Са, С <0.2

RP-NiCr20Co20Al13 

reduced, irregular
-40,-63, 40-100 microns

<0.3

20

base

20

-

13

Y Si Nb
С 0.01-0.15

AP-NiCr22Al10Y* 

gas-atomized, spheroidal
(equivalent of Amdry 962 / NiCrAlY 66 22 10 1)

-

21-23

base

-

-

9-11

Y 0.8-1.2
S+P+Si+Mn 1% max

AP-NiCr67Al12* 

gas-atomized, spheroidal
(equivalent of Amperit 457.642)

-

19-21

base

-

-

11-12

Y 0.2-0.5
Re 0.7-0.9  Hf 0.7-0.9

RP-NiCr20Si 

reduced, irregular
-40,-63, 40-100 microns

-

20

base

-

-

-

Si 2


06
miscellaneous
If required by customers, powders are made with other particle sizes.
07
Application areas