Computational metallurgy is a technique being used and developed in the field of bulk alloys to design and develop novel amorphous and nanocrystalline materials. This technology can be transitioned to develop chemistries for both wear and corrosion resistant thermal spray coatings. Using computational metallurgy and small scale laboratory experiments, nanostructured and amorphous chemistries can be designed to specifically accommodate one of the many environmental conditions challenging the oil and gas industry. This study reviews the design procedures behind developing three unique chemistries intended to function in different environments: 1) an Fe-based chemistry designed for metal to metal sliding wear resistance, 2) an Fe-based chemistry containing elevated refractory content intended specifically for spray and fuse applications to resist sulfurous corrosion, and 3) a Ni-based chemistry similar to Alloy C276 for high temperature corrosion resistance. All three alloys were designed using computational techniques and eventually manufactured into cored wires for use within the twin wire arc spray (TWAS) process. The fine grained structure provides unique benefits to each application including 1) high hardness, 2) ability to rapidly form protective scale, 3) low melting temperature and creep resistance.

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