NanoSteel Technology Overview - Lincoln PDF

NanoSteel Coatings | Technology Overview
Lincoln Electric Acquisition June 2014
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Example Applications
Thermal Spray Products
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Longer Life on Mission Critical Components: Power Generation
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Power Applications:
Stack to Stack Approach
1 2 3 4 5 6 SCR 7 8
Coal Handling Thermal spray
Waterwalls Superheater Reheater: Economizer SDA ID Fan
Overlay plate and overlay
Thermal spray Thermal spray Thermal spray Thermal spray Thermal spray Thermal spray
for wear plate for
for erosion for erosion for erosion for erosion for corrosion for erosion
protection of erosion control
control on control on control on control on control on control on fan
chutes and on ductwork
boiler tubes boiler tubes boiler tubes boiler tubes chamber walls blades
conveyors and LPA
Screens
4
1
2
5
6 7
8
NanoSteel provides turnkey solutions for major wear areas in power stations
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Power Applications:
Boiler Tubes
Erosion on waterwall tubes Biomass Boiler Tube Coating NanoSteel coating after 9 mos. in
service shows no sign of erosion
• Challenges • Solution
• Forced outages ~70 days • Proper understanding of wear patterns
• Current solution not working • Applied SHS8000 to varying thicknesses
• Goal of 100 days of no metal loss on tubes
• NanoSteel solution achieved 340 days
• ~5x improvement over old solution
SHS 8000 has proven performance in highly erosive boiler applications

SHS8000 Coating In-Situ Elevated Temperature Property Changes
Vickers Microhardness Low Stress Abrasion Resistance
• Coating hardness and wear resistance increase with temperature

• Note: constant 20 minute exposure time used
• Complete devitrification expected at 1116°F (602 C) after 20 minutes
• Can be used to predict coating performance at elevated temperatures

Power Applications:
Sentry 8000 LPA Screens
Uncoated screen after 12 mos. NanoSteel coated screen after 12 mos. NanoSteel coated screen - New
Put back into service for ~ 2 additional years
• SCR damage due to large particle ash (LPA) • SHS 8000 thermal sprayed on screens
• Current screens failing prematurely • SHS 8000 mitigates erosion while
• Customer needed 2x improvement over maintaining proper pressure drop
existing solution to handle both impact and • Screen geometry no longer a factor
erosion due to the versatility of thermal spray
options
Sentry™ 8000 LPA screens are engineered to maintain open area and extend screen service life

Power Applications:
Dry Scrubber Chambers
Corrosion scale buildup on ID SHS 7570 coated wall

of chamber wall
Catastrophic chamber
wall failure
• Prevent chloride pitting corrosion on spray • Extensive solution of ‘repaired’
drying absorption (S DA) chamber chamber walls
• Corrosion caused catastrophic failure • Repair all holes
• Goal was to have the solution last ~15yrs • SHS 7570 thermal spray for the
prevention of pitting and provide the
projected life goal
SHS 7570 offers superior corrosion control in harsh power applications

Power Applications:
Flue Gas Dispersion Assemblies
Vane oxidation & wear
NanoSteel Coated Vanes
• Erosion damage on SDA turning vanes • Replace damaged vanes
• Gas flow direction uncontrolled • SHS 8000 thermal sprayed on vanes
• Mixture of fly ash, lime milk, and
cooling tower blow down water
SHS 8000 significantly extends fan blade service life

Custom Design and Engineering Support: Pulp and Paper
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Pulp & Paper:
Paper Rolls
• Longer coating life • Provided NanoSteel with existing
• Longer time between maintenance specs and asked for an engineered
cycles solution
• Depending on roll NanoSteel has
TWAS and HVOF as solutions
• Outperformed existing solution by
~3x
NanoSteel TWAS/HVOF solution increases paper roll performance and reduces down time and maintenance
cycles

Longer Life on Mission Critical Components: Cement
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Cement Applications:
Steel Extension Chutes
• Steel chutes to heavy causing injuries • Use Al as the substrate (~40lbs)
(~80bls) • SHS 7170 thermal sprayed on chute
• Extend chute life due to high wear • Weight reduction of ~50%
NanoSteel coated chutes offer a lighter-weight, longer-lasting transfer chute

Thermal Spray
Benefits
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NanoSteel Thermal Spray Solutions: Key Benefits
• NanoSteel Thermal Spray Characteristics

• Development of amorphous, partially devitrified, fully devitrified structures
• Hardness, wear resistance, and erosion resistance increases with devitrification
• Devitrified Nanocomposite structure higher than metallic glass
• Metallic glass structure has higher corrosion resistance than devitrified structure
• Chemistry of the protective oxide layer in glass also very important
• NanoSteel Thermal Spray Key Properties

• Very high bond strength without the need of a bond coat
• Exceptional bond strength on aluminum substrates
• Good 3-body wear resistance
• Not as high as the archetypical 88 /12 WC Co materials
• Exceptional 2-body wear resistance
• Superior to carbide materials
• Very good corrosion resistance
• In certain environments like seawater with Cr, Mo, W containing glasses

Thin Coatings - Thermal Spray:
For Use in Existing Commercial Applications and Standard Forms
Product Form Application Process Market Example Applications
Power
TWAS
Generation
Pulp & Paper Boiler Tubes Screens
Wire
Rolls & Cylinders
Oil & Gas

HVOF
Mining
Powder Drill Pipe Valve
NanoSteel coatings are designed to extend life of critical components

Typical Coating:
Macrostructure
HVOF Coating Wire-Arc Coating
• Representative coating macrostructure

• Macrostructure of coatings not fully dense due to nature of spray process
• Typically 0.5 to 1% porosity in HVOF, 2 to 5% porosity in Wire-Arc
• Enabling structure achieved on the nanoscale level
• Need to utilize TEM microscopy to image structure
Macrostructure similar to other coatings but nanoscale microstructure enabling

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Thermal Spray Coatings:
Properties
Bond Strength - ASTM C633 Vickers Microhardness - ASTM E384
12000 1200
10000 1000
8000 800
HV (300g)
(psi)
6000 600
4000 400
2000 200
0 0
SHS 8000 SHS 9172 SHS 8000 SHS 9172 SHS 8000 SHS 9172 SHS 8000 SHS 9172
HVOF HVOF TWAS TWAS HVOF HVOF TWAS TWAS
Wear Resistance - ASTM G65 Proc. B

0.30
0.25
0.20
Mass Loss (g)
0.15
0.10
0.05
0.00
SHS 8000 SHS 9172 SHS 8000 SHS 9172
HVOF HVOF TWAS TWAS

Application Process:
HVOF
• HVOF – High Velocity Oxy Fuel
• Utilizes atomized powder feedstock
• Atomized powder is axially fed into a high velocity flame which accelerates the
powders to high velocities and imparts some heat which softens the particles
• The high velocity flame is produced by burning a fuel gas with oxygen in a
converging / diverging nozzle
• The particles are primarily solid when they impact the substrate and the high kinetic
energy provides for the deformation needed to obtain the mechanical bond
• Equipment Requirements
• Powder Feed Unit
• Fuel and Gas Control Unit
• HVOF Torch
• Complex process that is best suited for shop applications utilizing robotic equipment

HVOF Coating:
Example Nanostructures
As-Sprayed HVOF (SHS7574) Devitrified HVOF (SHS7574)
As-Sprayed HVOF (SHS7170) Devitrified HVOF (SHS7170)

NanoSteel HVOF Materials:
Major Benefits
HVOF Process: Design Strategy:

HVOF Materials:
1st Generation: Good overall hardness and
SHS7170 – 1st Generation abrasion resistance
SHS7574 – 2nd Generation 2nd Generation: Specialized properties such
SHS9172 – 2nd Generation as corrosion resistance or hardness
SHS8000 – 3rd Generation 3rd Generation: Optimized properties for

boiler applications
Example Characteristic Properties for HVOF Materials
Bond Strength Abrasion Resistance Microhardness
Bond strength > 11,150 psi Low mass loss: 0.07 g - 0.18 g 300 g load: 1056 - 1100 kg/mm2

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TWAS
TWAS – Twin Wire Arc Spray
• Utilizes two cored wire alloy feedstock
• Wires melted by an arc transferred between the two wires
• Molten material is atomized by stream of compressed air directed through the nozzle and
accelerated on to the target part to build up a coating
• Coating built up by layer composed of many small splats, most of which solidify upon contact with
the substrate
• Bonding is mechanical in nature and the surface to be coated must be prepped by cleaning and
profiling
• Eliminates surface contaminants – rust, paint, scale, others…
• Provides a textured surface allowing for mechanical bonding
• Allows for long continuous runs and automation
• Equipment Required
• Welding Power Source
• Compressed Air
• Twin wire thermal spray torch (TAFA 8830/8835 standard)

TWAS Coatings:
Example Nanostructures
As-Sprayed Wire-Arc (SHS7170) Devitrified Wire-Arc (SHS7170)
As-Sprayed Wire-Arc (SHS8000) Devitrified Wire-Arc (SHS8000)

NanoSteel Twin Roll Wire-Arc Materials:
Major Benefits
Wire-Arc Process: Design Strategy:

Twin Wire-Arc Materials:
1st Generation: Good overall hardness and
SHS7170W16 – 1st Generation abrasion resistance
SHS7570W16 – 2nd Generation 2nd Generation: Specialized properties such
SHS9172W16 – 2nd Generation as corrosion resistance or hardness
SHS8000W16 – 3rd Generation 3rd Generation: Optimized properties for

boiler applications
Example Characteristic Properties for Twin Roll Wire-Arc Materials
Bond Strength Abrasion Resistance High Microhardness
Bond strength > 11,000 psi Low mass loss indicates high 300 g load test load
Approaching HVOF abrasion resistance Microhardness > 1150 kg/mm2

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Longer Life on Mission Critical Components: Oil & Gas and Mining
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Hardfacing Application:
Oil & Gas – Sand Blender (Pump)
• High wear area causing PM issues • SHS 9800 weld overlay applied to
• Current solution lasting only one (1) casing internals and outlet
week • New application, trials currently
• Wet fracking sand and water underway (~10x improvement)
environment
Targeting minimum 10x life increase over current solution

Wear Pipe Application:
Slurry Transport – Concrete & Shotcrete
• Challenge
• 1800 ft vertical delivery pipe system
perfectly aligned
• Bare L80 casing was lasting 16 months
• Solution
• NanoSteel SHS 9800 ID clad casing
projected to last 17 years
Mine Engineers project savings of at least $1M through eliminated change outs

Wear Plate Application:
SUPRA Side Dump Haul Truck
• Heavy side doors causing premature • SHS 9800 wear plate
hydraulic failure • ~25% weight reduction
• Lighter solution • Excellent wear
• Longer life • No door failures reported post SHS
• Underground application 9800 liner installation
NanoSteel liners maximize lifetime without increasing liner package weight

Gold Mine Skip Car
After hauling 410,000 tons After hauling 625,000 tons After hauling 1 million tons
• Underground gold mine needed a • SHS 9800 was used to produce wear
lighter longer lasting solution for plate
underground applications • Showing a wear resistance of ~3.5x
• Needed to outperform CrC plate of previously trialed CrC plate
• In general: everything is more critical
when underground
NanoSteel liners now runs two full PM cycles before requiring replacement. Prior to switching to NanoSteel the
skip had to be removed from service once between scheduled PM cycles beforehand to replace the liner.

CAT 793 liner
• Contacted by top ten mining • SHS 9700 was wire was used for the
company to develop a lightweight trials
loner lasting wear plate • Installed in Oct 07 next to 500BHN
• 500 BHN only lasted 11months plate
before change out • 52 months later and 13M tons
• Initial testing would be on the back of remove from service
a 793 haul truck
¼” SHS9700 overlay provided > 4x wear life over ¾” 500 BHN plate and launched a wide variety of proven
applications across mine site locations

Custom Designed Wear Solutions
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Oil and Gas:
Weld Overlay Hardband for Drill Pipe
DEA 42 Testing
• Largest drill pipe OEM (Grant Prideco) •
Joint development effort produced
wanted to brand its own hardbanding Platinum HB
product • Resulted in more than 290,000 tool
• Goal was to produce the first joints or 1200 miles of pipe service
engineered hb that was casing with a record of six years in service
friendly and provided excellent tool • Subsequent development produced a
joint protection crack free engineered solution
• Sold globally under NanoSteel
Engineered hardbands for casing-friendly performance and crack-free application

NanoSteel Guardian Hardband Materials vs. Competitors:
ASTM G65 Wear Comparisons and Cracking Comparisons
1.4
ASTM G65 Testing - Mass Loss Comparisons 1.25
1.2
1.0 The wear resistance of the Guardian CF

is 3x greater than the wear resistance of
Mass Loss (g)
the Armacor Mstar. 300XT difficult to re-

0.8 weld and heavy cracking
0.64
0.6
0.4 0.33
0.22
0.2
0.09
0.0
Guardian CF Guardian HB Armacor Mstar Arnco 100XT Arnco 300XT
Single Layer Overlay on AISI 4140 Circle Beads on AISI 4140

Hardness ASTM G65 Crack Count
Material (Rc) ASTM Mass Loss (g) 260°C Preheat
Guardian CF 60 0.22 0 (Crack Free)
Guardian HB 58 0.33 2 (Moderate Cracking)
Armacor Mstar 55 0.64 18 (Heavy Cracking)
Arnco 100XT 59 1.25 0 (Crack Free)
Arnco 300XT 66 0.09 6 (Heavy Cracking)

Lighter Weight and Engineering Support
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Crush & Convey Application
Belt Conveyor – Skirt Liners
• High wear area causing PM issues • SHS 9800 was used to produce the
• Needed lighter solution for safety wear plate
• Longer lasting to make or exceed PM • 25% weight reduction
cycles • ~3-6x life increase
• Easy to install • Easier to install
• Solution must have a smooth low
friction surface minimizing sticking
Liners provided cut formed and ready to install with studs or countersunk holes

Processing Application:
Apron Feeder – Skirt and Wall Liners
Install Photos After 1.48 Million Tons

• ‘Same as Belt Conveyor- Skirt Liner’ • Same benefits as Belt Conveyor
• New design concept • Brick wall pattern was used to ‘break
the lines’ decreasing high wear zones
NanoSteel liners increase allow the mine to double liner size and still reduce weight

Processing Application:
Trommel Screen Liners
SHS9800 Wear Liner
• Longer life • SHS 9800 wear plate
• Wet and dry environment • Engineered solution (formability and
• 500 BHN failing prematurely hole design)
• Wear package designed to increase
wear life by ~5x over 500 BHN
NanoSteel was part of the entire process from design specifications to fabrication

Works with other Hardfacing Materials
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Longwall Armored Face Conveyors:
Pan Liners
• Heavy chain groove wear on the Q&T • SHS 9800 weld overlay used only on
plate the groove path
• Protection needed from both chain
and ore
• Frequent change outs need to be
reduced
Application of NanoSteel overlay has virtually eliminated chain groove wear and will allow the pans to run a full
longwall cycle without maintenance or repair.

Dipper / Bucket Liner Packages
• High wear within bucket • SHS 9800 wear plate for bucket liner
• Reduce weight • Combination of existing PTA with SHS 9192
• Longer service life for liner package weld overlay for the teeth
• Teeth not wearing out uniformly • More uniform wear on the teeth
NanoSteel liners & overlays increase availability and extend maintenance cycles

Easy Installation
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CAT 793 - 250 ton truck:
Rear Liner Installation

Weld Overlay
Benefits
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Thick Coatings - Weld Overlay:
For Use in Existing Commercial Applications in Standard Forms
Product Form Application Process Market Example Applications
GMAW Oil & Gas

OAW Mining Hardbanding Hardfacing
(OD Welding) (ID Welding)
Wire
SMAW Mining
Stick Electrode Hardfacing Repair
Mining
PTAW
Oil & Gas
Powder
Truck bed liner Downhole Tools
NanoSteel coatings are designed to extend life of critical components

NanoSteel Wearplate:
SHS 9800
• Designed for extreme wear environments Overlay Wear Plate

• Uses include
• Oil Sands equipment
• Wear plates for chutes and liners
• Hardfacing for grinders, conveyors
• Combination of favorable properties:

• Rockwell C (HRc) Hardness : 66 – 71 HRc
• Wear resistance (ASTM G65): 0.09 to 0.12 g
SHS 9800
• 3rd generation NanoSteel overlay material
• SHS 9192 SHS 9700 SHS 9800
• 8 element glass forming alloy

• Fe-Cr-Nb-Mo-B-C-Si-Mn (see table)
• Provides high hardness and wear resistance

NanoSteel Hardfacing Solutions:
Key Benefits
• NanoSteel Hardfacing: Approaches vs Carbide / Hardmetal

• Does not incorporate hard particles within the wire core
• Forms a high volume fraction of borocarbide phases during welding
• Provides a carbide fraction of 60-70% vs typical weld wires of 40-45%.
• Borocarbide are completely wetted by the matrix preventing premature pull-out
• Refined nature of the borocarbides allow reduction of stress concentration sites
• NanoSteel Hardfacing Key Characteristics

• Superior hardness and wear resistance
• Resilience to dilution
• Uniformity in wear resistance

Wear Resistant Products
Comparison to other Materials in the Market
NanoSteel
Cast Irons & Chrome & Complex

Tool Steel Carbides
Martensitic
Materials

NanoSteel Weld Overlay Products:
Major Benefit: Hardness / Wear Resistance
Hardness (Rockwell C) Abrasion Resistance (ASTM G65)
• Rockwell C hardness: Rc 67 - 71 • Dry sand abrasion resistance very high

• Single and double pass hardness similar due • ASTM G65: mass loss 0.09 to 0.14 g
to design to minimize dilution effects
• Uniform properties through entire thickness
• Uniform properties through entire thickness
• Bridges the gap between steel and carbide /
• Superior to Quench & Tempered steel plate hard metal performance

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NanoSteel Weld Overlay Properties
• Minimized Impact of Dilution:

• Typical Overlays
• Require multiple layers to achieve optimum hardness
• Wear resistance varies throughout weld deposit
• NanoSteel
• Achieves High hardness with single layer (w/in 50 µm)
• Wear resistance consistent throughout weld deposit
65% Angular WC 60% Spherical WC SHS 9800
• Phase Distribution
• Typical Overlays
• Distinct hard particles in soft matrix
• Non-uniform wear / “pull-out”
• NanoSteel
• No distinct hard particles – all hard
matrix
• Uniform wear w/ no “pull-outs”

Microstructural Scale Uniformity:
Leads to Uniformity in Wear
Secondary Electron Images of Wear Scars
65% Angular WC 60% Spherical WC NanoSteel (SHS9800)
• Images taken after 12,000 cycles of testing

• Preferential wear of matrix occurs in WC samples leading to premature failure
• Uniform wear found in the NanoSteel overlay
NanoSteel not susceptible to preferential wear of matrix material

GMAW / OAW / PTAW
• GMAW – Gas Metal Arc Welding

• Utilizes cored wire alloy feedstock
• Consumable and substrate by the arc transferred between the
consumable welding electrode and substrate
• Shielding gas protects molten weld pool from atmospheric
contamination
• OAW – Open Arc Welding
• Also referred to as flux cored (FCAW), self shielded, inner shield
• Machine requirements similar to GMAW, but does not require a
shielding gas
• Can be easier for field applications and eliminates costs associated
with shielding gases.
• PTAW – Plasma Transferred Arc Welding
• Feedstock – Atomized alloy powders
• Standard product size 53 to 180 microns
• A plasma arc transferred between the tungsten electrode in the
torch and the substrate
• The arc creates a molten puddle on the substrate and provides the
heat necessary to melt the incoming powder feedstock

NanoSteel Company
The Science
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Overview
Company Background
• Founded in 2002
• Worldwide exclusive license to technology developed at Idaho National
Laboratory
• Headquartered in Providence, RI with locations in Idaho Falls and Troy, MI
Products and Services
• Core competence ‒ designing proprietary nano-structured steel alloys with

exceptional properties for industrial applications
• Products designed to be manufactured and applied with existing
equipment and operational infrastructure
• Product forms ‒ metallic coatings, powder metals, foils and sheet steel

Materials Nanotechnology
• Nanocrystalline Material
• Defined by ASTM E 2456-06 “Terminology for Nanotechnology”
• Length scale from approximately 1 to 100 nanometers (nm)
• Ant - 5 million nm, human hair - 100,000 nm, red blood cell - 3000 nm
• Distinct Usages of Materials Nanotechnology

• Particulate Materials Nanotechnology (PMN)
• Shrinking the scale of the particle / device to the nanoscale
• Catalysts, pigments, UV absorption, nanomachines, (i.e. Feynman Vision)
• Thermal spray coatings using nanoparticulate feedstock
• Bulk Materials Nanotechnology (BMN)

• Shrinking the microstructural scale down to the nanoscale
• 2-d phase and grain sizes
• Structural refinement via solid / solid state transformations
• Glass > glass devitrification
• Applied as a platform technology
• Enabling solutions for mainstream solutions
NanoSteel Surface Technology is BMN

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NanoSteel Technology
NanoSteel Others
Bulk Materials Nanotechnology Particulate Materials Nanotechnology
• Nanometer sized microstructure in the alloy • Nanometer sized particles or devices
• Utilizes standard industrial scale production • Products: Pigments, coatings et al.
• Conventionally sized particles • Utilizes specialized small-scale production
Nano Nano
”Structures” ”Particles”
NanoSteel designs alloys with grain/crystal sizes in the nanometer realm

Achieved through combination of alloy composition and production process cooling rate

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NanoSteel Technology Progression
NanoSteel’s development path from metallic coatings to sheet steel

NanoSteel Patent Portfolio & R&D Rewards
Patents - Total World
2002
Thermal Spray
Powder
2012
2004 High Strength
Thermal Spray Nanostructured
Wire Steel
For Large Scale
Industrial
Components
2007 2009
Weld Overlay
Weld Overlay
GMAW/OAW Wire
For Wear Plate
Strategy: NanoSteel focused on owning IP rights to the entire class of nanostructured steels
(Patents based on alloy composition, microstructure and properties)

NanoSteel’s Products
High Strength Alloys for Wear Resistance and Structural Applications
Wear Resistance to Extend Service Life Lightweighting for Improved Efficiencies
Metallic Coatings Powder Metals Foils Sheet Steel
NanoSteel properties and performance is outside the boundaries of existing steel alloys

Bulk Materials NanoTechnology:
Technical Summary
• Crystalline materials contain nanoscale features which impact performance

Point defects 0-d Dislocation 1-d Grain Boundary 2-d
• Two approaches to improving material properties

• Type 1: Eliminate all defects – not commercially viable (circa 1960s)
• Type 2: Create high volume fraction of defects (Grain Boundary 2-d)
• Defect /defect interactions render dislocations immobile
• Smaller grain size means more grain boundaries
• NanoSteel’s SHS create high volume defects – Type 2:
Metallic Glass Nanostructure
• High “undercooling” - maintains liquidity below solidification temp
• High “nucleation” – grains form everywhere simultaneously
• High quantity of grains formed minimize grain size
• Creates uniform, fine microstructure
SHS Technology greatly Improves wear and corrosion resistance

Bulk Materials NanoTechnology (BMN)
• Cooling Rate 1 – Example structure showing metallic glass

• Cooling Rate 2 – Example structure showing devitrified nanocomposite

NanoSteel Product Overview
• Thermal Spray
• Thin Coatings
• NanoSteel Coatings applied primarily with two processes
• HVOF and TWAS
• Coatings can both field and shop applied
• Weld Overlay
• Thick Coatings
• Severe abrasion applications
• Sold as consumables
• Cored Wires, Stick Electrodes, and Powder
• Wear Plate / Pipe

• Finished Wear Products Plate and Pipe
• Shop Applied
• Produced in accordance to supplied drawings and
specifications

Product Forms:
Consumables
• Cored Wires
• Continuous cored wires with a metal sheath and an alloy
powder core
• NanoSteel Cored Wires are used for the following processes
• Thermal Spray – TWAS
• 1/16” diameter cored wires
• Weld Overlay – MIG / Open Arc Hardfacing
• 0.045”, 1/16”, 3/32”, 7/64”, and 1/8” diameter cored wires
• Atomized Powders
• Spherical atomized alloy powders
• Thermal Spray – HVOF
• 15 to 53 micron powder
• Weld Overlay Hardfacing – PTAW
• 53 to 180 micron powder
• Stick Electrodes
• Flux covered wire cored electrodes
• Weld Overlay Hardfacing – SMAW
• 5/32” diameter
NanoSteel alloys are available in common feedstock forms and usable on standard equipment

Overlay Limitations and Precautions
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General Selection Process
Items that should be considered prior to specifying an alloy for a

particular application
Substrate
Deposit Thickness
Operating Temperature
Tempering Effects
Impact Resistance
Corrosion Resistance

NanoSteel Overlay & Substrate Compatibility
NanoSteel alloys develop structures and properties based on their

designed chemistries.
Changes in overlay chemistry due to dilution with various substrate

materials can have significant effects on the properties of the NanoSteel
overlay
Nanosteel alloys are best suited for overlay on mild steel and low alloy
iron base substrates

Austenitic Iron (Fe) Based Substrates
• Austenitic Fe base alloys are not suitable for

overlay with NanoSteel alloys.
• Dilution with Austenitic alloys causes
significant microstructural changes in the weld
deposit
• Some Examples Include:
• 300 Series Stainless grades 304 and above
• Austenitic Mn Steel Alloys
• 12 – 15% Mn steel alloys
Micrograph showing SHS 9700 overlay
• Hadfield Mn steel on Hadfield Mn steel substrate.
• Fe based CrMn Alloys Extensive underbead cracking and
• Austenitic alloys are non-magnetic and typical microstructure for the SHS 9700
overlay
preliminary screening can made by testing with
a magnet

Hadfield Mn Steel Example
• SHS 9192 single layer overlay on Hadfield Mn steel showing typical spalling
failure with the overlay separating from the substrate
• Failure initiates at weld interface and propagates through material
• The defects form almost immediately upon solidification

Other Fe Based Substrates
• NanoSteel overlay are compatible with • Some weldable (Fe) based alloys
some grades of Fe based alloys with • High strength low alloy (HSLA) steels
proper procedures per substrate • 4140, 4130, 4340
requirements
• Lower alloyed tool steel grades
• Example: S7
• Some change in physical properties
• Medium carbon steel grades
can be expected when overlaying
alloyed iron based materials • Examples: 1040, 1050
• Hardness • Some stainless grades
• Wear Resistance • Examples: 17-4 PH, 410SS, 420SS
• Impact Resistance
Alloys similar to those above should be
evaluated on a per case basis
• These changes in expected properties
should be considered prior to selecting
a NanoSteel overlay material for an
application

17-4 Precipitation Hardening Example
SHS 9192 overlay on 17-4 PH SS

• Slight reduction in single layer hardness
• 68Rc on 17-4 Stainless steel
• 69-70 typical single layer on mild steel
• Double Layer properties in line with typical
for both hardness and wear resistance
• Microstructure Analysis
• Microstructures typical of the SHS 9192
• No evidence of underbead cracking

Others
The following substrates and materials are NOT suitable for overlay with NanoSteel
alloys
• All Cast irons

• All non Fe based materials
• Ni based alloys
• Cobalt based alloys
• Chrome Carbide Overlays
• Elevated chrome and carbon content leads to severe brittleness in NanoSteel
materials when applied over chrome carbides
• Tungsten Carbide Overlays
• Alloys containing greater than 5 wt% combined Ni and Mn are typically not
suitable for overlay with NanoSteel materials

Back Up
© 2013©
The
2013
NanoSteel
The NanoSteel
Company,
Company,
Inc. All Inc.
rights
Allreserved.
rights reserved. 71
Hardfacing Application:
Mining – Suction Pipe feeding Pump
• High wear area causing PM issues • SHS 9800 weld overlay applied to ID
• Current solution lasting 1.5 months of pipe
• Abrasive slurry containing crushed • Currently in trial with initial
ore and fractured steel grinding measurements projecting multiple
media wear life increase over bare pipe
Application requiring resistance to abrasive slurry with some steel grinding media

Thickener Rake – Squeegee Liners
• Current liner last 3.5 months • SHS 9800 wear plate
• Unit runs on 6 month PM cycles • Install later in Q2 of 2014
Projected life with NanoSteel liners is 30 months

© 2013 The NanoSteel Company, Inc. All rights reserved.
NanoSteel, the NanoSteel logo, Steel. Redefined. and Stick With Steel are either registered trademarks or trademarks of
The NanoSteel Company in the United States and/or other countries.

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NanoSteel Coatings | Technology Overview

Lincoln Electric Acquisition June 2014

© 2013 The NanoSteel Company, Inc. All rights reserved. 4

© 2013 The NanoSteel Company, Inc. All rights reserved. 5

Vickers Microhardness Low Stress Abrasion Resistance

• Coating hardness and wear resistance increase with temperature

© 2013 The NanoSteel Company, Inc. All rights reserved. 6

© 2013 The NanoSteel Company, Inc. All rights reserved. 7

Corrosion scale buildup on ID SHS 7570 coated wall

SHS 7570 offers superior corrosion control in harsh power applications

© 2013 The NanoSteel Company, Inc. All rights reserved. 8

Vane oxidation & wear

NanoSteel Coated Vanes

SHS 8000 significantly extends fan blade service life

© 2013 The NanoSteel Company, Inc. All rights reserved. 9

© 2013 The NanoSteel Company, Inc. All rights reserved. 11

NanoSteel coated chutes offer a lighter-weight, longer-lasting transfer chute

© 2013 The NanoSteel Company, Inc. All rights reserved. 13

• NanoSteel Thermal Spray Characteristics

• NanoSteel Thermal Spray Key Properties

© 2013 The NanoSteel Company, Inc. All rights reserved. 15

Product Form Application Process Market Example Applications

Rolls & Cylinders

Oil & Gas

Powder Drill Pipe Valve

NanoSteel coatings are designed to extend life of critical components

© 2013 The NanoSteel Company, Inc. All rights reserved. 16

HVOF Coating Wire-Arc Coating

• Representative coating macrostructure

© 2013 The NanoSteel Company, Inc. All rights reserved. 17

Wear Resistance - ASTM G65 Proc. B

© 2013 The NanoSteel Company, Inc. All rights reserved. 18

© 2013 The NanoSteel Company, Inc. All rights reserved. 19

As-Sprayed HVOF (SHS7170) Devitrified HVOF (SHS7170)

HVOF Process: Design Strategy:

SHS8000 – 3rd Generation 3rd Generation: Optimized properties for

Example Characteristic Properties for HVOF Materials

Bond Strength Abrasion Resistance Microhardness

© 2013 The NanoSteel Company, Inc. All rights reserved. 21

© 2013 The NanoSteel Company, Inc. All rights reserved. 22

As-Sprayed Wire-Arc (SHS8000) Devitrified Wire-Arc (SHS8000)

© 2013 The NanoSteel Company, Inc. All rights reserved. 23

Wire-Arc Process: Design Strategy:

SHS8000W16 – 3rd Generation 3rd Generation: Optimized properties for

Example Characteristic Properties for Twin Roll Wire-Arc Materials

Bond Strength Abrasion Resistance High Microhardness

© 2013 The NanoSteel Company, Inc. All rights reserved. 24

Targeting minimum 10x life increase over current solution

© 2013 The NanoSteel Company, Inc. All rights reserved. 26

© 2013 The NanoSteel Company, Inc. All rights reserved. 27

NanoSteel liners maximize lifetime without increasing liner package weight

© 2013 The NanoSteel Company, Inc. All rights reserved. 28

© 2013 The NanoSteel Company, Inc. All rights reserved. 29

© 2013 The NanoSteel Company, Inc. All rights reserved. 30

© 2013 The NanoSteel Company, Inc. All rights reserved. 32

1.0 The wear resistance of the Guardian CF

the Armacor Mstar. 300XT difficult to re-

Single Layer Overlay on AISI 4140 Circle Beads on AISI 4140