Patent ID: 7487840

Claim:
A process for applying a wear resistant layer to a downhole component for inserting into a well, comprising: thermal spraying the wear resistant layer onto at least a portion of an external surface of the downhole component, the wear resistant layer being formed of an iron-containing material having a composition prior to thermal spraying consisting essentially of: C: from about 0.40 to about 2.5 weight percent; Cr: from about 4.0 to about 35 weight percent; B: from about 3.5 to about 10.0 weight percent; Ni: from about 0.0 to about 2.0 weight percent; Nb: from about 0.0 to about 2.5 weight percent; Mn: from about 1.0 to about 3.5 weight percent; Si: from about 0.0 to about 2.5 weight percent; Ti: from about 0.0 to about 2.0 weight percent; V: from about 1.15 to about 2.0 weight percent; and W: from about 0.0 to about 2.5 weight percent; with iron (Fe) being a principal remaining element of the composition.