Patent ID: 8524375

Claim:
A work roll for use in metal or metal alloy sheet manufacture comprising a cylindrical-like structure having an outer peripheral surface and a thermally sprayed coating on the outer peripheral surface of said cylindrical-like structure, wherein said thermally sprayed coating is thermal sprayed from a thermal spray powder, said thermally sprayed coating comprising from about 65 to about 95 weight percent of one or more metal carbides represented by the formula M x C wherein M is one or more of W, Co, Mo and Cr, and from about 5 to about 35 weight percent of one or more transition metals selected from chromium, manganese, iron, cobalt and nickel; wherein said thermal spray powder has a particle size from about 5 to about 50 microns and a Group VI metal carbide grain size of from about 0.1 to about 2 microns; and wherein said thermally sprayed coating has a surface roughness less than about 60 microinches Ra; wherein M x C comprises one or more of MC, M 2 C, M 6 C, M 9 C and M 12 C phases; and wherein said thermally sprayed coating has a porosity of not greater than about 2.5%.