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A method is provided for forming a metallic overlay having enhanced toughness. The metallic overlay may be a weld, a metallic coating, or similar application. The method includes applying a glass forming metallic alloy to a substrate while the alloy is in a molten or semi-molten state. At the interf

A method is provided for forming a metallic overlay having enhanced toughness. The metallic overlay may be a weld, a metallic coating, or similar application. The method includes applying a glass forming metallic alloy to a substrate while the alloy is in a molten or semi-molten state. At the interface of the metallic alloy overlay and the substrate the substrate metal becomes at least partially molten and combines with the alloy to form metallurgical bonds. When the metallic alloy cools it experiences a high relative degree of thermal contraction. The metallurgical bonds between the substrate and the alloy constrain the contraction of the alloy at the interface with the substrate. This results in the inducement of compressive stresses in the metallic alloy overlay. The induced compressive stresses inhibit the formation of cracks in the overlay and/or mitigation of the effects of any cracks in the overlay.

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What is claimed is: 1. A method for forming a metallic overlay comprising: supplying a metal substrate with a thermal expansion coefficient "X"; supplying a metallic alloy, which has a thermal expansion coefficient "Y", wherein said metallic alloy has a coefficient of thermal expansion "Y" greater

What is claimed is: 1. A method for forming a metallic overlay comprising: supplying a metal substrate with a thermal expansion coefficient "X"; supplying a metallic alloy, which has a thermal expansion coefficient "Y", wherein said metallic alloy has a coefficient of thermal expansion "Y" greater than 15% of that of said substrate "X" and wherein Fe and Cr comprises at least 90 wt % of said metallic alloy, and Mo is present at levels of about 1.0 to 2.0 wt %; melting said metallic alloy and applying said metallic alloy to said metal substrate to form an alloy/substrate interface; forming metallurgical bonds between said metallic alloy and said substrate at said alloy/substrate interface; and causing said alloy to shrink while said alloy is constrained at said alloy/substrate interface thereby developing a residual compressive stress in said metallic alloy. 2. The method of claim 1, wherein said metallic alloy further comprises W, B, C, Si and Mn. 3. The method of claim 1, wherein Fe is present at levels above 50.0 wt %. 4. The method of claim 1, wherein Fe, Cr, Mo, and W comprise at least 90 wt % of said mixture. 5. The method of claim 1, wherein Fe and Cr comprise at least 90 wt % of said mixture, and Cr is present at levels of about 1.0 wt. %, and Mo is present at levels of about 1.0-2.0 wt %. 6. The method of claim 1, wherein Fe and Cr comprise at least 90 wt. % of said mixture, and Cr is present at levels of about 1.0 wt. %, and Mo is present at levels of about 1.0-2.0 wt. %, and W is present at levels of about 3.0-4.0 wt %, B is present at levels of about 1.0-2.0 wt %, C is present at levels of about 0.1-1.0 wt %, Si is present at levels of 0.1-1.0 wt % and Mn is present at levels of 0.1-1.0 wt %. 7. The method according to claim 1, wherein said metallic alloy has a composition of about 65.9 wt % Fe, 25.3 wt % Cr, 1.0 wt % Mo, 1.8 wt % W, 3.5 wt % B, 1.2 wt % C, 0.5 wt % Si, 0.8 wt % Mn. 8. The method according to claim 1, wherein said metallic alloy has a composition of 64.9 wt % Fe, 26.0 wt % Cr, 1.0 wt % Mo, 1.4 wt % W, 3.6 wt % B, 1.2 wt % C, 1.0 wt % Si, 0.8 wt % Mn. 9. The method according to claim 1, wherein said metallic alloy has a composition of 68.0 wt % Fe, 23.2 wt % Cr, 1.2 wt % Mo, 1.5 wt % W, 3.6 wt % B, 0.9 wt % C, 0.7 wt % Si, 0.8 wt % Mn. 10. The method according to claim 1, wherein applying said metallic alloy comprises welding. 11. The method according to claim 1, wherein applying said metallic alloy comprises thermal spray coating. 12. The method according to claim 1, wherein said iron based metallic alloy has a coefficient of thermal expansion in the range of 12 to 17 ppm ° C. 13. The method of claim 1, wherein said metallic alloy exhibits a fracture toughness of greater than 22 MPa(m)1/2. 14. The method of claim 1, wherein said metallic alloy exhibits a hardness greater than 5 GPa.