CA1062511A - Wear-resistant alloy, and method of making same - Google Patents
Wear-resistant alloy, and method of making sameInfo
- Publication number
- CA1062511A CA1062511A CA318,290A CA318290A CA1062511A CA 1062511 A CA1062511 A CA 1062511A CA 318290 A CA318290 A CA 318290A CA 1062511 A CA1062511 A CA 1062511A
- Authority
- CA
- Canada
- Prior art keywords
- alloy
- particles
- wear
- chromium
- resistant
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired
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Abstract
Abstract of the Disclosure A wear-resistant alloy comprising boron, chromium and iron having maximum hardness for a given composition is produced by rapidly cooling and solidfying spheroidal particles o the molten alloy mixture. She resultant solid particles are then cast in the desired form, or incorporated into a composite alloy wherein the solid particles are held together with a matrix of different material from the alloy.
Description
Background of the Invention This invention relates to a wear-resistant or abrasive resistant alloy, and method of producing this alloy. The invention particularly relates to such an alloy suitable for use in highly abrasive environments.
Ground-engaging tools such as ripper tips, bucket teeth and cutting edges for various types of earth-working machines are all subject to accelerated wear during working of the machines due to continual contact of these parts with rock, sand and earth. It is therefore desirable that these tools be comprised of a highly wear-resistant material, e.g., U.S. Patents 1,493,191; 3,275,426 and 3,334,996 and further~ that such material be relatively inexpensive to thereby minimize the cost when replacement inevitably becomes necessary; note, for instance, British Patent 1,338,140.
Many wear-resistant alloys have been developed for use in such tools and for other uses demanding an alloy of high abrasive resistance. Many such alloys, however, are composed of materials which are not readily available, or are expensive, or both. One such example is tungsten carbide which has excellent wear-resistant properties, but which is relatively expensive. Additionally, particularly in the case of tool manufacture, it is frequently impor-tant that the wear-resistant alloy be substantially unimpaired by heat treatment. For example, a convenient method of joining a metal part composed of a wear-resistant alloy to a steel ground-engaging tool is by brazing; this process, however, usually weakens the steel of the tool, making it necessary to hea~-treat the steel to strengthen it. Many alloys are adversely affected by such heat - 1 - ~
` 1062511 treatment, and either cannot be used under these circum-stances, or the steel cannot be treated to harden.
Frequently, also, known wear-resistant alloys are unsuitable for use with tools which are subjected to frequency shocks, since, typically, these wear-resistant hard alloys are brittle, and readily break under shock treatment.
Accordingly, it is an object of this invention to provide a specially treated inexpensive wear-resistant alloy comprised of readily available elements.
It is another object of this invention to provide a method of producing a highly wear-resistant alloy.
Brief Summary of the Invention According to one aspect of the invention there is provided a wear-resistant alloy in the form of cast spheroidal particles, said alloy comprising:
chromium - about 25 to about 61% by weight boron - about 6 to about 12% by weight Iron - balance According to another aspect of the invention there i-s provided a method of improving the hardness character-istics of an alloy comprising:
chromium - about 25 to about 61% by weight boron - about 6 to about 12% by weight Iron - balance;
the method comprising the steps of producing cast spheroidal particles of the alloy by streaming the molten alloy onto a hard surface thus breaking up the molten alloy into droplets and thereater rapidly quenching and solidifying the molten alloy with a quench liquid while still in the droplet configuration.
Other aspects of the invention disclosed herein are ` 106ZSll claimed in our co-pending patent application Serial No.
224,726 filed on April 16, 1975, of which the present application is a division.
As used herein the terms "composite" or "composite alloy" means an alloy material wherein two or more metal-lurgically distinct alloys are first prepared physically separate one from the other. These separate alloys are then physically mixed together, generally in the "dry"
state, and at ambient temperatures to produce an homo-geneous mixture thereof. This alloys mixture is thensubjected to heat processing wherein a temperature is achieved sufficiently high to cause at least one of the alloys to experience "melting" or at least incipient "melting" and to thereby "braze" the mixture into a single physical mass. It should be understood that at least one of the alloy components remains essentially physically unchanged during the "brazing" step.
The resulting "composite" alloy, although in a single mass, contains both the original alloys in dis-tinctly segregated portions within the mass, and both alloys continue to exhibit their individual metallurgical pro-perties on an individual basis, although the "composite"
alloy, as a whole, exhibits its separate and individual metallurgical and physical properties as well.
Brief Description of the Drawings Fig. 1 is a photomicrograph of alloy particles of this invention embedded in an alloy matrix. (magnifi-cation - 50X).
Fig. 2 is another photomicrograph of alloy particles of this invention embedded in an alloy matrix (magnification - lOOX).
Detailed Description of_the Invention The invention comprises a wear-resistant alloy comprised of relatively low cost, readily available elements, that are alloyed and then processed to yield extremely hard wear-resistant particles, expecially spheroids.
These spheroidal particles may be "brazed" together or alternately incorporated into a composite alloy that com-prises the spheroidal particles in a strong ductile alloy matrix. These composite alloys and tools reinforced therewith are claimed in Canadian patent application Serial No.
224,600 filed on April 15, 1975, entitled "Composite Wear-Resistant Alloy, and Tools from Same", and assigned to the same assignee as this application.
The wear-resistant alloy portion of the invention -is essentially an iron-chromium based alloy with boron therein.
More particularly, the alloy of the invention sub-stantially comprises boron, chromium and iron in the following amounts per cent by weight:
~1 r-4 106~511 .
Boron - about 6.0 to about 12~
Chromium - about 25 to about 61%
Iron - balance This combination of elements, in the portions indic-ated, gives a complex mixture of iron and chromium borides having extremely high hardness values, typically from about 1200 to about 1600 kg/mm Knoop ( or above about 70 on the Rockwell "C" hardness scale ). Although it would normally be expected that the high percentages of boron and chromium defined by the above ranges would result in an extremely brittle alloy composition, this in not really the case with the alloy Or t~le invention. ~ is lilcely that this c n be attributed to the high percentageso~ iron in the alloy, which forms an iron phase to give the necessary ductllity to the alloy composition.
An alloy, quite similar to the above-notéd compos-ition, is also useful as the wear-reslstant component in the invention. Specifically boron, chromium, iron and carbon in the ranges:
Boron 6.o to about 12 Chromium 61 to about 70%
Carbon 0.05 to about 2 Iron balance e~libits extreme hardness when processed iIl~O SilOt 2S described below.
This can be effectively accomplished by a method comprising pouring the molten alloy mixture onto a surface of material, such as graphite, at ambient temperatures, and which is positioned over a contalner of llquld coolant.
Preferably, the molten mixture is poured in a stream ~rom a suitable height (about 4 to 5 reet) above the cool surface.
Conveniently, the liquid coolant may be water, or other suitable liquid. The llquid coolant is arranged to a depth surficient to assure complete solidification Or the alloy particles before they reach the bottom Or the quenching liquidO
On striking the cold surrace, th~ mo~ten mixture explodes into thousands Or spheroidal particles Or various sizes, which immediately fall into the container Or cool~nt where they cool and solidify very rapidly.
High alloy compositions formed by this method exhibit properties of high strength and high hardness, with concom-itantly high resistance to wear. The extreme hardness and strength of these alloy particles are thought to be at least in part due to the surface tension set up in the particles as they form into spheroids after contacting the cold surface.
The relative hardness of the alloy particles produced by the above method has been compared by tests with similarly-sized alloy particles of the same chemistry produced by con-ventional methods. For example, in one test, solid slugs havingan alloy composition of 25% Cr, 8.8% B, and 66.2% Fe were broken up and screened to give particles of 10 to 20 mesh, which were found to have a Knoop hardness of about 1100 Kg/mm (500 gm. load). Similarly sized particles of the same compo-sition produced by the exploding method described above were found to have Knoop hardness of about 1400 Kg/mm (500 gm. load).
In a similar test utilizing an alloy composition of 40% Cr, 10 ~ and 50 Fe, the particles produced by breaking up a solid casting had a Knoop hardness of 1200 to 1300 Kg/mm (500 gm. load), whereas the exploded particles had a Knoop hardness of 1500 to 1600 Kg/mm (500 gm. load).
Even harder spheroidal particles have been produced from the alloy compositions including up to 2% carbon in addition to the boron, chromium and iron. One composition of about 62.5% Cr, 9% B, 1.8% C and Fe remainder produces a eutectic metallurgical structure of chromium borides and iron carbides. Alloys in this range of composition have yielded shot with a hardness range of 1700-2000 Knoop Rg/mm (100 gm.
load).
After solidification, the spheroidal alloy particles are removed from the liquid coolant. They are then most advantageously plated with a protective metal, particularly when the particles are to be subsequently brazed with a matrix alloy to form a desired composite alloy. This metal plating serves to protect the alloy from oxidation during storage and further serves to retard to some extent bonding of the particles with the substrate during brazing, thereby preventing alloy diffusion into this substrate. Diffusion tends to erode the hard spheroids and further degrades the desiréd crystalline structure of the shot particles, at least in the peripheral portions thereof. Suitably, the alloy particles are plated with nickel, although other metals which will provide the desired protection, such as copper or chromium, can be used.
The plating may be a conventional electro-plating method. The spheroidal particles are placed in a container such as a barrel with openings therein covered with fine mesh screens to retain the small particles within the container. The container is then submerged in a metallic plating solution, e.g.
Ni and rotated therein while electric current is applied. The plating solution can flow freely through the rotating barrel to reach all the particles therein. A metal coating of about 0.001 to about 0.003 inches is sufficient to retard oxidation and to minimize erosion by matrix alloy during the sintering or brazing step in production of composite alloys.
The spheroidal alloy particles may be formed, with or without plating by compacting, into a homogenous block of the desired shape. Also, the particles may either be cast 10625~1 - in place in the desired location, or may be cast separately, and then bonded in position. In addition, the alloy particles may be incorporated into a matrix of another material. While generally, greater hardness and strength results from a body comprised solely of the spheroidal alloy particles, it is frequently advantageous to provide a composite body of alloy particles and matrix material; for example, a composite alloy of spheroidal particles and strong, ductile matrix material is desirable if greater shock absorption capacity is desired.
Figures 1 and 2 of the drawing are photomicrographs of the composite alloy of the invention. They clearly show the spheroidal wear-resistant alloy particles. Figure 1 shows spheroidal particles that have a composition of 35% Cr, 10.9% B, remainder iron. The thin nickel plate surrounding the wear-resistant sphere is also apparent. Figure 2 is also a photo-micrograph of a specimen of composite alloy. The spheroidal particle was analyzed at 50% Cr, 10.9% B and the remainder Fe.
The spheroidal particle was also nickel plated.
The following Example is provided as an illustration of the method and composition of this invention.
Example Hard particles were made from a mixture of Armco Ingot Iron (Trade Mark), electrolytic chromium and ferrD boron melted in an induction furnace at 2600-2700F. The resultant composition of the wear resisting alloy was iron 66%, chromium 25%, and boron 9%. The molten alloy was dropped about 3 feet onto a slanted graphite plate located just above a tank filled with water. As the molten alloy stream struck the graphite plate, it was broken into various size particles. When it entered the water, the alloy solidified forming spheroidal particles.
The process above resulted in cast spheroidal partlcles comprised principally Or borides with a ICnoop Hardness Number o~ 1400 and above. These particles were then electrolytically cleaned and then coated with a nickcl pla~c to rctard sur~ace ox~dation and improve matrix alloy bonding.
Ground-engaging tools such as ripper tips, bucket teeth and cutting edges for various types of earth-working machines are all subject to accelerated wear during working of the machines due to continual contact of these parts with rock, sand and earth. It is therefore desirable that these tools be comprised of a highly wear-resistant material, e.g., U.S. Patents 1,493,191; 3,275,426 and 3,334,996 and further~ that such material be relatively inexpensive to thereby minimize the cost when replacement inevitably becomes necessary; note, for instance, British Patent 1,338,140.
Many wear-resistant alloys have been developed for use in such tools and for other uses demanding an alloy of high abrasive resistance. Many such alloys, however, are composed of materials which are not readily available, or are expensive, or both. One such example is tungsten carbide which has excellent wear-resistant properties, but which is relatively expensive. Additionally, particularly in the case of tool manufacture, it is frequently impor-tant that the wear-resistant alloy be substantially unimpaired by heat treatment. For example, a convenient method of joining a metal part composed of a wear-resistant alloy to a steel ground-engaging tool is by brazing; this process, however, usually weakens the steel of the tool, making it necessary to hea~-treat the steel to strengthen it. Many alloys are adversely affected by such heat - 1 - ~
` 1062511 treatment, and either cannot be used under these circum-stances, or the steel cannot be treated to harden.
Frequently, also, known wear-resistant alloys are unsuitable for use with tools which are subjected to frequency shocks, since, typically, these wear-resistant hard alloys are brittle, and readily break under shock treatment.
Accordingly, it is an object of this invention to provide a specially treated inexpensive wear-resistant alloy comprised of readily available elements.
It is another object of this invention to provide a method of producing a highly wear-resistant alloy.
Brief Summary of the Invention According to one aspect of the invention there is provided a wear-resistant alloy in the form of cast spheroidal particles, said alloy comprising:
chromium - about 25 to about 61% by weight boron - about 6 to about 12% by weight Iron - balance According to another aspect of the invention there i-s provided a method of improving the hardness character-istics of an alloy comprising:
chromium - about 25 to about 61% by weight boron - about 6 to about 12% by weight Iron - balance;
the method comprising the steps of producing cast spheroidal particles of the alloy by streaming the molten alloy onto a hard surface thus breaking up the molten alloy into droplets and thereater rapidly quenching and solidifying the molten alloy with a quench liquid while still in the droplet configuration.
Other aspects of the invention disclosed herein are ` 106ZSll claimed in our co-pending patent application Serial No.
224,726 filed on April 16, 1975, of which the present application is a division.
As used herein the terms "composite" or "composite alloy" means an alloy material wherein two or more metal-lurgically distinct alloys are first prepared physically separate one from the other. These separate alloys are then physically mixed together, generally in the "dry"
state, and at ambient temperatures to produce an homo-geneous mixture thereof. This alloys mixture is thensubjected to heat processing wherein a temperature is achieved sufficiently high to cause at least one of the alloys to experience "melting" or at least incipient "melting" and to thereby "braze" the mixture into a single physical mass. It should be understood that at least one of the alloy components remains essentially physically unchanged during the "brazing" step.
The resulting "composite" alloy, although in a single mass, contains both the original alloys in dis-tinctly segregated portions within the mass, and both alloys continue to exhibit their individual metallurgical pro-perties on an individual basis, although the "composite"
alloy, as a whole, exhibits its separate and individual metallurgical and physical properties as well.
Brief Description of the Drawings Fig. 1 is a photomicrograph of alloy particles of this invention embedded in an alloy matrix. (magnifi-cation - 50X).
Fig. 2 is another photomicrograph of alloy particles of this invention embedded in an alloy matrix (magnification - lOOX).
Detailed Description of_the Invention The invention comprises a wear-resistant alloy comprised of relatively low cost, readily available elements, that are alloyed and then processed to yield extremely hard wear-resistant particles, expecially spheroids.
These spheroidal particles may be "brazed" together or alternately incorporated into a composite alloy that com-prises the spheroidal particles in a strong ductile alloy matrix. These composite alloys and tools reinforced therewith are claimed in Canadian patent application Serial No.
224,600 filed on April 15, 1975, entitled "Composite Wear-Resistant Alloy, and Tools from Same", and assigned to the same assignee as this application.
The wear-resistant alloy portion of the invention -is essentially an iron-chromium based alloy with boron therein.
More particularly, the alloy of the invention sub-stantially comprises boron, chromium and iron in the following amounts per cent by weight:
~1 r-4 106~511 .
Boron - about 6.0 to about 12~
Chromium - about 25 to about 61%
Iron - balance This combination of elements, in the portions indic-ated, gives a complex mixture of iron and chromium borides having extremely high hardness values, typically from about 1200 to about 1600 kg/mm Knoop ( or above about 70 on the Rockwell "C" hardness scale ). Although it would normally be expected that the high percentages of boron and chromium defined by the above ranges would result in an extremely brittle alloy composition, this in not really the case with the alloy Or t~le invention. ~ is lilcely that this c n be attributed to the high percentageso~ iron in the alloy, which forms an iron phase to give the necessary ductllity to the alloy composition.
An alloy, quite similar to the above-notéd compos-ition, is also useful as the wear-reslstant component in the invention. Specifically boron, chromium, iron and carbon in the ranges:
Boron 6.o to about 12 Chromium 61 to about 70%
Carbon 0.05 to about 2 Iron balance e~libits extreme hardness when processed iIl~O SilOt 2S described below.
This can be effectively accomplished by a method comprising pouring the molten alloy mixture onto a surface of material, such as graphite, at ambient temperatures, and which is positioned over a contalner of llquld coolant.
Preferably, the molten mixture is poured in a stream ~rom a suitable height (about 4 to 5 reet) above the cool surface.
Conveniently, the liquid coolant may be water, or other suitable liquid. The llquid coolant is arranged to a depth surficient to assure complete solidification Or the alloy particles before they reach the bottom Or the quenching liquidO
On striking the cold surrace, th~ mo~ten mixture explodes into thousands Or spheroidal particles Or various sizes, which immediately fall into the container Or cool~nt where they cool and solidify very rapidly.
High alloy compositions formed by this method exhibit properties of high strength and high hardness, with concom-itantly high resistance to wear. The extreme hardness and strength of these alloy particles are thought to be at least in part due to the surface tension set up in the particles as they form into spheroids after contacting the cold surface.
The relative hardness of the alloy particles produced by the above method has been compared by tests with similarly-sized alloy particles of the same chemistry produced by con-ventional methods. For example, in one test, solid slugs havingan alloy composition of 25% Cr, 8.8% B, and 66.2% Fe were broken up and screened to give particles of 10 to 20 mesh, which were found to have a Knoop hardness of about 1100 Kg/mm (500 gm. load). Similarly sized particles of the same compo-sition produced by the exploding method described above were found to have Knoop hardness of about 1400 Kg/mm (500 gm. load).
In a similar test utilizing an alloy composition of 40% Cr, 10 ~ and 50 Fe, the particles produced by breaking up a solid casting had a Knoop hardness of 1200 to 1300 Kg/mm (500 gm. load), whereas the exploded particles had a Knoop hardness of 1500 to 1600 Kg/mm (500 gm. load).
Even harder spheroidal particles have been produced from the alloy compositions including up to 2% carbon in addition to the boron, chromium and iron. One composition of about 62.5% Cr, 9% B, 1.8% C and Fe remainder produces a eutectic metallurgical structure of chromium borides and iron carbides. Alloys in this range of composition have yielded shot with a hardness range of 1700-2000 Knoop Rg/mm (100 gm.
load).
After solidification, the spheroidal alloy particles are removed from the liquid coolant. They are then most advantageously plated with a protective metal, particularly when the particles are to be subsequently brazed with a matrix alloy to form a desired composite alloy. This metal plating serves to protect the alloy from oxidation during storage and further serves to retard to some extent bonding of the particles with the substrate during brazing, thereby preventing alloy diffusion into this substrate. Diffusion tends to erode the hard spheroids and further degrades the desiréd crystalline structure of the shot particles, at least in the peripheral portions thereof. Suitably, the alloy particles are plated with nickel, although other metals which will provide the desired protection, such as copper or chromium, can be used.
The plating may be a conventional electro-plating method. The spheroidal particles are placed in a container such as a barrel with openings therein covered with fine mesh screens to retain the small particles within the container. The container is then submerged in a metallic plating solution, e.g.
Ni and rotated therein while electric current is applied. The plating solution can flow freely through the rotating barrel to reach all the particles therein. A metal coating of about 0.001 to about 0.003 inches is sufficient to retard oxidation and to minimize erosion by matrix alloy during the sintering or brazing step in production of composite alloys.
The spheroidal alloy particles may be formed, with or without plating by compacting, into a homogenous block of the desired shape. Also, the particles may either be cast 10625~1 - in place in the desired location, or may be cast separately, and then bonded in position. In addition, the alloy particles may be incorporated into a matrix of another material. While generally, greater hardness and strength results from a body comprised solely of the spheroidal alloy particles, it is frequently advantageous to provide a composite body of alloy particles and matrix material; for example, a composite alloy of spheroidal particles and strong, ductile matrix material is desirable if greater shock absorption capacity is desired.
Figures 1 and 2 of the drawing are photomicrographs of the composite alloy of the invention. They clearly show the spheroidal wear-resistant alloy particles. Figure 1 shows spheroidal particles that have a composition of 35% Cr, 10.9% B, remainder iron. The thin nickel plate surrounding the wear-resistant sphere is also apparent. Figure 2 is also a photo-micrograph of a specimen of composite alloy. The spheroidal particle was analyzed at 50% Cr, 10.9% B and the remainder Fe.
The spheroidal particle was also nickel plated.
The following Example is provided as an illustration of the method and composition of this invention.
Example Hard particles were made from a mixture of Armco Ingot Iron (Trade Mark), electrolytic chromium and ferrD boron melted in an induction furnace at 2600-2700F. The resultant composition of the wear resisting alloy was iron 66%, chromium 25%, and boron 9%. The molten alloy was dropped about 3 feet onto a slanted graphite plate located just above a tank filled with water. As the molten alloy stream struck the graphite plate, it was broken into various size particles. When it entered the water, the alloy solidified forming spheroidal particles.
The process above resulted in cast spheroidal partlcles comprised principally Or borides with a ICnoop Hardness Number o~ 1400 and above. These particles were then electrolytically cleaned and then coated with a nickcl pla~c to rctard sur~ace ox~dation and improve matrix alloy bonding.
Claims (3)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A wear-resistant alloy in the form of cast spheroidal particles, said alloy comprising:
chromium - about 25 to about 61% by weight boron - about 6 to about 12% by weight Iron - balance.
chromium - about 25 to about 61% by weight boron - about 6 to about 12% by weight Iron - balance.
2. The alloy of Claim 1, wherein the spheroidal particles have a hardness in the range of 1400 kg/mm to 2000 kg/mm knoop.
3. A method of improving the hardness characteristics of an alloy comprising:
chromium - about 25 to about 61% by weight boron - about 6 to about 12% by weight Iron - balance;
the method comprising the steps of producing cast spheroidal particles of the alloy by streaming the molten alloy onto a hard surface thus breaking up the molten alloy into droplets and thereafter rapidly quenching and solidfying the molten alloy with a quench liquid while still in the droplet configuration.
chromium - about 25 to about 61% by weight boron - about 6 to about 12% by weight Iron - balance;
the method comprising the steps of producing cast spheroidal particles of the alloy by streaming the molten alloy onto a hard surface thus breaking up the molten alloy into droplets and thereafter rapidly quenching and solidfying the molten alloy with a quench liquid while still in the droplet configuration.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA318,290A CA1062511A (en) | 1974-05-02 | 1978-12-20 | Wear-resistant alloy, and method of making same |
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US05/466,141 US3970445A (en) | 1974-05-02 | 1974-05-02 | Wear-resistant alloy, and method of making same |
| CA224,726A CA1061606A (en) | 1974-05-02 | 1975-04-16 | Wear-resistant alloy, and method of making same |
| CA318,290A CA1062511A (en) | 1974-05-02 | 1978-12-20 | Wear-resistant alloy, and method of making same |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1062511A true CA1062511A (en) | 1979-09-18 |
Family
ID=27163909
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA318,290A Expired CA1062511A (en) | 1974-05-02 | 1978-12-20 | Wear-resistant alloy, and method of making same |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1062511A (en) |
-
1978
- 1978-12-20 CA CA318,290A patent/CA1062511A/en not_active Expired
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