CA1168479A - Alloy for welding rods and the like - Google Patents
Alloy for welding rods and the likeInfo
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- CA1168479A CA1168479A CA000363293A CA363293A CA1168479A CA 1168479 A CA1168479 A CA 1168479A CA 000363293 A CA000363293 A CA 000363293A CA 363293 A CA363293 A CA 363293A CA 1168479 A CA1168479 A CA 1168479A
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Abstract
A B S T R A C T
A low temperature, hard surfacing, nickel base alloy having good wear resistance, and comprising chromium, silicon and molybdenum in a nickel base having up to about 2. 5 percent by weight carbon, and welding rods made therefrom.
A low temperature, hard surfacing, nickel base alloy having good wear resistance, and comprising chromium, silicon and molybdenum in a nickel base having up to about 2. 5 percent by weight carbon, and welding rods made therefrom.
Description
This invention relates to a nickel based alloy, and more particularly to a novel and improved nickel based hard surfacing alloy.
One feature of this invention relates to the castability of this alloy, primarily for welding rods. Another Eeature of this invention relates to low temperature hard surfacing applications. A further Eeature of this invention relates to the weldability of the alloy.
It is well known in the alloy art to employ cobalt-base hard facing alloys, strengthened by tungsten and containing chromium-tungsten carbides, in diverse applications where wear resistance and hardness are required, either alone or in combination with corrosion re-sistance and elevated temperature capacity. Cast wear-resistant alloys with compositions related closely to those of the cobalt-base hard facing alloys have also been widely used, In recent years, the price oE cobalt has steadily increased, and supplies of the same have been severely lim-ited due to political condit ions i n foreign countries from which cobalt is impor~ed. Tungsten is also a ~carce material. In order to overcome the problems oF supply and increasing cost of cobalt, efEorts have been made to provide nickel based alloys for use on tools and other parts which are subject to elevated temperatures, and which require high temperature hardness and corrosion resistancè. Examples o~ such nickel based alloys are disclosed in United ~tates patents Nos. 2, 392, 821, 3, 385, 739 and 4) 075, 999, Experimental attempts have also been made heretofore to pro-vide nickel basecl alloys for low temperature hard surfacing applications.
Experimental attempts have also been made heretofore to provide nickel ~';~1 based alloys with good weldability char acteristics, and which could be used Ior casting welding rods. EIowe~er) the aforemen~1Oned prior attempts to pro~ide nickel based alloys for low temperature hard sur-tacing applications have Eailed because o the disadvantage of poor casta-bility characteristi cs. That is, the alloys produced by such last men-tioned attempts were porous, and they were too "snatty", and would not produce a good welding rod, The term "snotty" is a word used in the casting art to designate that an alloy is too thick and gooey, and it will not flow into a mold. A further disadvantage of the nickel based alloys produced in the aforementioned atttmpts, is that they were low in hard-ness and wearability.
It is an object of this in~ention to provide a nickel based alloy which has good castability and weldability characteristics, and which is adapted ~or low temperatwres, hard surfacing applications. It is a -~urther object of this invention to provide a nickel based alloy which is substantially free oï cobalt and tungsten. It is still another object of the present in~ention to provide a nickel based allog which o~ercomes the aforementioned disad~antages of the alloys produced in the aforementioned experimental attempts to produce nickel based allogs for low temper-ature, hard surfacing applications.
The alloy OI the presellt invention has about 50 to 60 percent by weight nickel, about 1. 8 to 2 5 percent by weight carbon, about 29 0 to 31. 0 percent by weight chromium, and about 8, 5 to 9. 5 percent by weight molybdenum. ~arious impurities may be present in the alloy in amounts as set forth hereinafter.
The alloy of the present inventlon is economical to produce, and it i9 adapted for use in low temperature applications which require good wear resistance and hard surEacing, as for example, in railrvad applications, forging construction applications as on shear bits, and oil drilling industrial applications as on drill bits. The alloy of the present invention is also a*vantageously adapted for casting welding rods, and it has optimum characteristics of castability and weldability, Other features and a*vantages of this invention will be apparent from the following detailed description, appended claims, and the accompanying draw;ngs.
In the drawings:
Fig, 1 of the accompanying drawing represents a graph of castability versus carbon plus silicon content for a number of standard alloys compared to the alloy of the present invention which is identified by the term "IOXN"
Fig., 2 represents a graph of the wear resistance in terms o~ weight loss per unit of time for the alloy " I~XN" of the present invention versus a number o:E standard alloys.
The alloy o~ this invent~on is nickel based and contains approximately 50 to 60 percent, by weight, nickel The base element, nickel, provides toughness, impact resistance, and a suitable, readily available eutectic constituent when combined with the proper types and amounts o~ a~loying elements as set forth hereinafter.
(~hromium is added to the nickel base, and it must be 29, 0 to 31. 0% by weight of the total alloy Chromium is added to impart hardness, abrasion and wear resistance to the alloy. The chromium combines with the nickel to form a eutectic matrix for the alloy system of this invention. It has been observed that chromium in excess of 31%, however, will adversely affect the carbide structure such that while the alloy will be harder, its wear resistance will be lower. ~lso, if the chromium level would be under 29%, both wear resistance and hard-ness would be in~dequate to accomplish the objectives of this invention.
Carbon must be added in the amount of 1. 8 to 2. 5% by weight of the total alloy. The carbon is necessary to Iorm the hard, dis-persed carbide microstructure oE this alloy, which contributes heavily to the hardness and wear resistance The carbon that is not tied up as carbides is present throughout the eutectic matrix and serves to provide a lubricant ( graphite ) in metal-to-metal wear. When the carbon content is below 1. 8%, enough carbides are not present to impart the required hardness. If carbon le~els exceed 2. 5~o, the grain structure is affected - such that the alloy becomes brittle and unsuitable for wear resistance, ~olbdenum is required to be present in the alloy in amounts Oe 8. 5 - 9. 5% by weight of the total alloy to achieve the proper amount and siæe of carbide particles. It has been observed that molybdenum under 8. 5% or over 9. 5% will noc give proper amount of carbides which make the a~loy hard and resistant to wear.
The final alloying element is silicon, and it must be present in the amount of 1. 5 - 2 5% by weight of total alloy. The silicon ser~es three required functions to accomplish the objectives of this invention.
The f irst function is that as a deoxidant during the melt down of the alloy, the casting o~ the alloy into rod, and the depo~si$ion o:E the rod. The second function is $o add fluidity to the alloy so that it may readily be cast into rod and eor acceptable deposition o:E the rod. The last function is to graphitize the carbon that is not tied up as a carbide. Silicon con-tent under 1. 5% results in an alloy that is not fluid enough in the molten condition to be deposited ( welded ) with current techniques. When the silicon content exceeds 2 5%, the alloy becomes too ~`luid and cannot be controlled to be properly deposited ~ welded ) to form an even wear sur-face.
The only impurity allowed in a high concentration is iron.
It may be present up to 3. 5% ma$imum by weight of the total alloy with-out any detrimental effects on the properties of the alloy. Manganese and cobalt may be present up to 0. 50% ma2~imum each by weight oE the total alloy. Other impurities may be present up to 0. 2% maximum each by weight of total alloy maximum.
Table I is the final chemistry or analys;is of the alloy of the present in~ention, which is identified herein as "IO~N".
TA~LE I
Percentage b~y Weight Carbon --------------------- 1, 8 - 2. 5 Silicon --------------------- 1. 5 - 2 5 Chromium ------------------ 29 0 - 31 0 Molybdenum ~ ------- 8.5 - 9.5 Iron ----------------------- 3. 5 maximum Cobalt --------------------- . 50 " "
Manganese~ ------ , 50 ma~imum Phosphorus ---------- ------ , 02 " "
Sulfur ------ -------- ----- . 02 " "
Boron ---------------------- ,02 " "
Tungsten ------------------- .02 " ~t Nickel---------------------- Balance ' The following Table II is a table o chemistries o~ common alloys which have been compared for castability and wear resistance in Figs. 1 and 2 o the drawing The residuals have been omitted in order to shorten tha tables, "Stellite" is a trademark of The Stellite Division of Cabot Corporation, Kokomo9 Ind, "Stellite"No, 6 is a co-balt based alloy that is used as an average industry standard for accept-:
able wear resistance. Poly Casib "Stellite" 6CS i s a cobalt based alloy made by Poly Cas', Inc, of Highland, Michigan. Samples "A", "B" and "C" are nickel based alloys which each have an analysis that does not fall within the analysis for an alloy of the present invention as set forth , in Table I hereinbefore, TABLE II
C~Si C_ Mn Si Ni Cr Mo W Fe Co Stellite ~6 2. 4 1. 2 . 4 1, 22, 2 29, 0, 15 4, 9 1, 5 Bal, Poly Cast 3, 7 1. 4 , 3 2, 3 1, 8 28, 8, 184, 0 , 75 Bal, Stellite ~ 6CS
A 3,3 2,3 ,5 1,0 Bal. 32,011.0 1,0 10.0 1,0 ., .
B 3. 7 2. 4 . 5 1, 3 Bal. 30. 01. 51, 0 3. 0 1. 0 C C3,3 1,9 .5 1.0 Bal. 32.011.0 1.0 10,0 1,0 I~OXN4. 0 1. 9 . 5 2. 1 Bal. 29, 69. 1 - 3, 5 It should be noted from a study of the data in Table II and Figs. 1 and 2, that the chemistry variances have been compared to wear resistance and castability rather than hardness. Hardness in the alloy of the present invention cannot be directly related to wear, and conse-quently, an abrasive friction metal-to-metal machine was designed to measure the weight loss, of a welding rod of each alloy.of Table II, created by heat and friction over a specific time period. The machine consisted of a cantilevered arm holding a test welding rod against a 7"
diameter tool steel wheel revolving at 1700 revolutions per minute. The weight of the test rod specimen was verified before and after a 15 minute run, and the loss in grams was tabulated on a relative basis.
The welding rod castability chart of Fig. 1 illustrates the im-portance of the silicon additions for casting economical, quality materials.
The following is a detailed description of a method of making the alloy of the present invention, including the master heat melt down and pouring procedures.
Restrictions /P arameters -Master heat size must not exceed 9()% of furnace capacity.
This is done to achieve complete deoxidation, and it also helps to avoid superheating of the molten bath prior to pouring.
An argon gas atmosphere must shield the charge materials from air during melt down and also while pouring.
Melt Down ~ ,~
The melt down may be accomplished in a coreless induction furnace, with preferably a 2000~ furnace and a 359 Kw /5~0 Hz power source .
The furnace is charged in the following order:
1. Add 1/2 of total silicon
One feature of this invention relates to the castability of this alloy, primarily for welding rods. Another Eeature of this invention relates to low temperature hard surfacing applications. A further Eeature of this invention relates to the weldability of the alloy.
It is well known in the alloy art to employ cobalt-base hard facing alloys, strengthened by tungsten and containing chromium-tungsten carbides, in diverse applications where wear resistance and hardness are required, either alone or in combination with corrosion re-sistance and elevated temperature capacity. Cast wear-resistant alloys with compositions related closely to those of the cobalt-base hard facing alloys have also been widely used, In recent years, the price oE cobalt has steadily increased, and supplies of the same have been severely lim-ited due to political condit ions i n foreign countries from which cobalt is impor~ed. Tungsten is also a ~carce material. In order to overcome the problems oF supply and increasing cost of cobalt, efEorts have been made to provide nickel based alloys for use on tools and other parts which are subject to elevated temperatures, and which require high temperature hardness and corrosion resistancè. Examples o~ such nickel based alloys are disclosed in United ~tates patents Nos. 2, 392, 821, 3, 385, 739 and 4) 075, 999, Experimental attempts have also been made heretofore to pro-vide nickel basecl alloys for low temperature hard surfacing applications.
Experimental attempts have also been made heretofore to provide nickel ~';~1 based alloys with good weldability char acteristics, and which could be used Ior casting welding rods. EIowe~er) the aforemen~1Oned prior attempts to pro~ide nickel based alloys for low temperature hard sur-tacing applications have Eailed because o the disadvantage of poor casta-bility characteristi cs. That is, the alloys produced by such last men-tioned attempts were porous, and they were too "snatty", and would not produce a good welding rod, The term "snotty" is a word used in the casting art to designate that an alloy is too thick and gooey, and it will not flow into a mold. A further disadvantage of the nickel based alloys produced in the aforementioned atttmpts, is that they were low in hard-ness and wearability.
It is an object of this in~ention to provide a nickel based alloy which has good castability and weldability characteristics, and which is adapted ~or low temperatwres, hard surfacing applications. It is a -~urther object of this invention to provide a nickel based alloy which is substantially free oï cobalt and tungsten. It is still another object of the present in~ention to provide a nickel based allog which o~ercomes the aforementioned disad~antages of the alloys produced in the aforementioned experimental attempts to produce nickel based allogs for low temper-ature, hard surfacing applications.
The alloy OI the presellt invention has about 50 to 60 percent by weight nickel, about 1. 8 to 2 5 percent by weight carbon, about 29 0 to 31. 0 percent by weight chromium, and about 8, 5 to 9. 5 percent by weight molybdenum. ~arious impurities may be present in the alloy in amounts as set forth hereinafter.
The alloy of the present inventlon is economical to produce, and it i9 adapted for use in low temperature applications which require good wear resistance and hard surEacing, as for example, in railrvad applications, forging construction applications as on shear bits, and oil drilling industrial applications as on drill bits. The alloy of the present invention is also a*vantageously adapted for casting welding rods, and it has optimum characteristics of castability and weldability, Other features and a*vantages of this invention will be apparent from the following detailed description, appended claims, and the accompanying draw;ngs.
In the drawings:
Fig, 1 of the accompanying drawing represents a graph of castability versus carbon plus silicon content for a number of standard alloys compared to the alloy of the present invention which is identified by the term "IOXN"
Fig., 2 represents a graph of the wear resistance in terms o~ weight loss per unit of time for the alloy " I~XN" of the present invention versus a number o:E standard alloys.
The alloy o~ this invent~on is nickel based and contains approximately 50 to 60 percent, by weight, nickel The base element, nickel, provides toughness, impact resistance, and a suitable, readily available eutectic constituent when combined with the proper types and amounts o~ a~loying elements as set forth hereinafter.
(~hromium is added to the nickel base, and it must be 29, 0 to 31. 0% by weight of the total alloy Chromium is added to impart hardness, abrasion and wear resistance to the alloy. The chromium combines with the nickel to form a eutectic matrix for the alloy system of this invention. It has been observed that chromium in excess of 31%, however, will adversely affect the carbide structure such that while the alloy will be harder, its wear resistance will be lower. ~lso, if the chromium level would be under 29%, both wear resistance and hard-ness would be in~dequate to accomplish the objectives of this invention.
Carbon must be added in the amount of 1. 8 to 2. 5% by weight of the total alloy. The carbon is necessary to Iorm the hard, dis-persed carbide microstructure oE this alloy, which contributes heavily to the hardness and wear resistance The carbon that is not tied up as carbides is present throughout the eutectic matrix and serves to provide a lubricant ( graphite ) in metal-to-metal wear. When the carbon content is below 1. 8%, enough carbides are not present to impart the required hardness. If carbon le~els exceed 2. 5~o, the grain structure is affected - such that the alloy becomes brittle and unsuitable for wear resistance, ~olbdenum is required to be present in the alloy in amounts Oe 8. 5 - 9. 5% by weight of the total alloy to achieve the proper amount and siæe of carbide particles. It has been observed that molybdenum under 8. 5% or over 9. 5% will noc give proper amount of carbides which make the a~loy hard and resistant to wear.
The final alloying element is silicon, and it must be present in the amount of 1. 5 - 2 5% by weight of total alloy. The silicon ser~es three required functions to accomplish the objectives of this invention.
The f irst function is that as a deoxidant during the melt down of the alloy, the casting o~ the alloy into rod, and the depo~si$ion o:E the rod. The second function is $o add fluidity to the alloy so that it may readily be cast into rod and eor acceptable deposition o:E the rod. The last function is to graphitize the carbon that is not tied up as a carbide. Silicon con-tent under 1. 5% results in an alloy that is not fluid enough in the molten condition to be deposited ( welded ) with current techniques. When the silicon content exceeds 2 5%, the alloy becomes too ~`luid and cannot be controlled to be properly deposited ~ welded ) to form an even wear sur-face.
The only impurity allowed in a high concentration is iron.
It may be present up to 3. 5% ma$imum by weight of the total alloy with-out any detrimental effects on the properties of the alloy. Manganese and cobalt may be present up to 0. 50% ma2~imum each by weight oE the total alloy. Other impurities may be present up to 0. 2% maximum each by weight of total alloy maximum.
Table I is the final chemistry or analys;is of the alloy of the present in~ention, which is identified herein as "IO~N".
TA~LE I
Percentage b~y Weight Carbon --------------------- 1, 8 - 2. 5 Silicon --------------------- 1. 5 - 2 5 Chromium ------------------ 29 0 - 31 0 Molybdenum ~ ------- 8.5 - 9.5 Iron ----------------------- 3. 5 maximum Cobalt --------------------- . 50 " "
Manganese~ ------ , 50 ma~imum Phosphorus ---------- ------ , 02 " "
Sulfur ------ -------- ----- . 02 " "
Boron ---------------------- ,02 " "
Tungsten ------------------- .02 " ~t Nickel---------------------- Balance ' The following Table II is a table o chemistries o~ common alloys which have been compared for castability and wear resistance in Figs. 1 and 2 o the drawing The residuals have been omitted in order to shorten tha tables, "Stellite" is a trademark of The Stellite Division of Cabot Corporation, Kokomo9 Ind, "Stellite"No, 6 is a co-balt based alloy that is used as an average industry standard for accept-:
able wear resistance. Poly Casib "Stellite" 6CS i s a cobalt based alloy made by Poly Cas', Inc, of Highland, Michigan. Samples "A", "B" and "C" are nickel based alloys which each have an analysis that does not fall within the analysis for an alloy of the present invention as set forth , in Table I hereinbefore, TABLE II
C~Si C_ Mn Si Ni Cr Mo W Fe Co Stellite ~6 2. 4 1. 2 . 4 1, 22, 2 29, 0, 15 4, 9 1, 5 Bal, Poly Cast 3, 7 1. 4 , 3 2, 3 1, 8 28, 8, 184, 0 , 75 Bal, Stellite ~ 6CS
A 3,3 2,3 ,5 1,0 Bal. 32,011.0 1,0 10.0 1,0 ., .
B 3. 7 2. 4 . 5 1, 3 Bal. 30. 01. 51, 0 3. 0 1. 0 C C3,3 1,9 .5 1.0 Bal. 32.011.0 1.0 10,0 1,0 I~OXN4. 0 1. 9 . 5 2. 1 Bal. 29, 69. 1 - 3, 5 It should be noted from a study of the data in Table II and Figs. 1 and 2, that the chemistry variances have been compared to wear resistance and castability rather than hardness. Hardness in the alloy of the present invention cannot be directly related to wear, and conse-quently, an abrasive friction metal-to-metal machine was designed to measure the weight loss, of a welding rod of each alloy.of Table II, created by heat and friction over a specific time period. The machine consisted of a cantilevered arm holding a test welding rod against a 7"
diameter tool steel wheel revolving at 1700 revolutions per minute. The weight of the test rod specimen was verified before and after a 15 minute run, and the loss in grams was tabulated on a relative basis.
The welding rod castability chart of Fig. 1 illustrates the im-portance of the silicon additions for casting economical, quality materials.
The following is a detailed description of a method of making the alloy of the present invention, including the master heat melt down and pouring procedures.
Restrictions /P arameters -Master heat size must not exceed 9()% of furnace capacity.
This is done to achieve complete deoxidation, and it also helps to avoid superheating of the molten bath prior to pouring.
An argon gas atmosphere must shield the charge materials from air during melt down and also while pouring.
Melt Down ~ ,~
The melt down may be accomplished in a coreless induction furnace, with preferably a 2000~ furnace and a 359 Kw /5~0 Hz power source .
The furnace is charged in the following order:
1. Add 1/2 of total silicon
2. Add 1/3 of total nickel
3. Add all iron
4. Add a]l molybdenum
5. Add I/3 of total carbon
6. Cover with 1/3 of total chromium
7. Add 1/2 of remaining nickel
8. Draw as much power as possible.
It is essential to continually draw full power and to prod the charge so that fresh metal is continuously being fed into the molten pool. This procedure pre-vents any superheating of the molten bath which is very injurious to the quality of the metal as it would pick up nitrogen and oxygen in eæcessive quantities.
It is imperative that the carbon is always covered with chrom- -ium. This will insure that the carbon goes into solution. The san~
wiching o~ carbon between the chromium additions forces the carbon into the bath throughout melt down and also tends to eliminate "bridging", which would cause superheating.
As the melt down continues:
It is essential to continually draw full power and to prod the charge so that fresh metal is continuously being fed into the molten pool. This procedure pre-vents any superheating of the molten bath which is very injurious to the quality of the metal as it would pick up nitrogen and oxygen in eæcessive quantities.
It is imperative that the carbon is always covered with chrom- -ium. This will insure that the carbon goes into solution. The san~
wiching o~ carbon between the chromium additions forces the carbon into the bath throughout melt down and also tends to eliminate "bridging", which would cause superheating.
As the melt down continues:
9 Add 1/2 of remaining carbon
10, Add 1/2 of remaining chromium
11. Add balance of nickel Continue melting as fast as possible.
12. Add balance of carbon
13. Add balance of chromium P r~
When the melt down is complete, bring to 2580 F. Do not exceed. Tilt furnace to heat frontal area of furnace so metal is within 6" of pouring spout. Maintain 2580 F. at this point and draw enough power to hold temperature. While in tilted position, a Fe~ Mg deoxi dant is added. This material should contain 40-50% Si, 7~10% Mg, 40-45'~o iron and total weight of deoxidant added should equal 1/2% of weight of total furnace charge. The deoxidant is added by small hand-fuls ~a~ward the back of the furnace. The molten bath, still being under power, will carry the deoxidant down under the surface and disperse it throughout the melt. The violent deoxidation process ( mg ) will actually inc~ease the bath by 10-30 F. AEter deoxidation, raise pouring temper-ature to 2620 F. ( do not exceed ) and pour immediately using remain-ing 1/2 oE silicon for ladle deoxidation.
The following is a detailed description of a method of casting the alloy of the present invention into welding rod.
The aUoy of the present invention may be cast into welding rod by conventional aspiration glass casting processes, or by C~O2 sand mold process. The description and details of the sand cast process are as 2 0 f ollows:
The mold is made of a mixture composed of 30 parts 80 grit washed silica sand, 2 parts Ely ash and 1 part standard commercial C02 sand binder. This mixture is mulled until homogenous in a typical foundry sand muller. The mul:Led mixture is put -into the sand hopper of a Redford International Welding rod molding machine. The mold machine is to be _9 _ operated under the normal automatic cycle mode. The only critical aspect of making a proper mold is the pressure and time duration the C2 gas is applie~ to the mold before it is removed Irom the machine.
The proper pressure is 20-22 P.~I and duration is 13-15 seconds. After the mold is removed from the machine it must be cured at 120 - 140 F.
for 24 hours minimum and must be used before 72 hours elapse from the time curing commenced.
The ~urnace used is a 12 pourld capacity, coreless induction, roll-over casting unit. The furnace is powered by a conventional 4. 2K~Iz, 30 Kw. motor-generator set as manufactured by Inductotherm Corporation.
The furnace is mounted to the standard roll-~ver stanchions.
Initial set-up requires a gasket, which is the same inside dia-meter and outside diameter O:e the shoulders of the mold, be made from 1/8" thick standard asbestos rollboard. Also needed is a copper chill plate 3/8" thick by 7" square.
After the furnace, which is under an argon atmosphere, has melted the master alloy of the invention, the molten metal is to be brought up to 2620 F. casting temperature. The asbestos gasket is placed a~er the furnace opening. Any slag or floating debris must be removed at this point. The mold is placed on the gasket. The chill plate is set on the other end of the mold and secured with the clamping mechanism of the rollover stanchion. The pressure of the cl aimping device on the chill plate, mold, gasket and furnace top provides a leak proof seal.The en--t ixe furn~ace wit~rno-ld attached is quickly turned over to fill the cavities in the mold. The fur-nace should be held in the inverted position for 3-8 seconds, depending 7~
on rod diameter being cast~ and then returned to its normal upright position. The mold is now removed from the furnace and allowed to cool for 3-5 minutes. The mold is then shaken free of the cast rods.
~hrink holes on each end of the rod must now be cut off b,y an abrasive saw. The individual rods are then passed into a conventional center-less grinder, such as a Cincinnati Number-2 through-feed centerless grinder, to remove the rough and sand impregnated outer surface. The removal is generally . 015" on the circumference of the rod.
While it will be apparent that the preferred embodiment of the invention herein disclosed is well calculated to fulfill the objects above stated, it will be appreciated that the inve ntion is susceptible to modification, variation and change.
.~
When the melt down is complete, bring to 2580 F. Do not exceed. Tilt furnace to heat frontal area of furnace so metal is within 6" of pouring spout. Maintain 2580 F. at this point and draw enough power to hold temperature. While in tilted position, a Fe~ Mg deoxi dant is added. This material should contain 40-50% Si, 7~10% Mg, 40-45'~o iron and total weight of deoxidant added should equal 1/2% of weight of total furnace charge. The deoxidant is added by small hand-fuls ~a~ward the back of the furnace. The molten bath, still being under power, will carry the deoxidant down under the surface and disperse it throughout the melt. The violent deoxidation process ( mg ) will actually inc~ease the bath by 10-30 F. AEter deoxidation, raise pouring temper-ature to 2620 F. ( do not exceed ) and pour immediately using remain-ing 1/2 oE silicon for ladle deoxidation.
The following is a detailed description of a method of casting the alloy of the present invention into welding rod.
The aUoy of the present invention may be cast into welding rod by conventional aspiration glass casting processes, or by C~O2 sand mold process. The description and details of the sand cast process are as 2 0 f ollows:
The mold is made of a mixture composed of 30 parts 80 grit washed silica sand, 2 parts Ely ash and 1 part standard commercial C02 sand binder. This mixture is mulled until homogenous in a typical foundry sand muller. The mul:Led mixture is put -into the sand hopper of a Redford International Welding rod molding machine. The mold machine is to be _9 _ operated under the normal automatic cycle mode. The only critical aspect of making a proper mold is the pressure and time duration the C2 gas is applie~ to the mold before it is removed Irom the machine.
The proper pressure is 20-22 P.~I and duration is 13-15 seconds. After the mold is removed from the machine it must be cured at 120 - 140 F.
for 24 hours minimum and must be used before 72 hours elapse from the time curing commenced.
The ~urnace used is a 12 pourld capacity, coreless induction, roll-over casting unit. The furnace is powered by a conventional 4. 2K~Iz, 30 Kw. motor-generator set as manufactured by Inductotherm Corporation.
The furnace is mounted to the standard roll-~ver stanchions.
Initial set-up requires a gasket, which is the same inside dia-meter and outside diameter O:e the shoulders of the mold, be made from 1/8" thick standard asbestos rollboard. Also needed is a copper chill plate 3/8" thick by 7" square.
After the furnace, which is under an argon atmosphere, has melted the master alloy of the invention, the molten metal is to be brought up to 2620 F. casting temperature. The asbestos gasket is placed a~er the furnace opening. Any slag or floating debris must be removed at this point. The mold is placed on the gasket. The chill plate is set on the other end of the mold and secured with the clamping mechanism of the rollover stanchion. The pressure of the cl aimping device on the chill plate, mold, gasket and furnace top provides a leak proof seal.The en--t ixe furn~ace wit~rno-ld attached is quickly turned over to fill the cavities in the mold. The fur-nace should be held in the inverted position for 3-8 seconds, depending 7~
on rod diameter being cast~ and then returned to its normal upright position. The mold is now removed from the furnace and allowed to cool for 3-5 minutes. The mold is then shaken free of the cast rods.
~hrink holes on each end of the rod must now be cut off b,y an abrasive saw. The individual rods are then passed into a conventional center-less grinder, such as a Cincinnati Number-2 through-feed centerless grinder, to remove the rough and sand impregnated outer surface. The removal is generally . 015" on the circumference of the rod.
While it will be apparent that the preferred embodiment of the invention herein disclosed is well calculated to fulfill the objects above stated, it will be appreciated that the inve ntion is susceptible to modification, variation and change.
.~
Claims (8)
- THE EMBODIMENTS OF THE INVENTION IN WHICH AN EXCLUSIVE
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
l. A low temperature, hard surfacing nickel based alloy, substantially free of cobalt and tungsten, consisting essentially of about 1.8 to 2.5 percent by weight carbon, about 1.5 to 2.5 percent by weight silicon, about 29.0 to 31.0 percent by weight chromium, about 8.5 to 9.5 percent by weight molybaenum, from 0 to about 0.5 percent by weight of manganese, from 0 to about 3.5 percent of iron and about 50 to 60 percent by weight of nickel. - 2. The alloy of claim 1, including, 0.5 percent by weight of manganese of the total alloy.
- 3. The alloy of claim 2, including 3.5 percent by weight of iron.
- 4. The alloy of claim 1 wherein the carbon comprises about 1.9 percent by weight of the alloy, the silicon comprises about 2.1 percent by weight of the alloy, the chromium comprises about 29.6 percent by weight of the alloy, the molybdenum comprises about 9.1 percent by weight of the alloy, and the alloy includes about 0.5 percent by weight of manganese, about 3.5 percent by weight of iron, and nickel comprises the balance of the alloy.
- 5. An article of manufacture comprising a low temperature, hard surfacing nickel based alloy welding rod, substantially free of cobalt and tungsten, consisting essentially of about 1.8 to 2.5 percent by weight carbon, about 1.5 to 2.5 percent by weight silicon, about 29.0 to 31.0 percent by weight chromium, about 8.5 to 9.5 percent by weight molybdenum, and about 50 to 60 percent by weight nickel.
- 6. The welding rod of claim 5, wherein the nickel based alloy includes, 0.5 percent by weight of manganese of the total alloy.
- 7. The welding rod of claim 6, wherein the nickel based alloy includes, 3.5 percent by weight of iron.
- 8. The welding rod of claim 5, wherein the carbon comprises about 1.9 percent by weight of the alloy, the silicon comprises about 2.1 percent by weight of the alloy, the chromium comprises about 29.6 percent by weight of the alloy, the molybdenum comprises about 9.1 percent by weight of the alloy, and the alloy includes about .5 percent by weight of manganese, about 3.5 percent by weight of iron, and nickel comprises the balance of the alloy.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000363293A CA1168479A (en) | 1980-10-27 | 1980-10-27 | Alloy for welding rods and the like |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA000363293A CA1168479A (en) | 1980-10-27 | 1980-10-27 | Alloy for welding rods and the like |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1168479A true CA1168479A (en) | 1984-06-05 |
Family
ID=4118265
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000363293A Expired CA1168479A (en) | 1980-10-27 | 1980-10-27 | Alloy for welding rods and the like |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1168479A (en) |
-
1980
- 1980-10-27 CA CA000363293A patent/CA1168479A/en not_active Expired
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