CA3167432A1 - Cast product having alumina barrier layer - Google Patents
Cast product having alumina barrier layer Download PDFInfo
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- CA3167432A1 CA3167432A1 CA3167432A CA3167432A CA3167432A1 CA 3167432 A1 CA3167432 A1 CA 3167432A1 CA 3167432 A CA3167432 A CA 3167432A CA 3167432 A CA3167432 A CA 3167432A CA 3167432 A1 CA3167432 A1 CA 3167432A1
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- Prior art keywords
- cast product
- mass
- aluminum oxide
- layer
- barrier layer
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 title claims abstract description 72
- 230000004888 barrier function Effects 0.000 title claims abstract description 61
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims abstract description 44
- 239000011159 matrix material Substances 0.000 claims abstract description 34
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 33
- 229910052742 iron Inorganic materials 0.000 claims abstract description 30
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 29
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 28
- 239000006104 solid solution Substances 0.000 claims abstract description 22
- 230000003746 surface roughness Effects 0.000 claims description 12
- 229910052782 aluminium Inorganic materials 0.000 claims description 9
- 229910052593 corundum Inorganic materials 0.000 claims description 9
- 239000010431 corundum Substances 0.000 claims description 9
- 229910052719 titanium Inorganic materials 0.000 claims description 7
- 229910052721 tungsten Inorganic materials 0.000 claims description 7
- 229910052726 zirconium Inorganic materials 0.000 claims description 7
- 229910052761 rare earth metal Inorganic materials 0.000 claims description 6
- 238000006243 chemical reaction Methods 0.000 claims description 5
- 229910052758 niobium Inorganic materials 0.000 claims description 5
- 239000012535 impurity Substances 0.000 claims description 4
- 239000004215 Carbon black (E152) Substances 0.000 claims description 3
- 229930195733 hydrocarbon Natural products 0.000 claims description 3
- 150000002430 hydrocarbons Chemical class 0.000 claims description 3
- 239000013078 crystal Substances 0.000 claims description 2
- 229910052748 manganese Inorganic materials 0.000 claims 1
- 230000003647 oxidation Effects 0.000 abstract description 9
- 238000007254 oxidation reaction Methods 0.000 abstract description 9
- 230000007797 corrosion Effects 0.000 abstract description 5
- 238000005260 corrosion Methods 0.000 abstract description 5
- 238000005121 nitriding Methods 0.000 abstract description 5
- 238000010438 heat treatment Methods 0.000 description 59
- 239000000956 alloy Substances 0.000 description 16
- 230000000052 comparative effect Effects 0.000 description 16
- 229910045601 alloy Inorganic materials 0.000 description 15
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 15
- 229910052760 oxygen Inorganic materials 0.000 description 15
- 239000001301 oxygen Substances 0.000 description 15
- 229910052799 carbon Inorganic materials 0.000 description 9
- 239000000463 material Substances 0.000 description 9
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 7
- 230000001590 oxidative effect Effects 0.000 description 7
- 230000015572 biosynthetic process Effects 0.000 description 6
- 238000004939 coking Methods 0.000 description 6
- 229910052751 metal Inorganic materials 0.000 description 6
- 239000002184 metal Substances 0.000 description 6
- 229910052750 molybdenum Inorganic materials 0.000 description 6
- 229910001566 austenite Inorganic materials 0.000 description 5
- 239000000571 coke Substances 0.000 description 5
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 238000004381 surface treatment Methods 0.000 description 5
- 238000009750 centrifugal casting Methods 0.000 description 4
- 230000001965 increasing effect Effects 0.000 description 4
- 238000002844 melting Methods 0.000 description 3
- 230000008018 melting Effects 0.000 description 3
- 230000009467 reduction Effects 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 2
- 239000005977 Ethylene Substances 0.000 description 2
- 230000009471 action Effects 0.000 description 2
- 238000005266 casting Methods 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 125000004122 cyclic group Chemical group 0.000 description 2
- QDOXWKRWXJOMAK-UHFFFAOYSA-N dichromium trioxide Chemical compound O=[Cr]O[Cr]=O QDOXWKRWXJOMAK-UHFFFAOYSA-N 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 229910044991 metal oxide Inorganic materials 0.000 description 2
- 150000004706 metal oxides Chemical class 0.000 description 2
- 239000002245 particle Substances 0.000 description 2
- 238000005728 strengthening Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 229910052684 Cerium Inorganic materials 0.000 description 1
- 229910020598 Co Fe Inorganic materials 0.000 description 1
- OTMSDBZUPAUEDD-UHFFFAOYSA-N Ethane Chemical compound CC OTMSDBZUPAUEDD-UHFFFAOYSA-N 0.000 description 1
- 229910002551 Fe-Mn Inorganic materials 0.000 description 1
- 229910001111 Fine metal Inorganic materials 0.000 description 1
- 229910052779 Neodymium Inorganic materials 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000005255 carburizing Methods 0.000 description 1
- 230000003197 catalytic effect Effects 0.000 description 1
- 230000008878 coupling Effects 0.000 description 1
- 238000010168 coupling process Methods 0.000 description 1
- 238000005859 coupling reaction Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000010410 dusting Methods 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 230000006698 induction Effects 0.000 description 1
- 229910052747 lanthanoid Inorganic materials 0.000 description 1
- 150000002602 lanthanoids Chemical class 0.000 description 1
- 229910052746 lanthanum Inorganic materials 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 230000000737 periodic effect Effects 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 229910052706 scandium Inorganic materials 0.000 description 1
- 230000003068 static effect Effects 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 229910052717 sulfur Inorganic materials 0.000 description 1
- 230000008719 thickening Effects 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/10—Oxidising
- C23C8/12—Oxidising using elemental oxygen or ozone
- C23C8/14—Oxidising of ferrous surfaces
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/06—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases
- C23C8/08—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using gases only one element being applied
- C23C8/10—Oxidising
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/08—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tubular bodies or pipes
- C21D9/14—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tubular bodies or pipes wear-resistant or pressure-resistant pipes
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/055—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C19/00—Alloys based on nickel or cobalt
- C22C19/03—Alloys based on nickel or cobalt based on nickel
- C22C19/05—Alloys based on nickel or cobalt based on nickel with chromium
- C22C19/051—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
- C22C19/056—Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 10% but less than 20%
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C30/00—Alloys containing less than 50% by weight of each constituent
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/005—Ferrous alloys, e.g. steel alloys containing rare earths, i.e. Sc, Y, Lanthanides
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/04—Ferrous alloys, e.g. steel alloys containing manganese
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/06—Ferrous alloys, e.g. steel alloys containing aluminium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/48—Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/50—Ferrous alloys, e.g. steel alloys containing chromium with nickel with titanium or zirconium
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/54—Ferrous alloys, e.g. steel alloys containing chromium with nickel with boron
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C38/00—Ferrous alloys, e.g. steel alloys
- C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
- C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
- C22C38/58—Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.5% by weight of manganese
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/80—After-treatment
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D13/00—Centrifugal casting; Casting by using centrifugal force
- B22D13/02—Centrifugal casting; Casting by using centrifugal force of elongated solid or hollow bodies, e.g. pipes, in moulds rotating around their longitudinal axis
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/68—Temporary coatings or embedding materials applied before or during heat treatment
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
- C21D1/68—Temporary coatings or embedding materials applied before or during heat treatment
- C21D1/70—Temporary coatings or embedding materials applied before or during heat treatment while heating or quenching
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D2251/00—Treating composite or clad material
- C21D2251/02—Clad material
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D6/00—Heat treatment of ferrous alloys
- C21D6/004—Heat treatment of ferrous alloys containing Cr and Ni
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
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- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Thermal Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- Physics & Mathematics (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Compounds Of Alkaline-Earth Elements, Aluminum Or Rare-Earth Metals (AREA)
- Laminated Bodies (AREA)
Abstract
The present invention provides a cast product that can further enhance the stability of an alumina barrier layer and can exhibit further superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like when used under a high-temperature atmosphere. The cast product according to the present invention is a cast product having an alumina barrier layer including an aluminum oxide on a surface of a matrix, and the aluminum oxide is (A1(1,)M0203, where M is at least one of Cr, Ni, Si, and Fe, and x satisfies a relationship 0<x<0.5.
Furthermore, the cast product according to the present invention is a cast product having an alumina barrier layer including an aluminum oxide on a surface of a matrix, and at least one of Cr, Ni, Si, and Fe forms a solid solution in the aluminum oxide, and at least one of Cr, Ni, Si, and Fe forming the solid solution with Al is contained so as to satisfy a relationship Al/(Cr+Ni+Si+Fe)>2.0 in an atomic % ratio.
Furthermore, the cast product according to the present invention is a cast product having an alumina barrier layer including an aluminum oxide on a surface of a matrix, and at least one of Cr, Ni, Si, and Fe forms a solid solution in the aluminum oxide, and at least one of Cr, Ni, Si, and Fe forming the solid solution with Al is contained so as to satisfy a relationship Al/(Cr+Ni+Si+Fe)>2.0 in an atomic % ratio.
Description
CAST PRODUCT HAVING ALUMINA BARRIER LAYER
This application is a divisional of Canadian application serial No. 2940179 filed on December 17, 2014.
BACKGROUND OF THE INVENTION
Field of the Invention [00011 The present invention relates to a cast product having an alumina barrier layer, and more specifically, to a cast product having an alumina barrier layer with a stable structure.
Description of the Related Art [00021 Heat-resistant steel castings such as reaction tubes and decomposition tubes for producing ethylene, and hearth rolls, radiant tubes and metal dusting-resistant materials for use in carburizing heat-treatment furnaces are exposed to a high-temperature atmosphere, and therefore are made of an austenite-based heat-resistant alloy having superior high-temperature strength.
[00031 A metal oxide layer is formed on the surface of this type of austenite-based heat-resistant alloy during use in a high-temperature atmosphere.
This oxide layer serves as a barrier, and thus protects the base material under a high-temperature atmosphere.
[00041 On the other hand, when Cr-oxides (mainly constituted by Cr2O3) are formed as the metal oxide, the Cr-oxide layer has an insufficient function for preventing the entry of oxygen and carbon due to its low denseness, thus causing the internal oxidation under a high-temperature atmosphere and the thickening of the oxide film. Moreover, the Cr-oxide layer is likely to become detached during repeated cycles of heating and cooling. Even if the Cr-oxide layer do not become detached, the Cr-oxide layer has an insufficient function for preventing the entry of oxygen and carbon from an outside atmosphere, and therefore, there is a disadvantageous situation in which oxygen and Date Recue/Date Received 2022-07-12 carbon pass through the film and cause the internal oxidation or carburization of the base material.
[00051 To address this, it is proposed that an oxide layer including alumina (A1203) as a main component that has high denseness and makes it difficult for oxygen and carbon to pass therethrough is formed on the surface of the base material by increasing the content of Al compared with that in a common austenite-based heat-resistant alloy (see Patent Documents 1 and 2, for example).
[00061 However, Al is a ferrite-forming element, and therefore, when the content of Al is increased, the ductility of the materials is deteriorated and the high-temperature strength is reduced. This tendency of reduction of the ductility is observed particularly when the content of Al exceeds 5%
For this reason, the austenite-based heat-resistant alloy of Patent Documents 1 and 2 can be expected to have an enhanced barrier function due to A1203, but has the disadvantage of causing a reduction of the ductility of the base material.
[00071 Therefore, in order to provide a cast product that can secure the high-temperature stability of A1203 and can achieve a superior barrier function under a high-temperature atmosphere without reducing the ductility of the materials, Patent Document 3 proposes a cast product in which an alumina barrier layer including A1203 is formed on the inner surface of a cast body and Cr-based particles that contain Cr at a higher concentration than that of a matrix of the base material are dispersed at an interface between the alumina barrier layer and the cast body by performing heat treatment under an oxidizing atmosphere after processing the inner surface such that a surface roughness (Ra) of the cast body is 0.05 to 2.5 pm (see Patent Document 3, for example).
[00081 Due to the presence of a stable alumina barrier layer, superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like of the cast product of Patent document 3 can be
This application is a divisional of Canadian application serial No. 2940179 filed on December 17, 2014.
BACKGROUND OF THE INVENTION
Field of the Invention [00011 The present invention relates to a cast product having an alumina barrier layer, and more specifically, to a cast product having an alumina barrier layer with a stable structure.
Description of the Related Art [00021 Heat-resistant steel castings such as reaction tubes and decomposition tubes for producing ethylene, and hearth rolls, radiant tubes and metal dusting-resistant materials for use in carburizing heat-treatment furnaces are exposed to a high-temperature atmosphere, and therefore are made of an austenite-based heat-resistant alloy having superior high-temperature strength.
[00031 A metal oxide layer is formed on the surface of this type of austenite-based heat-resistant alloy during use in a high-temperature atmosphere.
This oxide layer serves as a barrier, and thus protects the base material under a high-temperature atmosphere.
[00041 On the other hand, when Cr-oxides (mainly constituted by Cr2O3) are formed as the metal oxide, the Cr-oxide layer has an insufficient function for preventing the entry of oxygen and carbon due to its low denseness, thus causing the internal oxidation under a high-temperature atmosphere and the thickening of the oxide film. Moreover, the Cr-oxide layer is likely to become detached during repeated cycles of heating and cooling. Even if the Cr-oxide layer do not become detached, the Cr-oxide layer has an insufficient function for preventing the entry of oxygen and carbon from an outside atmosphere, and therefore, there is a disadvantageous situation in which oxygen and Date Recue/Date Received 2022-07-12 carbon pass through the film and cause the internal oxidation or carburization of the base material.
[00051 To address this, it is proposed that an oxide layer including alumina (A1203) as a main component that has high denseness and makes it difficult for oxygen and carbon to pass therethrough is formed on the surface of the base material by increasing the content of Al compared with that in a common austenite-based heat-resistant alloy (see Patent Documents 1 and 2, for example).
[00061 However, Al is a ferrite-forming element, and therefore, when the content of Al is increased, the ductility of the materials is deteriorated and the high-temperature strength is reduced. This tendency of reduction of the ductility is observed particularly when the content of Al exceeds 5%
For this reason, the austenite-based heat-resistant alloy of Patent Documents 1 and 2 can be expected to have an enhanced barrier function due to A1203, but has the disadvantage of causing a reduction of the ductility of the base material.
[00071 Therefore, in order to provide a cast product that can secure the high-temperature stability of A1203 and can achieve a superior barrier function under a high-temperature atmosphere without reducing the ductility of the materials, Patent Document 3 proposes a cast product in which an alumina barrier layer including A1203 is formed on the inner surface of a cast body and Cr-based particles that contain Cr at a higher concentration than that of a matrix of the base material are dispersed at an interface between the alumina barrier layer and the cast body by performing heat treatment under an oxidizing atmosphere after processing the inner surface such that a surface roughness (Ra) of the cast body is 0.05 to 2.5 pm (see Patent Document 3, for example).
[00081 Due to the presence of a stable alumina barrier layer, superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like of the cast product of Patent document 3 can be
2 Date Recue/Date Received 2022-07-12 maintained for a long period of time of use under a high-temperature atmosphere.
PRIOR ART DOCUMENTS
PATENT DOCUMENTS
[00091 Patent Document 1: JP 552-78612A
Patent Document 2: JP 557-39159A
Patent Document 3: WO 2010/113830 [00101 It is an object of the present invention to provide a cast product that can further enhance the stability of the alumina barrier layer and can exhibit further superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like when used under a high-temperature atmosphere.
SUMMARY OF THE INVENTION
[00111 The cast product according to the present invention is a cast product having an alumina barrier layer including an aluminum oxide on a surface of a matrix, wherein the aluminum oxide is (Al(i-x)M())203, where M is at least one of Cr, Ni, Si, and Fe, and x satisfies a relationship 0<x<0.5.
[00121 Also, the cast product according to the present invention is a cast product having an alumina barrier layer including an aluminum oxide on a surface of a matrix, wherein at least one of Cr, Ni, Si, and Fe forms a solid solution in the aluminum oxide, and the at least one of Cr, Ni, Si, and Fe forming the solid solution with Al is contained so as to satisfy a relationship Al/(Cr+Ni+Si+Fe)>2.0 in an atomic % ratio.
EFFECTS OF THE INVENTION
[00131 With the cast product of the present invention, at least one of Cr, Ni, Si, and Fe forms a solid solution in an alumina barrier layer formed on a
PRIOR ART DOCUMENTS
PATENT DOCUMENTS
[00091 Patent Document 1: JP 552-78612A
Patent Document 2: JP 557-39159A
Patent Document 3: WO 2010/113830 [00101 It is an object of the present invention to provide a cast product that can further enhance the stability of the alumina barrier layer and can exhibit further superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like when used under a high-temperature atmosphere.
SUMMARY OF THE INVENTION
[00111 The cast product according to the present invention is a cast product having an alumina barrier layer including an aluminum oxide on a surface of a matrix, wherein the aluminum oxide is (Al(i-x)M())203, where M is at least one of Cr, Ni, Si, and Fe, and x satisfies a relationship 0<x<0.5.
[00121 Also, the cast product according to the present invention is a cast product having an alumina barrier layer including an aluminum oxide on a surface of a matrix, wherein at least one of Cr, Ni, Si, and Fe forms a solid solution in the aluminum oxide, and the at least one of Cr, Ni, Si, and Fe forming the solid solution with Al is contained so as to satisfy a relationship Al/(Cr+Ni+Si+Fe)>2.0 in an atomic % ratio.
EFFECTS OF THE INVENTION
[00131 With the cast product of the present invention, at least one of Cr, Ni, Si, and Fe forms a solid solution in an alumina barrier layer formed on a
3 Date Recue/Date Received 2022-07-12 surface of a matrix, thus enabling an aluminum oxide phase to have a stable structure. With the aluminum oxide, it is possible to suppress the coupling between the matrix and oxygen and the formation of oxides containing Cr, Ni, Si, Fe and the like as a main component on the surface of the matrix.
[00141 This makes it possible that the cast product of the present invention exhibits further superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like when used under a high-temperature atmosphere.
[00151 Accordingly, when the cast product of the present invention is used for a reaction tube for producing ethylene, for example, it is possible to suppress the occurrence of coking, to prevent the yield from being reduced by the reduction of heat exchange rate and thermal conductivity due to the occurrence of coking, and to extend continuous operating time. In addition, since coking is unlikely to occur, it is possible to reduce the frequency and time period for coking-removing operation and to enhance operation efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[00161 FIG. 1 is a cross-sectional view of a cast product before heat treatment.
FIG. 2 is a schematic cross-sectional view illustrating a state where a dilute-Al layer is formed by low-temperature heat treatment.
FIG. 3 is a schematic cross-sectional view illustrating a state where a concentrated-Al layer is formed between the dilute-Al layer and a matrix by high-temperature heat treatment.
FIG. 4 shows a TEM photograph of a film of Working Example 2 and graphs illustrating the results of an EDX analysis.
FIG. 5 shows a TEM photograph of a film of Working Example 7 and graphs illustrating the results of an EDX analysis.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[00141 This makes it possible that the cast product of the present invention exhibits further superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like when used under a high-temperature atmosphere.
[00151 Accordingly, when the cast product of the present invention is used for a reaction tube for producing ethylene, for example, it is possible to suppress the occurrence of coking, to prevent the yield from being reduced by the reduction of heat exchange rate and thermal conductivity due to the occurrence of coking, and to extend continuous operating time. In addition, since coking is unlikely to occur, it is possible to reduce the frequency and time period for coking-removing operation and to enhance operation efficiency.
BRIEF DESCRIPTION OF THE DRAWINGS
[00161 FIG. 1 is a cross-sectional view of a cast product before heat treatment.
FIG. 2 is a schematic cross-sectional view illustrating a state where a dilute-Al layer is formed by low-temperature heat treatment.
FIG. 3 is a schematic cross-sectional view illustrating a state where a concentrated-Al layer is formed between the dilute-Al layer and a matrix by high-temperature heat treatment.
FIG. 4 shows a TEM photograph of a film of Working Example 2 and graphs illustrating the results of an EDX analysis.
FIG. 5 shows a TEM photograph of a film of Working Example 7 and graphs illustrating the results of an EDX analysis.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
4 Date Recue/Date Received 2022-07-12 [00171 Hereinafter, embodiments of the present invention will be described in detail.
A cast product of the present invention has an alumina barrier layer including an aluminum oxide on the surface of a matrix.
[00181 The aluminum oxide in the alumina barrier layer is (Al(i-x)M())203, where M is at least one of Cr, Ni, Si, and Fe, and x is adjusted so as to satisfy the relationship 0<x<0.5.
[00191 Also, at least one of Cr, Ni, Si, and Fe forms a solid solution in the aluminum oxide in the alumina barrier layer, and at least one of Cr, Ni, Si, and Fe forming a solid solution with Al is contained so as to satisfy the relationship Al/(Cr+Ni+Si+Fe)>2.0 in an atomic % ratio.
[00201 Explanation of reasons for limiting components As long as the cast product of the present invention is made of a heat-resistant alloy containing Cr in an amount of 15 mass% or more, Ni in an amount of 18 mass% or more, and Al in an amount of 1 to 5 mass%, it is possible to obtain the effects of the present invention. The cast product of the present invention is made of the following components, for example. It should be noted that in the following description, the term "%" refers to "mass%" unless otherwise stated.
[00211 C: 0.05 to 0.7%
C acts to improve castability and enhance a high-temperature creep rupture strength. Therefore, the content of C is set to at least 0.05%.
However, if the content is too large, a primary carbide of Cr7C3 is likely to be extensively formed and the movement of Al for forming the alumina barrier layer is suppressed. As a result, Al is insufficiently supplied to the surface portion of a cast body and the alumina barrier layer is locally divided, and thus the continuity of the alumina barrier layer is impaired. Moreover, a secondary carbide excessively deposits to reduce ductility and toughness.
Therefore, the upper limit is set to 0.7%. It should be noted that the content of C is more desirably 0.3 to 0.5%.
A cast product of the present invention has an alumina barrier layer including an aluminum oxide on the surface of a matrix.
[00181 The aluminum oxide in the alumina barrier layer is (Al(i-x)M())203, where M is at least one of Cr, Ni, Si, and Fe, and x is adjusted so as to satisfy the relationship 0<x<0.5.
[00191 Also, at least one of Cr, Ni, Si, and Fe forms a solid solution in the aluminum oxide in the alumina barrier layer, and at least one of Cr, Ni, Si, and Fe forming a solid solution with Al is contained so as to satisfy the relationship Al/(Cr+Ni+Si+Fe)>2.0 in an atomic % ratio.
[00201 Explanation of reasons for limiting components As long as the cast product of the present invention is made of a heat-resistant alloy containing Cr in an amount of 15 mass% or more, Ni in an amount of 18 mass% or more, and Al in an amount of 1 to 5 mass%, it is possible to obtain the effects of the present invention. The cast product of the present invention is made of the following components, for example. It should be noted that in the following description, the term "%" refers to "mass%" unless otherwise stated.
[00211 C: 0.05 to 0.7%
C acts to improve castability and enhance a high-temperature creep rupture strength. Therefore, the content of C is set to at least 0.05%.
However, if the content is too large, a primary carbide of Cr7C3 is likely to be extensively formed and the movement of Al for forming the alumina barrier layer is suppressed. As a result, Al is insufficiently supplied to the surface portion of a cast body and the alumina barrier layer is locally divided, and thus the continuity of the alumina barrier layer is impaired. Moreover, a secondary carbide excessively deposits to reduce ductility and toughness.
Therefore, the upper limit is set to 0.7%. It should be noted that the content of C is more desirably 0.3 to 0.5%.
5 Date Recue/Date Received 2022-07-12 [00221 Si: more than 0% to 2.5% or less Si is contained to serve as a decoddizer for molten alloy and to enhance the fluidity of molten alloy. If the content is too large, a high-temperature creep rupture strength is reduced, and therefore, the upper limit is set to 2.5%. It should be noted that the content of Si is more desirably 2.0% or less.
[00231 Mn: more than 0% to 3.0% or less Mn is contained to serve as a deoxidizer for molten alloy and to fix S
in molten alloy. If the content is too large, high-temperature creep rupture strength is reduced, and therefore, the upper limit is set to 3.0%. It should be noted that the content of Mn is more desirably 1.6% or less.
[00241 Cr: 15.0 to 50.0%
Cr is contained in an amount of 15.0% or more in order to contribute to the enhancement of high-temperature strength and cyclic oxidation resistance. However, if the content is too large, high-temperature creep rupture strength is reduced, and therefore, the upper limit is set to 50.0%.
It should be noted that the content of Cr is more desirably 23.0 to 35.0%.
[00251 Ni: 18.0 to 70.0%
Ni is an element that is necessary to secure cyclic oxidation resistance and the stability of a metal structure. If the content of Ni is small, the content of Fe relatively becomes large. As a result, a Cr-Fe-Mn oxide is likely to be formed on the surface of the cast body, and thus the formation of the alumina barrier layer is inhibited. Therefore, the content of Ni is set to at least 18.0%. Even if the content of Ni exceeds 70.0%, it is impossible to obtain the efficacy corresponding to the increasing amount, and therefore, the upper limit is set to 70.0%. It should be noted that the content of Ni is more desirably 28.0 to 45.0%.
[00261 Al: 1.0 to 5.0%
Al is an element that is effective for enhancing carburization resistance and coking resistance. Also, in the present invention, Al is an
[00231 Mn: more than 0% to 3.0% or less Mn is contained to serve as a deoxidizer for molten alloy and to fix S
in molten alloy. If the content is too large, high-temperature creep rupture strength is reduced, and therefore, the upper limit is set to 3.0%. It should be noted that the content of Mn is more desirably 1.6% or less.
[00241 Cr: 15.0 to 50.0%
Cr is contained in an amount of 15.0% or more in order to contribute to the enhancement of high-temperature strength and cyclic oxidation resistance. However, if the content is too large, high-temperature creep rupture strength is reduced, and therefore, the upper limit is set to 50.0%.
It should be noted that the content of Cr is more desirably 23.0 to 35.0%.
[00251 Ni: 18.0 to 70.0%
Ni is an element that is necessary to secure cyclic oxidation resistance and the stability of a metal structure. If the content of Ni is small, the content of Fe relatively becomes large. As a result, a Cr-Fe-Mn oxide is likely to be formed on the surface of the cast body, and thus the formation of the alumina barrier layer is inhibited. Therefore, the content of Ni is set to at least 18.0%. Even if the content of Ni exceeds 70.0%, it is impossible to obtain the efficacy corresponding to the increasing amount, and therefore, the upper limit is set to 70.0%. It should be noted that the content of Ni is more desirably 28.0 to 45.0%.
[00261 Al: 1.0 to 5.0%
Al is an element that is effective for enhancing carburization resistance and coking resistance. Also, in the present invention, Al is an
6 Date Recue/Date Received 2022-07-12 element that is essential for forming the alumina barrier layer on the surface of the cast body. Therefore, the content of Al is set to at least 1.0%.
However, if the content of Al exceeds 5%, the ductility is deteriorated, and therefore, the upper limit is set to 5.0% in the present invention. It should be noted that the content of Al is more desirably 2.5 to 3.8%.
[00271 Rare earth elements: 0.005 to 0.4%
The term "rare earth elements" means 17 elements including 15 elements of the lanthanide series ranging from La to Lu in the periodic table, and Y and Sc. It is preferable that rare earth elements to be contained in the heat-resistant alloy of the present invention include at least one element selected from the group consisting of Ce, La and Nd. Rare earth elements contribute to the formation of the alumina barrier layer and the enhancement of stability thereof.
When the alumina barrier layer is formed by heat treatment under a high-temperature oxidizing atmosphere, rare earth elements that are contained in an amount of 0.005% or more effectively contribute to the formation of the alumina barrier layer.
On the other hand, if the content is too large, the ductility and toughness are deteriorated, and therefore, the upper limit is set to 0.4%.
[00281 W: 0.5 to 10.0% and/or Mo: 0.1 to 5.0%
W and Mo enhance creep rupture strength by forming a solid solution in a matrix and strengthening an austenite phase. At least one of W and Mo is contained in order to achieve this efficacy. The content of W is set to 0.5%
or more, and the content of Mo is set to 0.1% or more.
However, if the contents of W and Mo are too large, ductility is reduced and carburization resistance is deteriorated. Moreover, as in the case where the content of C is large, a primary carbide of (Cr, W, Mo)7C3 is likely to be extensively formed and the movement of Al for forming the alumina barrier layer is suppressed. As a result, Al is insufficiently supplied to the surface portion of the cast body and the alumina barrier layer is locally
However, if the content of Al exceeds 5%, the ductility is deteriorated, and therefore, the upper limit is set to 5.0% in the present invention. It should be noted that the content of Al is more desirably 2.5 to 3.8%.
[00271 Rare earth elements: 0.005 to 0.4%
The term "rare earth elements" means 17 elements including 15 elements of the lanthanide series ranging from La to Lu in the periodic table, and Y and Sc. It is preferable that rare earth elements to be contained in the heat-resistant alloy of the present invention include at least one element selected from the group consisting of Ce, La and Nd. Rare earth elements contribute to the formation of the alumina barrier layer and the enhancement of stability thereof.
When the alumina barrier layer is formed by heat treatment under a high-temperature oxidizing atmosphere, rare earth elements that are contained in an amount of 0.005% or more effectively contribute to the formation of the alumina barrier layer.
On the other hand, if the content is too large, the ductility and toughness are deteriorated, and therefore, the upper limit is set to 0.4%.
[00281 W: 0.5 to 10.0% and/or Mo: 0.1 to 5.0%
W and Mo enhance creep rupture strength by forming a solid solution in a matrix and strengthening an austenite phase. At least one of W and Mo is contained in order to achieve this efficacy. The content of W is set to 0.5%
or more, and the content of Mo is set to 0.1% or more.
However, if the contents of W and Mo are too large, ductility is reduced and carburization resistance is deteriorated. Moreover, as in the case where the content of C is large, a primary carbide of (Cr, W, Mo)7C3 is likely to be extensively formed and the movement of Al for forming the alumina barrier layer is suppressed. As a result, Al is insufficiently supplied to the surface portion of the cast body and the alumina barrier layer is locally
7 Date Recue/Date Received 2022-07-12 divided, and thus the continuity of the alumina barrier layer is likely to be impaired. Furthermore, since W and Mo have a large atomic radius, they suppress the movement of Al and Cr and inhibit the formation of the alumina barrier layer due to the formation of a solid solution in the matrix.
Therefore, the content of W is set to 10.0% or less, and the content of Mo is set to 5.0% or less. It should be noted that when both elements are contained, the total content is preferably set to 10.0% or less.
[00291 In addition, the following components can be contained.
[00301 At least one selected from the group consisting of Ti in an amount of 0.01 to 0.6%, Zr in an amount of 0.01 to 0.6%, and Nb in an amount of 0.1 to 1.8%
Ti, Zr and Nb are elements that are likely to form carbides, and form less solid solutions in the matrix than W and Mo. Therefore, Ti, Zr and Nb do not exhibit any particular action of forming the alumina barrier layer, but enhance creep rupture strength. At least one of Ti, Zr and Nb can be contained as needed. The content of Ti or Zr is set to 0.01% or more and the content of Nb is set to 0.1% or more.
However, if they are excessively added, ductility is reduced.
Furthermore, Nb reduces the peeling resistance of the alumina barrier layer.
Therefore, the upper limit of the content of Ti or Zr is set to 0.6%, and the upper limit of the content of Nb is set to 1.8%.
[00311 B: more than 0% to 0.1% or less Since B exhibits an action of strengthening the particle boundaries of the cast body, B can be contained as needed. It should be noted that if the content of B is large, creep rupture strength is reduced, and therefore, the content of B is set to 0.1% or less even in the case where B is added.
[00321 The heat-resistant alloy making up the cast body of the present invention includes the above-described components and Fe as the balance. P, S, and other impurities that are inevitably mixed in the alloy when melting the alloy may be contained as long as such impurities are contained in an
Therefore, the content of W is set to 10.0% or less, and the content of Mo is set to 5.0% or less. It should be noted that when both elements are contained, the total content is preferably set to 10.0% or less.
[00291 In addition, the following components can be contained.
[00301 At least one selected from the group consisting of Ti in an amount of 0.01 to 0.6%, Zr in an amount of 0.01 to 0.6%, and Nb in an amount of 0.1 to 1.8%
Ti, Zr and Nb are elements that are likely to form carbides, and form less solid solutions in the matrix than W and Mo. Therefore, Ti, Zr and Nb do not exhibit any particular action of forming the alumina barrier layer, but enhance creep rupture strength. At least one of Ti, Zr and Nb can be contained as needed. The content of Ti or Zr is set to 0.01% or more and the content of Nb is set to 0.1% or more.
However, if they are excessively added, ductility is reduced.
Furthermore, Nb reduces the peeling resistance of the alumina barrier layer.
Therefore, the upper limit of the content of Ti or Zr is set to 0.6%, and the upper limit of the content of Nb is set to 1.8%.
[00311 B: more than 0% to 0.1% or less Since B exhibits an action of strengthening the particle boundaries of the cast body, B can be contained as needed. It should be noted that if the content of B is large, creep rupture strength is reduced, and therefore, the content of B is set to 0.1% or less even in the case where B is added.
[00321 The heat-resistant alloy making up the cast body of the present invention includes the above-described components and Fe as the balance. P, S, and other impurities that are inevitably mixed in the alloy when melting the alloy may be contained as long as such impurities are contained in an
8 Date Recue/Date Received 2022-07-12 amount within a range that is usually allowable to this type of alloy material.
[00331 Cast product Molten metal having a composition including the above-described components is produced and cast by centrifugal casting, static casting, or the like into the cast product of the present invention having the above composition.
[00341 The obtained cast product can be shaped depending on the intended application.
One example of the cast product is a tube, in particular, a reaction tube used under a high-temperature environment.
[00351 It is particularly preferable to produce the cast product of the present invention by centrifugal casting. This is because when using centrifugal casting, a fine metal structure grows in the radial direction with orientation due to the progress of cooling by a metal mold and thus an alloy structure in which Al easily moves can be obtained.
[00361 Heat treatment, which will be described later, is performed on the cast product. The alumina barrier layer having a stable phase structure is formed by the heat treatment.
[00371 Heat treatment The heat treatment is performed on the cast product of the present invention under an oxidizing atmosphere. The heat treatment can be divided into low-temperature heat treatment and high-temperature heat treatment. It should be noted that the low-temperature heat treatment and the high-temperature heat treatment can be performed in separate steps or the high-temperature heat treatment may be performed subsequently to the low-temperature heat treatment.
[00381 Low-temperature heat treatment The low-temperature heat treatment is treatment in which an aluminum oxide layer is formed on the surface of the matrix under an oxidizing atmosphere. One example of a low temperature is a temperature
[00331 Cast product Molten metal having a composition including the above-described components is produced and cast by centrifugal casting, static casting, or the like into the cast product of the present invention having the above composition.
[00341 The obtained cast product can be shaped depending on the intended application.
One example of the cast product is a tube, in particular, a reaction tube used under a high-temperature environment.
[00351 It is particularly preferable to produce the cast product of the present invention by centrifugal casting. This is because when using centrifugal casting, a fine metal structure grows in the radial direction with orientation due to the progress of cooling by a metal mold and thus an alloy structure in which Al easily moves can be obtained.
[00361 Heat treatment, which will be described later, is performed on the cast product. The alumina barrier layer having a stable phase structure is formed by the heat treatment.
[00371 Heat treatment The heat treatment is performed on the cast product of the present invention under an oxidizing atmosphere. The heat treatment can be divided into low-temperature heat treatment and high-temperature heat treatment. It should be noted that the low-temperature heat treatment and the high-temperature heat treatment can be performed in separate steps or the high-temperature heat treatment may be performed subsequently to the low-temperature heat treatment.
[00381 Low-temperature heat treatment The low-temperature heat treatment is treatment in which an aluminum oxide layer is formed on the surface of the matrix under an oxidizing atmosphere. One example of a low temperature is a temperature
9 Date Recue/Date Received 2022-07-12 of less than 1050 C. It is desirably 600 to 900 C. It is desirable to perform the low-temperature heat treatment for 5 to 15 hours.
[00391 By performing the low-temperature heat treatment, oxygen comes into contact with a matrix 10 as shown in FIG. 1 to oxidize Al, Cr, Ni, Si, and .. Fe that has diffused from the matrix 10 to the surface of the matrix, and an oxide layer 22 is formed as shown in FIG. 2. Since this heat treatment is performed at a low temperature, Al forms oxides prior to Cr, Ni, Si, and Fe.
Accordingly, an aluminum oxide layer 22 that contains Al as a main component and in which at least one of Cr, Ni, Si, and Fe, which have similarly diffused from the matrix, forms a solid solution is the oxide layer.
[00401 In the aluminum oxide formed by the low-temperature heat treatment, at least one of Cr, Ni, Si, and Fe forming a solid solution with Al is contained so as to satisfy the relationship Al/(Cr+Ni+Si+Fe)>2.0 in an atomic % ratio. In addition, it is desirable that the composition thereof is (Al(i-x)M0203, where M is at least one of Cr, Ni, Si, and Fe, and x satisfies the relationship 0<x<0.5. Moreover, at least Cr forms a solid solution in the aluminum oxide, and Cr forming a solid solution with Al is more preferably contained so as to satisfy the relationship Al/Cr>10 in atomic % ratio, and still more preferably the relationship A1/Cr>15. Furthermore, at least one of Ni, Si, and Fe forms a solid solution, and it is more desirable that the total atomic % of at least one of Ni, Si, and Fe forming a solid solution with Al is
[00391 By performing the low-temperature heat treatment, oxygen comes into contact with a matrix 10 as shown in FIG. 1 to oxidize Al, Cr, Ni, Si, and .. Fe that has diffused from the matrix 10 to the surface of the matrix, and an oxide layer 22 is formed as shown in FIG. 2. Since this heat treatment is performed at a low temperature, Al forms oxides prior to Cr, Ni, Si, and Fe.
Accordingly, an aluminum oxide layer 22 that contains Al as a main component and in which at least one of Cr, Ni, Si, and Fe, which have similarly diffused from the matrix, forms a solid solution is the oxide layer.
[00401 In the aluminum oxide formed by the low-temperature heat treatment, at least one of Cr, Ni, Si, and Fe forming a solid solution with Al is contained so as to satisfy the relationship Al/(Cr+Ni+Si+Fe)>2.0 in an atomic % ratio. In addition, it is desirable that the composition thereof is (Al(i-x)M0203, where M is at least one of Cr, Ni, Si, and Fe, and x satisfies the relationship 0<x<0.5. Moreover, at least Cr forms a solid solution in the aluminum oxide, and Cr forming a solid solution with Al is more preferably contained so as to satisfy the relationship Al/Cr>10 in atomic % ratio, and still more preferably the relationship A1/Cr>15. Furthermore, at least one of Ni, Si, and Fe forms a solid solution, and it is more desirable that the total atomic % of at least one of Ni, Si, and Fe forming a solid solution with Al is
10 atm% or less.
[00411 The aluminum oxide formed by the above-described low-temperature heat treatment has a metastable y or 0 alumina structure, which is a porous structure. Accordingly, the strength is not enough.
[00421 High-temperature heat treatment The high-temperature heat treatment is heat treatment that is performed after the low-temperature heat treatment, and in which, as described later, the phase of the aluminum oxide formed by the low-temperature heat treatment is transformed to an a alumina structure Date Recue/Date Received 2022-07-12 (corundum structure), and an aluminum oxide layer containing Al at a high concentration is formed between that aluminum oxide layer and the matrix.
[00431 The high-temperature heat treatment can be performed by heating the cast product on which the low-temperature heat treatment has been performed and the alumina barrier layer having a y or 0 alumina structure has been formed, at a high temperature under an oxidizing atmosphere.
One example of a high temperature is a temperature of 1050 C or more. It is desirable to perform the high-temperature heat treatment for 3 to 15 hours.
[00441 By performing the high-temperature heat treatment, the phase of the aluminum oxide that was formed first and has a y or 0 alumina structure is transformed to a stable a alumina structure (corundum structure). In the present invention, at least one of Cr, Ni, Si, and Fe forms a solid solution in the aluminum oxide layer having a y or 0 alumina structure. This makes it possible to promote the phase transformation from a y or 0 alumina structure to an a alumina structure (corundum structure) compared with the case where the aluminum oxide layer contains Al in a high ratio.
[00451 Then, the high-temperature heat treatment is further continuously performed on the cast product having the aluminum oxide layer in which the phase has been transformed to an a alumina structure (corundum structure), and thus oxygen passes through the aluminum oxide layer 22 as shown in FIG. 3.
[00461 The oxygen that has passed through the aluminum oxide layer 22 oxidizes Al that diffuses from the matrix, and an aluminum oxide layer 24 that contains Al at a high concentration is formed.
[00471 Here, as shown in FIG. 3, the aluminum oxide layer that is formed by the low-temperature heat treatment and in which at least one of Cr, Ni, Si, and Fe forms a solid solution is referred to as "dilute-Al layer", and the aluminum oxide layer that is formed between the dilute-Al layer and the surface of the matrix and contains Al at a high concentration is referred to as "concentrated-Al layer". Specifically, in the concentrated-Al layer 24,
[00411 The aluminum oxide formed by the above-described low-temperature heat treatment has a metastable y or 0 alumina structure, which is a porous structure. Accordingly, the strength is not enough.
[00421 High-temperature heat treatment The high-temperature heat treatment is heat treatment that is performed after the low-temperature heat treatment, and in which, as described later, the phase of the aluminum oxide formed by the low-temperature heat treatment is transformed to an a alumina structure Date Recue/Date Received 2022-07-12 (corundum structure), and an aluminum oxide layer containing Al at a high concentration is formed between that aluminum oxide layer and the matrix.
[00431 The high-temperature heat treatment can be performed by heating the cast product on which the low-temperature heat treatment has been performed and the alumina barrier layer having a y or 0 alumina structure has been formed, at a high temperature under an oxidizing atmosphere.
One example of a high temperature is a temperature of 1050 C or more. It is desirable to perform the high-temperature heat treatment for 3 to 15 hours.
[00441 By performing the high-temperature heat treatment, the phase of the aluminum oxide that was formed first and has a y or 0 alumina structure is transformed to a stable a alumina structure (corundum structure). In the present invention, at least one of Cr, Ni, Si, and Fe forms a solid solution in the aluminum oxide layer having a y or 0 alumina structure. This makes it possible to promote the phase transformation from a y or 0 alumina structure to an a alumina structure (corundum structure) compared with the case where the aluminum oxide layer contains Al in a high ratio.
[00451 Then, the high-temperature heat treatment is further continuously performed on the cast product having the aluminum oxide layer in which the phase has been transformed to an a alumina structure (corundum structure), and thus oxygen passes through the aluminum oxide layer 22 as shown in FIG. 3.
[00461 The oxygen that has passed through the aluminum oxide layer 22 oxidizes Al that diffuses from the matrix, and an aluminum oxide layer 24 that contains Al at a high concentration is formed.
[00471 Here, as shown in FIG. 3, the aluminum oxide layer that is formed by the low-temperature heat treatment and in which at least one of Cr, Ni, Si, and Fe forms a solid solution is referred to as "dilute-Al layer", and the aluminum oxide layer that is formed between the dilute-Al layer and the surface of the matrix and contains Al at a high concentration is referred to as "concentrated-Al layer". Specifically, in the concentrated-Al layer 24,
11 Date Recue/Date Received 2022-07-12 Al/(Cr+Ni+Si+Fe) is larger than that in the dilute-Al layer 22.
[00481 It is thought that the reason why in terms of the alumina barrier layer, the concentrated-Al layer formed between the matrix and the dilute-Al layer contains Al at a higher concentration than the dilute-Al layer at the surface is as follows.
[00491 The formed dilute-Al layer 22 allows a small amount of oxygen to pass therethrough under an oxidizing atmosphere.
Al, Cr, Ni, Si, and Fe diffuse from the matrix 10 side to the matrix surface side as shown in FIG. 3. However, since Al needs a smaller amount of energy for binding to oxygen than Cr, Ni, Si, and Fe, Al priorly binds to oxygen, and the aluminum oxide layer (concentrated-Al layer 24) containing aluminum oxide at a high concentration is formed between the matrix 10 and the dilute-Al layer 22.
[00501 The concentrated-Al layer 24 is formed by high-temperature heat treatment, and thus has a stable a alumina structure (corundum structure).
It is desirable that 80 vol% or more of a crystal structure of each of the dilute-Al layer 22 and the concentrated-Al layer 24 is an a alumina structure (corundum structure).
[00511 Since the alumina barrier layer 20 is constituted by the dilute-Al layer 22 and the concentrated-Al layer 24 formed between the matrix 10 and the dilute-Al layer 22, both of which have stable a alumina structures (corundum structures), the alumina barrier layer 20 has high denseness, serves as a barrier for preventing oxygen, carbon and nitrogen from entering the base material from the outside during use under a high-temperature atmosphere in the cast product provided therewith, and can maintain superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like for a long period of time.
[00521 It should be noted that the concentrated-Al layer 24 is desirably formed so as to be thicker than the dilute-Al layer 22, and it is preferable to form the concentrated-Al layer 24 such that the thickness of the
[00481 It is thought that the reason why in terms of the alumina barrier layer, the concentrated-Al layer formed between the matrix and the dilute-Al layer contains Al at a higher concentration than the dilute-Al layer at the surface is as follows.
[00491 The formed dilute-Al layer 22 allows a small amount of oxygen to pass therethrough under an oxidizing atmosphere.
Al, Cr, Ni, Si, and Fe diffuse from the matrix 10 side to the matrix surface side as shown in FIG. 3. However, since Al needs a smaller amount of energy for binding to oxygen than Cr, Ni, Si, and Fe, Al priorly binds to oxygen, and the aluminum oxide layer (concentrated-Al layer 24) containing aluminum oxide at a high concentration is formed between the matrix 10 and the dilute-Al layer 22.
[00501 The concentrated-Al layer 24 is formed by high-temperature heat treatment, and thus has a stable a alumina structure (corundum structure).
It is desirable that 80 vol% or more of a crystal structure of each of the dilute-Al layer 22 and the concentrated-Al layer 24 is an a alumina structure (corundum structure).
[00511 Since the alumina barrier layer 20 is constituted by the dilute-Al layer 22 and the concentrated-Al layer 24 formed between the matrix 10 and the dilute-Al layer 22, both of which have stable a alumina structures (corundum structures), the alumina barrier layer 20 has high denseness, serves as a barrier for preventing oxygen, carbon and nitrogen from entering the base material from the outside during use under a high-temperature atmosphere in the cast product provided therewith, and can maintain superior oxidation resistance, carburization resistance, nitriding resistance, corrosion resistance, and the like for a long period of time.
[00521 It should be noted that the concentrated-Al layer 24 is desirably formed so as to be thicker than the dilute-Al layer 22, and it is preferable to form the concentrated-Al layer 24 such that the thickness of the
12 Date Recue/Date Received 2022-07-12 concentrated-Al layer 24 is one fifth or more of that of the alumina barrier layer 20.
[00531 It is more desirable that the dilute-Al layer 22 has a thickness of 0.04 to 8.0 pm and the concentrated-Al layer 24 has a thickness of 0.01 to 2.0 pm.
[00541 It is desirable to heat the cast product while rotating it in order to preferably form the aluminum oxide layer in the above-described low-temperature heat treatment and high-temperature heat treatment. This makes it possible to heat the cast product uniformly and bring the cast product into contact with oxygen in a good state. As a result, it is possible to reduce the surface roughness (Ra) of the formed alumina barrier layer 20.
[00551 Surface treatment It is possible to perform surface treatment on the alumina barrier layer of the cast product as needed. One example of the surface treatment is polishing. For example, when the cast product is used for a reaction tube, Fe, Ni and the like of the cast product come into contact with a hydrocarbon as a raw material and coke (carbon) is likely to adhere to the inner surface of the tube due to the catalytic action of Fe and Ni, but it is possible to suppress the adhesion of coke by performing the surface treatment to reduce the surface roughness (Ra) of the alumina barrier layer.
[00561 It is desirable to perform the surface treatment such that the surface roughness (Ra) of the alumina barrier layer is 15 pm or less. The surface roughness (Ra) is more desirably 0.05 to 10 pm.
Example 1 [00571 Molten metal was produced by atmospheric melting in a high-frequency induction melting furnace and cast by metal mold centrifugal casting into tube bodies having alloy chemical compositions shown in Table 1 below. The tube body has an inner diameter of 80 mm, an outer diameter of 100 mm, and a length of 250 mm.
[00531 It is more desirable that the dilute-Al layer 22 has a thickness of 0.04 to 8.0 pm and the concentrated-Al layer 24 has a thickness of 0.01 to 2.0 pm.
[00541 It is desirable to heat the cast product while rotating it in order to preferably form the aluminum oxide layer in the above-described low-temperature heat treatment and high-temperature heat treatment. This makes it possible to heat the cast product uniformly and bring the cast product into contact with oxygen in a good state. As a result, it is possible to reduce the surface roughness (Ra) of the formed alumina barrier layer 20.
[00551 Surface treatment It is possible to perform surface treatment on the alumina barrier layer of the cast product as needed. One example of the surface treatment is polishing. For example, when the cast product is used for a reaction tube, Fe, Ni and the like of the cast product come into contact with a hydrocarbon as a raw material and coke (carbon) is likely to adhere to the inner surface of the tube due to the catalytic action of Fe and Ni, but it is possible to suppress the adhesion of coke by performing the surface treatment to reduce the surface roughness (Ra) of the alumina barrier layer.
[00561 It is desirable to perform the surface treatment such that the surface roughness (Ra) of the alumina barrier layer is 15 pm or less. The surface roughness (Ra) is more desirably 0.05 to 10 pm.
Example 1 [00571 Molten metal was produced by atmospheric melting in a high-frequency induction melting furnace and cast by metal mold centrifugal casting into tube bodies having alloy chemical compositions shown in Table 1 below. The tube body has an inner diameter of 80 mm, an outer diameter of 100 mm, and a length of 250 mm.
13 Date Recue/Date Received 2022-07-12 a Ell CD
[0058] Table 1 CD
Alloy chemical composition (the balance includes Fe and inevitable impurities) (mass%) No.
C Si Mn Cr Ni Al REM W Mo Ti Zr Nb B
CD Work.
CD 0.33 0.49 0.32 24.5 43.6 1.2 0.25 2.1 0.6 0.7 Ex. 1 CD
0- Work.
0.45 0.49 0.9 24.3 34.6 1.0 0.16 1.5 0.13 Ex. 2 Work.
Ex. 3 0.4 0.33 0.7 23.8 31.5 3.3 0.26 2.8 0.03 17.)' Work.
0.46 1.5 1.2 25.2 35.0 2.8 0.21 4.2 0.09 0.12 Ex. 4 Work.
0.26 0.41 0.5 23.5 34.6 3.1 0.07 0.9 0.07 Ex. 5 Work.
0.31 0.4 0.2 18.3 67.1 4.7 0.01 0.4 1.6 Ex. 6 Work.
0.38 0.26 0.4 23.8 34.4 4.9 0.11 0.95 0.1 Ex. 7 Work.
0.67 1.5 1.1 23.9 40.1 4.9 0.19 2.9 0.03 Ex. 8 Comp.
0.33 1.78 0.17 25.0 33.4 0.0 0.11 0.83 0.12 Ex. 1 Comp.
0.40 1.3 0.9 25.4 15.0 0.9 0.29 2.9 Ex. 2 Comp.
0.27 1.02 0.2 23.8 33.6 1.1 0.19 11.7 Ex. 3 Comp.
0.34 0.6 0.2 25.0 45.4 2.9 0.09 1.5 1.3 Ex. 4 Comp.
0.45 1.43 1.3 22.9 34.7 3.2 0.24 3.15 0.23 Ex. 5 Comp.
0.45 0.54 0.7 23.8 29.7 5.1 0.15 1.5 0.21 Ex. 6
[0058] Table 1 CD
Alloy chemical composition (the balance includes Fe and inevitable impurities) (mass%) No.
C Si Mn Cr Ni Al REM W Mo Ti Zr Nb B
CD Work.
CD 0.33 0.49 0.32 24.5 43.6 1.2 0.25 2.1 0.6 0.7 Ex. 1 CD
0- Work.
0.45 0.49 0.9 24.3 34.6 1.0 0.16 1.5 0.13 Ex. 2 Work.
Ex. 3 0.4 0.33 0.7 23.8 31.5 3.3 0.26 2.8 0.03 17.)' Work.
0.46 1.5 1.2 25.2 35.0 2.8 0.21 4.2 0.09 0.12 Ex. 4 Work.
0.26 0.41 0.5 23.5 34.6 3.1 0.07 0.9 0.07 Ex. 5 Work.
0.31 0.4 0.2 18.3 67.1 4.7 0.01 0.4 1.6 Ex. 6 Work.
0.38 0.26 0.4 23.8 34.4 4.9 0.11 0.95 0.1 Ex. 7 Work.
0.67 1.5 1.1 23.9 40.1 4.9 0.19 2.9 0.03 Ex. 8 Comp.
0.33 1.78 0.17 25.0 33.4 0.0 0.11 0.83 0.12 Ex. 1 Comp.
0.40 1.3 0.9 25.4 15.0 0.9 0.29 2.9 Ex. 2 Comp.
0.27 1.02 0.2 23.8 33.6 1.1 0.19 11.7 Ex. 3 Comp.
0.34 0.6 0.2 25.0 45.4 2.9 0.09 1.5 1.3 Ex. 4 Comp.
0.45 1.43 1.3 22.9 34.7 3.2 0.24 3.15 0.23 Ex. 5 Comp.
0.45 0.54 0.7 23.8 29.7 5.1 0.15 1.5 0.21 Ex. 6
14 [00591 Two steps of heat treatment that differed in a heating temperature were performed on each of Working Examples 1 to 8, which were obtained examples of the present invention, and Comparative Examples 1 to 6 under an oxidizing atmosphere. First, the low-temperature heat treatment was performed, and the high-temperature heat treatment was subsequently performed. The low-temperature heat treatment was performed for 5 hours, and the high-temperature heat treatment was performed for 5 hours.
[00601 Table 2 N Low-temperature heat High-temperature heat o.
treatment temperature ( C) treatment temperature ( C) Work. Ex. 1 700 1050 Work. Ex. 2 900 1100 Work. Ex. 3 800 1050 Work. Ex. 4 800 1100 Work. Ex. 5 900 1100 Work. Ex. 6 600 1050 Work. Ex. 7 700 1100 Work. Ex. 8 600 1150 Comp. Ex. 1 800 900 Comp. Ex. 2 1000 1250 Comp. Ex. 3 1200 1300 Comp. Ex. 4 500 1150 Comp. Ex. 5 900 1000 Comp. Ex. 6 600 800 [00611 The atomic percentages of elements (Al, Cr, Fe, Ni, Si, 0) contained in the alumina barrier layer formed on the surface of a sample tube of each of Working Examples 1 to 8 and Comparative Examples 1 to 6 that had been subjected to the heat treatment were measured by an EDX analysis (energy dispersive X-ray spectrometry). Table 3 shows the results.
Date Recue/Date Received 2022-07-12 w x cp ) c [0062] Table 3 cp w Co Fe+1\11 .
ncentrated-Al ro' Al Cr Fe Ni Si 0 Cr+Fe Al/
X +Ni+Si (Cr+Fe Al/Cr +Si layer thickness No' atm%atm%atm%atm%atm%atm%1 om ( ) ( ) ( ) ( ) ( ) ( ) (atm%) +Ni+Si) (atm%) /A barrier layer co thickness co ci Work.
N) 41.66 2.7 4.46 3.52 48.56 10.7 3.9
[00601 Table 2 N Low-temperature heat High-temperature heat o.
treatment temperature ( C) treatment temperature ( C) Work. Ex. 1 700 1050 Work. Ex. 2 900 1100 Work. Ex. 3 800 1050 Work. Ex. 4 800 1100 Work. Ex. 5 900 1100 Work. Ex. 6 600 1050 Work. Ex. 7 700 1100 Work. Ex. 8 600 1150 Comp. Ex. 1 800 900 Comp. Ex. 2 1000 1250 Comp. Ex. 3 1200 1300 Comp. Ex. 4 500 1150 Comp. Ex. 5 900 1000 Comp. Ex. 6 600 800 [00611 The atomic percentages of elements (Al, Cr, Fe, Ni, Si, 0) contained in the alumina barrier layer formed on the surface of a sample tube of each of Working Examples 1 to 8 and Comparative Examples 1 to 6 that had been subjected to the heat treatment were measured by an EDX analysis (energy dispersive X-ray spectrometry). Table 3 shows the results.
Date Recue/Date Received 2022-07-12 w x cp ) c [0062] Table 3 cp w Co Fe+1\11 .
ncentrated-Al ro' Al Cr Fe Ni Si 0 Cr+Fe Al/
X +Ni+Si (Cr+Fe Al/Cr +Si layer thickness No' atm%atm%atm%atm%atm%atm%1 om ( ) ( ) ( ) ( ) ( ) ( ) (atm%) +Ni+Si) (atm%) /A barrier layer co thickness co ci Work.
N) 41.66 2.7 4.46 3.52 48.56 10.7 3.9
15.43 7.98 0.50 o Ex. 1 N) N) Work' 39.2 O 3.6 1.4 3.2 52.6 8.2 4.8 10.89 4.6 0.30 '74 Ex. 2 N) Work' 46.6 0.1 0.1 53.2 0.2 233.0 466.0 0.1 0.80 Ex. 3 Work.
40.96 2.23 2.34 2.12 52.35 6.7 6.1 18.37 4.46 0.60 Ex. 4 Work.
38.4 1.5 10.1 6.4 1.2 42.4 19.2 2.0 25.60 17.7 0.40 Ex. 5 Work' 42.49 1.31 2.13 1.95 52.12 5.4 7.9 32.44 4.08 0.75 Ex. 6 Work' 42.69 1.28 55.93 1.3 33.4 33.35 0 0.70 Ex. 7 Work. 41.8 2.4 3.9 6.5 45.4 12.8 3.3 17.42 10.4 0.50 Ex. 8 Comp.
4.61 10.25 7.09 31 47.05 53.0 0.0 0.00 48.34 0.00 Ex. 1 Comp.
11.17 15.25 30.1 25.28 1.47 16.73 72.1 0.2 0.73 56.85 0.10 Ex. 2 Comp.
6.7 35.46 1.65 1.8 1.64 52.75 40.6 0.2 0.19 5.09 0.05 Ex. 3 Comp.
36.7 6.7 1.8 10.3 44.5 18.8 1.95 5.48 12.1 0.15 Ex. 4 Comp.
9.77 21.54 11.34 9.51 1.02 46.82 43.4 0.2 0.45 21.87 0.10 Ex. 5 Comp.
8.35 11 15.18 13.76 51.71 39.9 0.2 0.76 28.94 0.05 Ex. 6
40.96 2.23 2.34 2.12 52.35 6.7 6.1 18.37 4.46 0.60 Ex. 4 Work.
38.4 1.5 10.1 6.4 1.2 42.4 19.2 2.0 25.60 17.7 0.40 Ex. 5 Work' 42.49 1.31 2.13 1.95 52.12 5.4 7.9 32.44 4.08 0.75 Ex. 6 Work' 42.69 1.28 55.93 1.3 33.4 33.35 0 0.70 Ex. 7 Work. 41.8 2.4 3.9 6.5 45.4 12.8 3.3 17.42 10.4 0.50 Ex. 8 Comp.
4.61 10.25 7.09 31 47.05 53.0 0.0 0.00 48.34 0.00 Ex. 1 Comp.
11.17 15.25 30.1 25.28 1.47 16.73 72.1 0.2 0.73 56.85 0.10 Ex. 2 Comp.
6.7 35.46 1.65 1.8 1.64 52.75 40.6 0.2 0.19 5.09 0.05 Ex. 3 Comp.
36.7 6.7 1.8 10.3 44.5 18.8 1.95 5.48 12.1 0.15 Ex. 4 Comp.
9.77 21.54 11.34 9.51 1.02 46.82 43.4 0.2 0.45 21.87 0.10 Ex. 5 Comp.
8.35 11 15.18 13.76 51.71 39.9 0.2 0.76 28.94 0.05 Ex. 6
16 [00631 All of Working Examples 1 to 8, which are examples of the present invention, satisfy the relationship Al/(Cr+Ni+Si+Fe)>2.0 in atomic % ratio.
Furthermore, they satisfy the relationship A1/Cr>10. On the other hand, Comparative Example 1 contains no Al in the matrix, and therefore, no aluminum oxide is formed and both Al/(Cr+Ni+Si+Fe) and Al/Cr are zero.
[00641 Moreover, all of Comparative Examples 2 to 6 satisfy the relationships A]/(Cr+Ni+Si+Fe)<2.0 and A1/Cr<10.
[00651 Furthermore, Fe+Ni+Si is 10 atm% or less in Working Examples 1 to 4, and 6 and 7, and Comparative Example 3, and more than 10 atm% in other working examples and comparative examples.
[00661 The ratio of the thickness of the concentrated-Al layer with respect to the thickness of the formed alumina barrier layer was measured in each of obtained Working Examples 1 to 8 and Comparative Examples 1 to 6. Table 3 above shows the results.
[00671 Table 3 shows that the ratio of the thickness of the concentrated-Al layer with respect to the thickness of the alumina barrier layer is 0.3 or more, that is, one fifth or more in each working example, but it is 0.15 at most in the comparative examples. It should be noted that since Comparative Example 1 contains no Al, no alumina barrier layer is formed.
[00681 This shows that since the low-temperature heat treatment was performed on the working examples, which were examples of the present invention, at a temperature of less than 1050 C and the high-temperature heat treatment was performed thereon at a temperature of 1050 C or more, the dilute-Al layer was formed on the surface of the matrix by the low-temperature heat treatment and then the concentrated-Al layer could be formed between the dilute-Al layer and the matrix by the high-temperature heat treatment.
[00691 On the other hand, it is thought that the ratio of the thickness of the concentrated-Al layer with respect to the thickness of the alumina barrier layer was 0.15 at most in Comparative Examples 2 to 6 on which the alumina
Furthermore, they satisfy the relationship A1/Cr>10. On the other hand, Comparative Example 1 contains no Al in the matrix, and therefore, no aluminum oxide is formed and both Al/(Cr+Ni+Si+Fe) and Al/Cr are zero.
[00641 Moreover, all of Comparative Examples 2 to 6 satisfy the relationships A]/(Cr+Ni+Si+Fe)<2.0 and A1/Cr<10.
[00651 Furthermore, Fe+Ni+Si is 10 atm% or less in Working Examples 1 to 4, and 6 and 7, and Comparative Example 3, and more than 10 atm% in other working examples and comparative examples.
[00661 The ratio of the thickness of the concentrated-Al layer with respect to the thickness of the formed alumina barrier layer was measured in each of obtained Working Examples 1 to 8 and Comparative Examples 1 to 6. Table 3 above shows the results.
[00671 Table 3 shows that the ratio of the thickness of the concentrated-Al layer with respect to the thickness of the alumina barrier layer is 0.3 or more, that is, one fifth or more in each working example, but it is 0.15 at most in the comparative examples. It should be noted that since Comparative Example 1 contains no Al, no alumina barrier layer is formed.
[00681 This shows that since the low-temperature heat treatment was performed on the working examples, which were examples of the present invention, at a temperature of less than 1050 C and the high-temperature heat treatment was performed thereon at a temperature of 1050 C or more, the dilute-Al layer was formed on the surface of the matrix by the low-temperature heat treatment and then the concentrated-Al layer could be formed between the dilute-Al layer and the matrix by the high-temperature heat treatment.
[00691 On the other hand, it is thought that the ratio of the thickness of the concentrated-Al layer with respect to the thickness of the alumina barrier layer was 0.15 at most in Comparative Examples 2 to 6 on which the alumina
17 Date Recue/Date Received 2022-07-12 barrier layer was formed for the following reasons.
In Comparative Example 2, the cast body contained Al in a small amount of 0.9%, and Al for forming a film on the surface of the cast body was insufficient. In Comparative Example 3, since the low-temperature heat treatment was performed at a high temperature of 1200 C, oxides containing Cr, Ni, Si, Fe and the like as a main component were formed before the alumina barrier layer having a y or 0 alumina structure was formed. In Comparative Example 4, since the low-temperature heat treatment was performed at a low temperature of 500 C, no alumina barrier layer having a y or 0 alumina structure was formed. In Comparative Examples 5 and 6, the high-temperature heat treatment was performed at a low temperature of 1000 C. As a result, a small amount of oxygen passed through the dilute-Al layer in the high-temperature heat treatment after the dilute-Al layer was formed in the low-temperature heat treatment, and Al did not obtain sufficient energy for binding to the oxygen taken in because the temperature was low.
[00701 Next, a coking test was performed on the obtained sample tubes.
The coking test was performed by placing the sample tubes in an electric furnace, supplying a hydrocarbon (ethane) to the sample tubes, and then heating them at a high temperature (955 C) for a predetermined time (12 to 24 hours). After the test, the degrees of carburization of the inner surfaces of the sample tubes were compared, and the weight ratio of coke (carbon) adhering to the inner surface of each sample tube was measured.
Table 4 shows the results.
In Comparative Example 2, the cast body contained Al in a small amount of 0.9%, and Al for forming a film on the surface of the cast body was insufficient. In Comparative Example 3, since the low-temperature heat treatment was performed at a high temperature of 1200 C, oxides containing Cr, Ni, Si, Fe and the like as a main component were formed before the alumina barrier layer having a y or 0 alumina structure was formed. In Comparative Example 4, since the low-temperature heat treatment was performed at a low temperature of 500 C, no alumina barrier layer having a y or 0 alumina structure was formed. In Comparative Examples 5 and 6, the high-temperature heat treatment was performed at a low temperature of 1000 C. As a result, a small amount of oxygen passed through the dilute-Al layer in the high-temperature heat treatment after the dilute-Al layer was formed in the low-temperature heat treatment, and Al did not obtain sufficient energy for binding to the oxygen taken in because the temperature was low.
[00701 Next, a coking test was performed on the obtained sample tubes.
The coking test was performed by placing the sample tubes in an electric furnace, supplying a hydrocarbon (ethane) to the sample tubes, and then heating them at a high temperature (955 C) for a predetermined time (12 to 24 hours). After the test, the degrees of carburization of the inner surfaces of the sample tubes were compared, and the weight ratio of coke (carbon) adhering to the inner surface of each sample tube was measured.
Table 4 shows the results.
18 Date Recue/Date Received 2022-07-12 [00711 Table 4 No. Carburization Weight ratio of Surface resistance formed coke roughness (Ra) Work. Ex. 1 Good 0.4 0.13 Work. Ex. 2 Fair 0.6 5.51 Work. Ex. 3 Good 0.8 7.63 Work. Ex. 4 Good 0.6 1.53 Work. Ex. 5 Fair 1.0 11.7 Work. Ex. 6 Good 0.6 1.54 Work. Ex. 7 Good 0.7 2.02 Work. Ex. 8 Good 1.1 13.8 Comp. Ex. 1 Poor 0.9 9.17 Comp. Ex. 2 Poor 0.7 4.5 Comp. Ex. 3 Poor 1.5 18.1 Comp. Ex. 4 Poor 0.7 8.32 Comp. Ex. 5 Poor 0.8 6.27 Comp. Ex. 6 Poor 1.4 16.47 [00721 Table 4 shows that all of Working Examples 1 to 8, which were examples of the present invention, had favorable carburization resistance.
On the other hand, all of the comparative examples were carburized to the inside of the sample tube.
[00731 It is because the alumina barrier layer having a stable a alumina structure (corundum structure) that was constituted by the concentrated-Al layer and the dilute-Al layer was preferably formed on the surface of the matrix that Working Examples 1 to 8 had superior carburization resistance.
In particular, Working Examples 1, 3, 4, and 6 to 8 had extremely superior carburization resistance compared with the other working examples. It is thought that this is because a smaller amount of the concentrated-Al layer was formed in Working Examples 2 and 5 than in the other working examples.
[00741 Furthermore, the surface roughness (Ra) of each sample tube was measured. Table 4 shows the results as well. Table 4 shows that the weight ratio of the formed coke and the surface roughness (Ra) were substantially in proportion to each other. Accordingly, the surface roughness (Ra) is preferably 15 pm or less, and more preferably 10 pm or less.
On the other hand, all of the comparative examples were carburized to the inside of the sample tube.
[00731 It is because the alumina barrier layer having a stable a alumina structure (corundum structure) that was constituted by the concentrated-Al layer and the dilute-Al layer was preferably formed on the surface of the matrix that Working Examples 1 to 8 had superior carburization resistance.
In particular, Working Examples 1, 3, 4, and 6 to 8 had extremely superior carburization resistance compared with the other working examples. It is thought that this is because a smaller amount of the concentrated-Al layer was formed in Working Examples 2 and 5 than in the other working examples.
[00741 Furthermore, the surface roughness (Ra) of each sample tube was measured. Table 4 shows the results as well. Table 4 shows that the weight ratio of the formed coke and the surface roughness (Ra) were substantially in proportion to each other. Accordingly, the surface roughness (Ra) is preferably 15 pm or less, and more preferably 10 pm or less.
19 Date Recue/Date Received 2022-07-12 [00751 It is possible to adjust the surface roughness (Ra) by performing the heat treatment while rotating the cast product. It is thought that it is because the heat treatment for forming a film was not properly performed and the surface roughness was increased due to the peeling and restoration of the film that the surface roughness of Comparative Examples 3 and 6 exceeded 15 pm.
Example 2 [00761 The alumina barrier layers of Inventive Examples 2 and 7 are observed using a transmission electron microscope (TEM). Furthermore, the EDX analysis was performed on the dilute-Al layer and the concentrated-Al layer of each inventive example. FIG. 4 shows the results from Inventive Example 2, and FIG. 5 shows the results from Inventive Example 7.
[00771 FIG. 4 shows that in Inventive Example 2, small amounts of Cr, Fe, and Ni were detected in the dilute-Al layer 22 formed on the surface side, which contained Al oxides as a main component. On the other hand, no Cr, Fe, Ni, and the like were detected in the concentrated-Al layer 24 but AL
Accordingly, it is found that the concentrated-Al layer 24 was made of aluminum oxide having a very high purity.
[00781 FIG. 5 shows that in Inventive Example 7, a small amount of Cr was detected in the dilute-Al layer 22 formed on the surface side, which mainly included Al oxides. On the other hand, nothing but Al was detected in the concentrated-Al layer 24. Accordingly, it is found that the concentrated-Al layer 24 was made of aluminum oxide having a very high purity.
Example 2 [00761 The alumina barrier layers of Inventive Examples 2 and 7 are observed using a transmission electron microscope (TEM). Furthermore, the EDX analysis was performed on the dilute-Al layer and the concentrated-Al layer of each inventive example. FIG. 4 shows the results from Inventive Example 2, and FIG. 5 shows the results from Inventive Example 7.
[00771 FIG. 4 shows that in Inventive Example 2, small amounts of Cr, Fe, and Ni were detected in the dilute-Al layer 22 formed on the surface side, which contained Al oxides as a main component. On the other hand, no Cr, Fe, Ni, and the like were detected in the concentrated-Al layer 24 but AL
Accordingly, it is found that the concentrated-Al layer 24 was made of aluminum oxide having a very high purity.
[00781 FIG. 5 shows that in Inventive Example 7, a small amount of Cr was detected in the dilute-Al layer 22 formed on the surface side, which mainly included Al oxides. On the other hand, nothing but Al was detected in the concentrated-Al layer 24. Accordingly, it is found that the concentrated-Al layer 24 was made of aluminum oxide having a very high purity.
20 Date Recue/Date Received 2022-07-12
Claims (9)
1. A cast product having an alumina barrier layer including an aluminum oxide on a surface of a matrix, wherein the aluminum oxide is (A10,01\40203, where M is at least one of Cr, Ni, Si, and Fe, and x satisfies a relationship 0<x<0.5, and wherein the matrix includes C in an amount of 0.05 to 0.7 mass%, Si in an amount of more than 0 mass% to 2.5 mass% or less, Mn in an amount of more than 0 mass% to 3.0 mass% or less, Cr in an amount of 15.0 to 50.0 mass%, Ni in an amount of 18.0 to 70.0 mass%, Al in an amount of 1.0 to 5.0 mass%, rare earth elements in an amount of 0.005 to 0.4 mass%, W in an amount of 0.5 to 10.0 mass% and/or Mo in an amount of 0.1 to 5.0 mass%, at least one selected from the group consisting of Ti in an amount of 0.01 to 0.6 mass%, Zr in an amount of 0.01 to 0.6 mass%, and Nb in an amount of 0.1 to 1.8 mass%, and the balance includes Fe and inevitable impurities.
2. The cast product according to claim 1, wherein the aluminum oxide is substantially crystalline in structure, and 80 vol% or more of the crystal structure of the aluminum oxide is a corundum structure.
3. The cast product according to claim 1 or 2, wherein at least Cr forms a solid solution in the aluminum oxide, and the Cr forming the solid solution in the aluminum oxide is contained so as to satisfy a relationship A1/Cr>10 in an atomic % ratio.
Date Recue/Date Received 2022-07-12
Date Recue/Date Received 2022-07-12
4. The cast product according to any one of claims 1 to 3, wherein at least one of Ni, Si, and Fe forms a solid solution in the aluminum oxide, and a total atomic % of the at least one of Ni, Si, and Fe forming the solid solution in the aluminum oxide is 10 atm% or less.
5. The cast product according to any one of claims 1 to 4, wherein the alumina barrier layer has an Al-concentrated layer on the matrix side and an Al-dilute layer on the surface side, and wherein the Al-concentrated layer is larger than the Al-dilute layer with respect to a relationship Al/(Cr+Ni+Si+Fe) at atomic % ratio.
6. The cast product according to claim 5, wherein a thickness of the Al-concentrated layer is one fifth or more of a thickness of the alumina barrier layer.
7. The cast product according to any one of claims 1 to 6, wherein the alumina barrier layer has a surface roughness (Ra) of 15 pm or less.
8. The cast product according to any one of claims 1 to 7, wherein the matrix further includes B in an amount of more than 0 mass% to 0.1 mass% or less.
9. A reaction tube, configured to carry a hydrocarbon gas, made of the cast product according to any one of claims 1 to 8, the alumina barrier layer being formed on an inner surface of the tube.
Date Recue/Date Received 2022-07-12
Date Recue/Date Received 2022-07-12
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP2014-067836 | 2014-03-28 | ||
| JP2014067836A JP6247977B2 (en) | 2014-03-28 | 2014-03-28 | Cast products having an alumina barrier layer |
| CA2940179A CA2940179C (en) | 2014-03-28 | 2014-12-17 | Cast product having alumina barrier layer |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2940179A Division CA2940179C (en) | 2014-03-28 | 2014-12-17 | Cast product having alumina barrier layer |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA3167432A1 true CA3167432A1 (en) | 2015-10-01 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA3167432A Pending CA3167432A1 (en) | 2014-03-28 | 2014-12-17 | Cast product having alumina barrier layer |
| CA2940179A Active CA2940179C (en) | 2014-03-28 | 2014-12-17 | Cast product having alumina barrier layer |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA2940179A Active CA2940179C (en) | 2014-03-28 | 2014-12-17 | Cast product having alumina barrier layer |
Country Status (7)
| Country | Link |
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| US (1) | US20170306468A1 (en) |
| EP (1) | EP3124645B1 (en) |
| JP (1) | JP6247977B2 (en) |
| CN (1) | CN106460144B (en) |
| CA (2) | CA3167432A1 (en) |
| ES (1) | ES2765349T3 (en) |
| WO (1) | WO2015145896A1 (en) |
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| US20190292631A1 (en) * | 2016-05-20 | 2019-09-26 | Sandvik Intellectual Property Ab | An object comprising a pre-oxidized nickel-based alloy |
| JP6339284B1 (en) * | 2017-11-06 | 2018-06-06 | 株式会社クボタ | Steel products used in contact with steel |
| GB2611082A (en) * | 2021-09-27 | 2023-03-29 | Alloyed Ltd | A stainless steel |
| CN115404413B (en) * | 2022-08-22 | 2023-11-28 | 北京首钢吉泰安新材料有限公司 | Iron-chromium-aluminum alloy, preparation method thereof and electric heating element |
Family Cites Families (16)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4204862A (en) * | 1975-10-29 | 1980-05-27 | Nippon Steel Corporation | Austenitic heat-resistant steel which forms Al2 O3 film in high-temperature oxidizing atmosphere |
| JPS5331517A (en) * | 1976-09-04 | 1978-03-24 | Mazda Motor Corp | Two-phase stain less steel |
| GB2017148B (en) * | 1978-03-22 | 1983-01-12 | Pompey Acieries | Nickel chromium iron alloys possessing very high resistantance to carburization at very high temperature |
| JPH05195138A (en) * | 1992-01-24 | 1993-08-03 | Kubota Corp | Heat resistant alloy having excellent carburization resistance and high creep rupture strength under conditions of high temperature and low stress |
| US5413642A (en) * | 1992-11-27 | 1995-05-09 | Alger; Donald L. | Processing for forming corrosion and permeation barriers |
| KR100372482B1 (en) * | 1999-06-30 | 2003-02-17 | 스미토모 긴조쿠 고교 가부시키가이샤 | Heat resistant Ni base alloy |
| JP4841931B2 (en) * | 2005-10-25 | 2011-12-21 | 財団法人電力中央研究所 | Method for improving oxidation resistance of heat-resistant metal material and method for producing heat-resistant metal member |
| US7744813B2 (en) | 2007-01-04 | 2010-06-29 | Ut-Battelle, Llc | Oxidation resistant high creep strength austenitic stainless steel |
| US8748008B2 (en) * | 2008-06-12 | 2014-06-10 | Exxonmobil Research And Engineering Company | High performance coatings and surfaces to mitigate corrosion and fouling in fired heater tubes |
| US8906170B2 (en) | 2008-06-24 | 2014-12-09 | General Electric Company | Alloy castings having protective layers and methods of making the same |
| DE102008051014A1 (en) | 2008-10-13 | 2010-04-22 | Schmidt + Clemens Gmbh + Co. Kg | Nickel-chromium alloy |
| CA2755886C (en) | 2009-03-31 | 2015-12-22 | Kubota Corporation | Cast product having alumina barrier layer |
| BR112013009481A2 (en) | 2010-10-21 | 2016-07-26 | Exxonmobil Res & Eng Co | bimetallic tube formed from alumina for refinery process furnaces and methods of manufacture and use thereof |
| JP6068158B2 (en) * | 2012-03-30 | 2017-01-25 | 株式会社クボタ | Cast products having an alumina barrier layer |
| CA3051675C (en) | 2012-03-23 | 2021-07-06 | Kubota Corporation | Cast product having alumina barrier layer and method for producing same |
| JP6005963B2 (en) * | 2012-03-23 | 2016-10-12 | 株式会社クボタ | Method for producing a cast product having an alumina barrier layer |
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2014
- 2014-03-28 JP JP2014067836A patent/JP6247977B2/en active Active
- 2014-12-17 US US15/116,738 patent/US20170306468A1/en not_active Abandoned
- 2014-12-17 WO PCT/JP2014/083417 patent/WO2015145896A1/en active Application Filing
- 2014-12-17 CA CA3167432A patent/CA3167432A1/en active Pending
- 2014-12-17 CN CN201480077579.XA patent/CN106460144B/en active Active
- 2014-12-17 EP EP14887198.1A patent/EP3124645B1/en active Active
- 2014-12-17 CA CA2940179A patent/CA2940179C/en active Active
- 2014-12-17 ES ES14887198T patent/ES2765349T3/en active Active
Also Published As
| Publication number | Publication date |
|---|---|
| CA2940179C (en) | 2022-09-20 |
| ES2765349T3 (en) | 2020-06-08 |
| WO2015145896A1 (en) | 2015-10-01 |
| JP2015190005A (en) | 2015-11-02 |
| EP3124645A4 (en) | 2017-11-01 |
| EP3124645B1 (en) | 2019-10-23 |
| CA2940179A1 (en) | 2015-10-01 |
| CN106460144B (en) | 2019-01-15 |
| JP6247977B2 (en) | 2017-12-13 |
| EP3124645A1 (en) | 2017-02-01 |
| US20170306468A1 (en) | 2017-10-26 |
| CN106460144A (en) | 2017-02-22 |
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