EP0207697B1 - Rostfreie Gussstahllegierung und Verfahren zu ihrer Herstellung - Google Patents

Rostfreie Gussstahllegierung und Verfahren zu ihrer Herstellung Download PDF

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Publication number
EP0207697B1
EP0207697B1 EP86304758A EP86304758A EP0207697B1 EP 0207697 B1 EP0207697 B1 EP 0207697B1 EP 86304758 A EP86304758 A EP 86304758A EP 86304758 A EP86304758 A EP 86304758A EP 0207697 B1 EP0207697 B1 EP 0207697B1
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Prior art keywords
article
cast
stainless steel
balance
hours
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EP86304758A
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French (fr)
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EP0207697A1 (de
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Ralph A. Mendelson
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Honeywell International Inc
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AlliedSignal Inc
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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
    • C22C38/60—Ferrous alloys, e.g. steel alloys containing lead, selenium, tellurium, or antimony, or more than 0.04% by weight of sulfur

Definitions

  • the present invention relates to relatively low-cost stainless steel alloys used for casting applications, e.g. turbine and turbocharger housings, exhaust manifolds, combustion chambers, etc. having satisfactory corrosion resistance and other properties at room and elevated temperatures in the operating range up to 2000°F (1093°C).
  • Cast articles of this type in particular, automotive or aircraft tubocharger housings, are subject to elevated operating temperatures up to about 2000°F (1093°C), and must be abel to contain a turbine wheel generating very high rotational speeds.
  • the temperature reaches 1300-1400°F (704-760°C) resulting in hausing metal termperatures of 1200-1300°F (649-704°C).
  • the operating temperatures extend up to the 1750-2000°F (954-1909°C) range, which results in metal temperatures of 1550-1950°F (843-1066°C) at the gas inlet or tongue section of the turbocharger housing since this inlet area is within a few degrees of the turbine exhaust temperature and is insulated so that heat is not dissipated rapidly. It is in metal sections such as this gas inlet area of an automotive turbocharger where the exhaust gas initially contacts the turbocharger, that thermal cracking is encountered, unless relatively expensive stainless steel casting alloys are employed.
  • the commercially available HD alloy which is inherently a duplex material contains about 26-30% chromium and 4-7% nickel, however, because of the relatively low nickel content, it is subject to sigma phase formation, which becomes very brittle and gives rise to thermal cracking when used at elevated temperatures, particularly when the cast material is subjected to thermal cycling.
  • a stainless steel casting alloy of higher nickel content such as commercially available high nickel ductile iron casting alloys.
  • NiResist Trade Mark
  • HK30 a chromium-nickel-iron stainless steel alloy containing approximately 30% chromium and 20% nickel, balance essentially iron.
  • the HK series stainless steel alloys in general have about 18-22% nickel and are fully austentic.
  • the HK stainless steel alloys are some of the strongest stainless steel casting alloys, in terms of creep strength, however, while meeting the high temperature property requirements for turbocharger housings, they are quite expensive and present casting difficulties because of their high nickel content.
  • a cast stainless steel article having a duplex metallurgical structure of about 20-80% ferrite, the balance being austenite and being substantially devoid of sigma phase, the article comprising essentially in weight percent:- and optionally the balance being iron with incidental impurities.
  • the manganese and/or molybdenum would be present as a sulphide former and one or other would be selected.
  • Such an article may have good resistance to thermal cracking when subjected to cycling between room temperature and a service temperature of 1500-1950°F (816-1066°C) and which, in the solution treated condition, may be resistant to oxidation corrosion, may have a room temperature tensile strength of at least 75.000psi (52.7 kg/mm 2 ) and at least about 7% elongation.
  • a duplex stainless steel alloy that is, a two phase alloy having both ferritic and austenitic structure, can be used for cast metal parts subject to high operating temperatures, such as automobile turbocharger housings, gasoline engine exhaust manifolds, and cast furnace or combustion chamber components, thereby combining the high temperature properties of the austenitic phase with the castability and low thermal expansion characteristic of the ferritic phase.
  • the article has a Nitrogen content of 0.3-0.4 weight percent.
  • the article has a composition including by weight: 27-31 % Cr, 4-6% Ni, 0.2-0.4% C, 0.5-1.0% Mn, up to 1.0% Mo, 1-2% Si, 0.5-1.5% Nb (niobium or columbium), 0.3-0.4% N up to 0.03% P, 0.2-0.4% S, up to 0.50 Cu, up to 0.20% Al, the balance being iron.
  • the article has a duplex structure of 40-60% ferrite, the balance being austenite.
  • a preferred composition for the article, by weight may be 31 % chromium, 5% nickel, 0.24% carbon, 0.65% manganese, 1% silicon, 0.35% molybdenum, 0.3% sulphur, 0.9% comlumbium (niobium), 0.32% nitrogen, the balance being iron.
  • a method for producing a cast stainless steel article having a duplex metallurgical structure of about 20-80% ferrite, the balance being austenite comprising the steps of: melting a commercial steel mixture to a target chemistry as defined above for the article in accordance with the invention, heating the steel alloy mixture to a temperature of about 2850-2900°F (1566-1593°C) for a time sufficient to homogenise the melt; pouring the steel at a tap temperature of about 2850°F(1566°C) into moduls employing gates designed to minimise porosity; and allowing the article to solidify.
  • the method includes subjecting the cast article to a solution treatment at about 2000-2200°F (1093-1204°C) for 1-4 hours or longer to redistribute M 23 C 6 carbide (where «M» is essentially chromium).
  • the method includes the step of removing the gates by snap breaking after the cast article has cooled to room temperature and before the solution treatment.
  • the solution treated article is air cooled following the solution treatment and is preferably also subjected to a strengthening treatment at about 1400-1600°F (760-871 °) for up to 24 hours.
  • a preferred stainless steel casting composition for turbine housings in accondance with the present invention, is an H-series stainless steel with a relatively low nickel content which is modified with nitrogen to obtain a ferrite/austenite duplex structure having ferrite in the range of 20-80%, preferably 40-60% ferrite, having improved resistance to thermal cracking.
  • the amount of ferrite present in the alloy microstructure is determined by the chemistry of the alloy, the fabrication technique, and the heat treatment employed. It is not believed that the ferritic phase contributes to the high temperature properties of the cast alloy.
  • stainless steel castings according to the invention may be brittle and hence some form of solution treatment is preferable.
  • the brittleness prior to heat treatment has been found to enhance the steel casting method of the present invention, since the cast steel gating can be designed for gate removal by snapping rather than machine cutting.
  • the preferred solution treatment is conducted at 2000-2200°F (1093-1204°C) for 1 1 to 4 hours followed by air cooling. Follwing the solution treatment, the alloy may be subjected to a strengthening treatment of 1400-1600°F (760-871 °C) for up to 24 hours, but since the cast articles encounter temperatures in this temperature range during service, the strengthening treatment may be effected in situ during testing or initial service of the cast articles.
  • the primary strengthening mechanism of the stainless steel casting of the present invention is believed to be by carbide dispersion in a solid solution strengthened matrix.
  • MC carbide where «M» is essentially Cb, (Nb)
  • the brittle M 23 C 6 carbide constituent (where «M» is essentially Cr) is spheroidized or partially dissolved during solution treatment.
  • This dissolved carbide reprecipi- tates at the lower temperatures encountered during normal operating conditions and thus enhances the strenghth of the alloy in service.
  • the solution treatment redistributes, i.e. dissolves or spheroi- dizes the M 23 C 6 carbide, the spheroidized or droplet form of the carbide being more ductile than the original angular form.
  • Sulphur is added to the stainless steel casting alloy of the present invention, in an amount of 0.2-0.4% to enhance machinability, and is combined with manganese or molybdenum as MnS or MoS.
  • Silicon which adds to the fluidity of the cast alloys, is normally present in commercial steels in an amount up to 2%, and 2.5-1.5% niobium is added for strengthening since niobium produces the very stable MC carbide. Tantalum may be similarly beneficial for strengthening but is more expensive than niobium.
  • Turbine housings were prepared for testing in accordance with the present invention made of the DMS016 alloys shown in Table I and the resulting castings had the properties shown in Table II.
  • Table I also shows the compositions of the closely related HC, HD and HK series alloys.
  • the pouring temperature varied from 2733-2770° (1500-1521 °C) for twelve (12) ladles poured in connection with the above example.
  • the charge material was a commercial mixture approximating the desired chemistry of the DMS016 alloys in accordance with the invention.
  • Figure 1 is a 400X photomicrograph, showing the microstructure of alloy DMS016 modified with 0.16% N, at 400X showing approximately 10% austenite, which is the lighter phase, the darker phase being ferrite.
  • the microstructure shown in Figure 2 (0.20%N) contains about 20% austenite
  • the microstructure shown in Figure 3 (0.32%N) contains about 40-50% austenite
  • the microstructure shown in Figure 4 having 0.35% N contains about 50-55% austenite.
  • a particular requirement for a turbocharger housing is that it must contain a wheel burst.
  • the contain- . ment test is performed to determine whether the turbine housing of the particular alloy will contain a wheel which bursts as the rotating speed is increased in accordance with a particular containment requirement policy.
  • Turbocharger manufacturers typically have several burst containment tests, i.e. for auto (gasoline), diesel and aircraft turbochargers. The first two tests are generally similar, while the latter (aircraft) may differ primarily in the use of a mechanically weakened wheel.
  • a test of the alloy designated DMS016 2 was run on a containment burst test stand.
  • the shaft-wheel was modified to facilitate bursting, in accordance with standard aircraft test procedures, by drilling an axial hole in the hub and three holes in the back disc to obtain a three piece hub burst.
  • the turbine inlet temperature was controlled to 1750°F (954°C) at the turbine inlet flange and the turbocharger was ' stabilised for 10 minutes at 97,500 rpm at 1750°F (954°C) turbine inlet temperature.
  • the turbocharger was then rapidly accelerated until the weakened wheel burst at approximately 159,000 rpm.
  • the housing was found to contain the wheel burst.
  • a conventional aircraft turbine housing 10, as shown in Figure 5 was cast from the alloy of the present invention designated DMS016 2 and completed 600 hours of gas stand cyclic durability testing at an inlet temperature of 1750°F (954°C). Visual examination of the unit after completion of 600 hours of testing showed no cracks either at the tongue section 12, shown in Figure 5, or at the top of the volute (gas passage) surface. Hence, the cast housing made of alloy DMS016 2 was found to have excellent resistance to thermal cracking.
  • Oxidation testing at 1500°F (816°C) showed a weight loss of 0.03% after 100 hours.
  • the sulphidation test at 1700°F (927°C) showed a weight loss of approximately 0.4% in one hour.
  • the turbocharger housing finite element thermal stress model shown in Figure 5 compared the standard NiResist material (D-5S) with a similar housing model constructed of the alloy DMS016 2 , and the results shown in Table III, show that while DMS016 2 developed greater stress, it had a greater fatigue life.
  • the temperature at the tongue 12 was 1520°F (827°C) and in the waste gate port region 16 was 1480°F (804°C). While these results were based on very limited creep data, the values for which may vary significantly, the data as shown in Table III indicates greater durability in the alloy of the present invention, DMS016 2 .
  • the finite element stress analysis identified two distinct critical areas where fatigue cracks are expected to occur, namely the tongue 12 and the waste gate port region 16. Thus, it was found that DMS016 2 has higher strength at elevated temperatures than D5S (NiResist) and also has a higher modulus of elasticity and a slightly lower co-efficient of thermal expansion. The result is a casting able to withstand higher thermal stress.
  • the DMS016 alloy appears to meet the development guidelines that were established in that it has castability, machinability and service properties equal to or superior to D5S NiResist and in many areas approaches the properties of HK30 stainless steel, a more expensive high nickel material.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Treatment Of Steel In Its Molten State (AREA)
  • Heat Treatment Of Articles (AREA)
  • Supercharger (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Heat Treatment Of Steel (AREA)
  • Turbine Rotor Nozzle Sealing (AREA)
  • Moulds For Moulding Plastics Or The Like (AREA)
  • Heat Treatment Of Sheet Steel (AREA)

Claims (11)

1. Gegenstand aus nichtrostendem Gußstahl mit einem metallurgischen Doppelgefüge von etwa 20 - 80% Ferrit, Rest Austenit, bei dem eine Sigma-Phase im wesentlichen fehlt, bestehend aus (in Gewichtsprozent):
Figure imgb0011
Figure imgb0012
der Rest Eisen mit zufälligen Verunreinigungen.
2. Gegenstand nach Anspruch 1, gekennzeichnet durch einen Stickstoffgehalt von 0,3 - 0,4 Gewichtsprozent.
3. Gegenstand nach Anspruch 1 oder 2, gekennzeichnet durch eine Doppelstruktur von 40 - 60% Ferrit, Rest Austenit.
4. Gegenstand nach einem der vorausgehenden Ansprüche, dadurch gekennzeichnet durch (in Gewichtsprozent) 31 % Chrom, 5% Nickel, 0,24% Kohlenstoff, 0,65% Mangan, 1 % Silizium, 0,35% Molybdän, 0,3% Schwefel, 0,9% Niobium, 0,32% Stickstoff, Rest Eisen.
5. Gegenstand nach einem der vorausgehenden Ansprüche, dadurch gekennzeichnet, daß er 1 bis 4 Stunden lang bei etwa 1093-1204° C in Lösung behandelt worden ist.
6. Gegenstand nach Anspruch 5, dadurch gekennzeichnet, daß er nach der Lösungsbehandlung luftgekühlt und anschliessend einer der Verfestigung dienenden, bis zu 24 Stunden andauernden Wärmebehandlung bei 760 - 871 °C unterzogen wird.
7. Verfahren zum Herstellen eines Gegenstandes aus nichtrostendem Gußstahl mit einer metallurgischen Doppelstruktur aus etwa 20 - 80% Ferrit, Rest Austenit, dadurch gekennzeichnet, daß ein kommerzielles Stahlgemisch in ein chemisches Material geschmolzen wird, dessen Zusammensetzung in Gewichtsprozent ist:
Figure imgb0013
Figure imgb0014
der Rest Eisen mit zufälligen Verunreinigungen, daß das Stahllegierungsgemisch auf eine Temperatur von etwa 1566 - 1593 °C über eine Zeitdauer erhitzt wird, die ausreicht, um die Schmelze zu homogenisieren, daß der Stahl bei einer Anstichtemperatur von etwa 1566 °C in Formen gegossen wird, wobei Ausgänge verwendet werden, die so ausgelegt sind, daß die Porosität ein Minimum wird, und daßsich der Gegenstand verfestigen kann.
8. Verfahren nach Anspruch 7, dadurch gekennzeichnet, daß der Gußgegenstand einer Lösungsbehandlung bei etwa 1093 -1204 °C über 1 bis 4 Stunden Zeitdauer oder länger unterzogen wird, um M23C6-Karbit neu zu verteilen (wobei «M» im wesentlichen Chrom ist).
9. Verfahren nach Anspruch 8, dadurch gekennzeichnet, daß die Ausgänge durch Schnapp-Brechen entfernt werden, nachdem der Gußgegenstand auf Raumtemperatur abgekühlt ist, und bevor die Lösungsbehandlung durchgeführt wird.
10. Verfahren nach Anspruch 8 oder 9, dadurch gekennzeichnet, daß der durch Lösung behandelte Gegenstand im Anschluß an die Lösungsbehandlung luftgekühlt wird.
11. Verfahren nach einem der Ansprüche 8 bis 10, dadurch gekennzeichnet, daß der Gußgegenstand einer Verfestigungsbehandlung bei etwa 760 - 810 °C über eine Zeitdauer bis zu 24 Stunden unterzogen wird.
EP86304758A 1985-06-26 1986-06-20 Rostfreie Gussstahllegierung und Verfahren zu ihrer Herstellung Expired EP0207697B1 (de)

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AT86304758T ATE46194T1 (de) 1985-06-26 1986-06-20 Rostfreie gussstahllegierung und verfahren zu ihrer herstellung.

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US74915385A 1985-06-26 1985-06-26
US749153 1985-06-26

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JP (1) JPH0672294B2 (de)
AT (1) ATE46194T1 (de)
BR (1) BR8505304A (de)
DE (1) DE3665488D1 (de)
ES (1) ES8707569A1 (de)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012170188A2 (en) * 2011-06-06 2012-12-13 Borgwarner Inc. Exhaust-gas turbocharger
US9534281B2 (en) 2014-07-31 2017-01-03 Honeywell International Inc. Turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same
US9896752B2 (en) 2014-07-31 2018-02-20 Honeywell International Inc. Stainless steel alloys, turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same
US10316694B2 (en) 2014-07-31 2019-06-11 Garrett Transportation I Inc. Stainless steel alloys, turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same

Families Citing this family (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS6331535A (ja) * 1986-07-23 1988-02-10 Jgc Corp 炭素析出抑止性含炭素化合物処理装置
WO1995031581A1 (de) * 1994-05-17 1995-11-23 Ksb Aktiengesellschaft Hartguss mit hoher korrosions- und verschleissbeständigkeit
US6761777B1 (en) * 2002-01-09 2004-07-13 Roman Radon High chromium nitrogen bearing castable alloy
US10975718B2 (en) 2013-02-12 2021-04-13 Garrett Transportation I Inc Stainless steel alloys, turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same
DE102016208301A1 (de) * 2016-05-13 2017-11-16 Continental Automotive Gmbh Stahl-Werkstoff für Hochtemperatur-Anwendungen und Turbinengehäuse aus diesem Werkstoff
CN109487174A (zh) * 2018-11-30 2019-03-19 山西太钢不锈钢股份有限公司 一种兼顾高温强度与低温韧性的双相不锈钢板材制造方法
CN109766634B (zh) * 2019-01-11 2023-04-18 徐州徐工矿业机械有限公司 一种矿用大型铸钢件数字化正向研发方法
EP3959452A1 (de) * 2019-04-25 2022-03-02 Volvo Truck Corporation Schwungradanordnung, fahrzeug und verfahren zur herstellung einer schwungradanordnung
DE102020128884A1 (de) 2020-11-03 2022-05-05 BMTS Technology GmbH & Co. KG Austenitische Stahllegierung und Turbinengehäuse oder Turbinengehäusebauteil für einen Abgasturbolader

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3563729A (en) * 1968-04-16 1971-02-16 Crucible Inc Free-machining corrosion-resistant stainless steel
US3969109A (en) * 1974-08-12 1976-07-13 Armco Steel Corporation Oxidation and sulfidation resistant austenitic stainless steel
US4405389A (en) * 1982-10-21 1983-09-20 Ingersoll-Rand Company Austenitic stainless steel casting alloy for corrosive applications

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2012170188A2 (en) * 2011-06-06 2012-12-13 Borgwarner Inc. Exhaust-gas turbocharger
WO2012170188A3 (en) * 2011-06-06 2013-01-31 Borgwarner Inc. Exhaust-gas turbocharger
CN103534459A (zh) * 2011-06-06 2014-01-22 博格华纳公司 排气涡轮增压器
US9534281B2 (en) 2014-07-31 2017-01-03 Honeywell International Inc. Turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same
US9896752B2 (en) 2014-07-31 2018-02-20 Honeywell International Inc. Stainless steel alloys, turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same
US10316694B2 (en) 2014-07-31 2019-06-11 Garrett Transportation I Inc. Stainless steel alloys, turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same

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Publication number Publication date
ES556779A0 (es) 1987-08-01
ES8707569A1 (es) 1987-08-01
EP0207697A1 (de) 1987-01-07
ATE46194T1 (de) 1989-09-15
DE3665488D1 (en) 1989-10-12
JPH0672294B2 (ja) 1994-09-14
BR8505304A (pt) 1987-02-17
JPS624855A (ja) 1987-01-10

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