EP1631694B1 - Erosion-corrosion resistant carbide cermets for long term high temperature service - Google Patents
Erosion-corrosion resistant carbide cermets for long term high temperature service Download PDFInfo
- Publication number
- EP1631694B1 EP1631694B1 EP04752554A EP04752554A EP1631694B1 EP 1631694 B1 EP1631694 B1 EP 1631694B1 EP 04752554 A EP04752554 A EP 04752554A EP 04752554 A EP04752554 A EP 04752554A EP 1631694 B1 EP1631694 B1 EP 1631694B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- composition
- cermet
- vol
- binder
- phase
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 230000007774 longterm Effects 0.000 title claims description 9
- 238000005260 corrosion Methods 0.000 title description 9
- 239000011195 cermet Substances 0.000 claims description 54
- 239000000203 mixture Substances 0.000 claims description 46
- 239000011230 binding agent Substances 0.000 claims description 44
- 239000011651 chromium Substances 0.000 claims description 33
- 229910045601 alloy Inorganic materials 0.000 claims description 23
- 239000000956 alloy Substances 0.000 claims description 23
- 239000000919 ceramic Substances 0.000 claims description 21
- 229910052804 chromium Inorganic materials 0.000 claims description 20
- UFGZSIPAQKLCGR-UHFFFAOYSA-N chromium carbide Chemical compound [Cr]#C[Cr]C#[Cr] UFGZSIPAQKLCGR-UHFFFAOYSA-N 0.000 claims description 19
- 229910003470 tongbaite Inorganic materials 0.000 claims description 19
- 238000000034 method Methods 0.000 claims description 18
- 229910052751 metal Inorganic materials 0.000 claims description 15
- 239000002184 metal Substances 0.000 claims description 15
- 230000003628 erosive effect Effects 0.000 claims description 14
- 229910052759 nickel Inorganic materials 0.000 claims description 13
- 239000002245 particle Substances 0.000 claims description 10
- 229910052742 iron Inorganic materials 0.000 claims description 9
- 229910052782 aluminium Inorganic materials 0.000 claims description 6
- 229910052748 manganese Inorganic materials 0.000 claims description 6
- 229910052710 silicon Inorganic materials 0.000 claims description 6
- 229910052719 titanium Inorganic materials 0.000 claims description 6
- 239000000463 material Substances 0.000 claims description 5
- 230000002045 lasting effect Effects 0.000 claims description 2
- 238000000926 separation method Methods 0.000 claims description 2
- 239000007787 solid Substances 0.000 claims description 2
- 239000000843 powder Substances 0.000 description 20
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 8
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 8
- 230000007797 corrosion Effects 0.000 description 8
- 238000001878 scanning electron micrograph Methods 0.000 description 8
- 238000004626 scanning electron microscopy Methods 0.000 description 7
- 238000002149 energy-dispersive X-ray emission spectroscopy Methods 0.000 description 6
- VNNRSPGTAMTISX-UHFFFAOYSA-N chromium nickel Chemical compound [Cr].[Ni] VNNRSPGTAMTISX-UHFFFAOYSA-N 0.000 description 5
- 229910001120 nichrome Inorganic materials 0.000 description 5
- 239000011148 porous material Substances 0.000 description 5
- 229910052786 argon Inorganic materials 0.000 description 4
- 230000000052 comparative effect Effects 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 4
- 238000004458 analytical method Methods 0.000 description 3
- 238000004364 calculation method Methods 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 229910010271 silicon carbide Inorganic materials 0.000 description 3
- 238000012546 transfer Methods 0.000 description 3
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 2
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 239000003082 abrasive agent Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 230000002939 deleterious effect Effects 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 238000011068 loading method Methods 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 150000001247 metal acetylides Chemical class 0.000 description 2
- 238000000386 microscopy Methods 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- 238000002156 mixing Methods 0.000 description 2
- 238000000399 optical microscopy Methods 0.000 description 2
- 239000003208 petroleum Substances 0.000 description 2
- JTJMJGYZQZDUJJ-UHFFFAOYSA-N phencyclidine Chemical class C1CCCCN1C1(C=2C=CC=CC=2)CCCCC1 JTJMJGYZQZDUJJ-UHFFFAOYSA-N 0.000 description 2
- 238000003825 pressing Methods 0.000 description 2
- 238000005245 sintering Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000012360 testing method Methods 0.000 description 2
- 230000009466 transformation Effects 0.000 description 2
- 238000000844 transformation Methods 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- 230000004580 weight loss Effects 0.000 description 2
- 239000010963 304 stainless steel Substances 0.000 description 1
- 229910006091 NiCrSi Inorganic materials 0.000 description 1
- 229910018487 Ni—Cr Inorganic materials 0.000 description 1
- 241000566150 Pandion haliaetus Species 0.000 description 1
- 229910000589 SAE 304 stainless steel Inorganic materials 0.000 description 1
- 229910021418 black silicon Inorganic materials 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000003251 chemically resistant material Substances 0.000 description 1
- -1 chrome carbides Chemical class 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 238000004231 fluid catalytic cracking Methods 0.000 description 1
- 229920001903 high density polyethylene Polymers 0.000 description 1
- 239000004700 high-density polyethylene Substances 0.000 description 1
- 238000003384 imaging method Methods 0.000 description 1
- 238000013507 mapping Methods 0.000 description 1
- 238000005297 material degradation process Methods 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 239000002905 metal composite material Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 230000003647 oxidation Effects 0.000 description 1
- 238000007254 oxidation reaction Methods 0.000 description 1
- 239000008188 pellet Substances 0.000 description 1
- 238000010587 phase diagram Methods 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 230000002035 prolonged effect Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 239000013557 residual solvent Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
- 230000002459 sustained effect Effects 0.000 description 1
- 238000004627 transmission electron microscopy Methods 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- RUDFQVOCFDJEEF-UHFFFAOYSA-N yttrium(III) oxide Inorganic materials [O-2].[O-2].[O-2].[Y+3].[Y+3] RUDFQVOCFDJEEF-UHFFFAOYSA-N 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
- C22C29/067—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds comprising a particular metallic binder
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
- C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
- C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
Definitions
- the present invention relates to cermet compositions. More particularly the invention relates to chromium carbide containing cermet compositions and their use in high temperature erosion and corrosion applications.
- Abrasive and chemically resistant materials find use in many applications where metal surfaces are subjected to substances which would otherwise promote erosion or corrosion of the metal surfaces.
- Reactor vessels and transfer lines used in various chemical and petroleum processes are examples of equipment having metal surfaces that often are provided with materials to protect the surfaces against material degradation. Because these vessels and transfer lines are typically used at high temperatures protecting them against degradation is a technological challenge.
- refractory liners are used to protect metal surfaces exposed at high temperature to erosive or corrosive environments. The lifespan of these refractory liners, however, is significantly limited by mechanical attrition of the liner, especially when exposed to high velocity particulates, often encountered in petroleum and petrochemical processing. Refractory liners also commonly exhibit cracking and spallation. Thus, there is a need for liner material that is more resistant to erosion and corrosion at high temperatures.
- Ceramic metal composites or cermets are known to possess the attributes of the hardness of ceramics and the fracture toughness of metal but only when used at relatively moderate temperatures, for example, from 25°C to no more than about 300°C.
- Tungsten carbide (WC) based cermets for example, have both hardness and fracture toughness making them useful in high wear applications such as in cutting tools and drill bits cooled with fluids.
- WC based cermets degrade at sustained high temperatures, greater than about 600°F (315°C).
- Chromium carbide has been a potentially suitable ceramic phase for use in cermets because its three crystallographic forms: the cubic (Cr 23 C 6 ) the hexagonal (Cr 7 C 3 ) and the orthorhombic (Cr 3 C 2 ) have excellent oxidation resistance at elevated temperatures; yet cermets formed from these carbides typically undergo transformations at elevated temperatures which result in the formation of microstructural phases which have a deleterious effect on the properties of such cermets.
- EP-A-0 641 869 relates to powders for use in spray-coating, comprising particles containing of metal carbide core (containing Cr 3 C 2 ) and Ni-Cr alloys.
- the object of the present invention is to provide new and improved cermet compositions.
- Another object of the invention is to provide chromium carbide containing cermet compositions suitable for use at high temperatures.
- Another object of the invention is to provide chromium carbide containing cermet compositions with long term microstructural stability suitable for long term service at high temperatures.
- Yet another object of the invention is to provide an improved method for protecting metal surfaces against erosion and corrosion under high temperature conditions.
- the present invention is a cermet composition
- a cermet composition comprising a chromium carbide ceramic phase dispersed in a binder phase.
- the ceramic phase which constitutes about 50 vol% to about 95 vol% of the total volume of the cermet composition is a chromium carbide selected from the group consisting of Cr 23 C 6 , Cr 7 C 3 , and mixtures thereof.
- the binder phase is selected from the group consisting of (i) alloys containing about 60 wt% to about 98 wt% Ni; about 2 wt% to about 35 wt% Cr; and up to 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof; and (ii) alloys containing about 0.01 wt% to about 35 wt% Fe; about 25 wt% to about 97.99 wt% Ni, about 2 wt% to about 35 wt% Cr; and up to about 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof, the wt% in each instance based on the total weight of the alloy.
- Figure 1 is a scanning electron microscopy (SEM) image of the surface of a cermet made with an initial Cr 3 C 2 in 30 vol% Ni-20 Cr binder.
- Ni-20 Cr indicates 80 wt% Ni and 20 wt% Cr.
- Figure 2 is a SEM image of the surface of a cermet made with an initial Cr 7 C 3 in 30 vol% Ni-20 Cr binder.
- Figure 3 is a SEM image of the surface of a cermet made with an initial Cr 23 C 6 in a 30 vol% Ni-20 Cr binder.
- Figure 4 is a SEM image of the surface of a cermet made with an initial Cr 3 C 2 in a 30vol% 304 stainless steel (304SS) binder after exposure to 800°C for 1000 hours.
- 304SS 30vol% 304 stainless steel
- the invention is a cermet composition
- a chromium carbide ceramic phase dispersed in a continuous binder phase.
- the ceramic phase constitutes about 50 vol% to about 95 vol% of the total volume of the cennet composition, the ceramic phase being a chromium carbide selected from the group consisting of Cr 23 C 6 , Cr 7 C 3 , and mixtures thereof, where this group is intended to include sub and super stoichiometric variances thereof.
- the particle size diameter of the ceramic phase typically is below about 3 mm, preferably below about 100 ⁇ m and more preferably below about 50 ⁇ m.
- the dispersed ceramic particles can be any shape. Some non-limiting examples include spherical, ellipsoidal, polyhedral, distorted spherical, distorted ellipsoidal and distorted polyhedral shaped. By particle size diameter is meant the measure of longest axis of the 3-D shaped particle. Microscopy methods such as optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) can be used to determine the particle sizes.
- OM optical microscopy
- SEM scanning electron microscopy
- TEM transmission electron microscopy
- the binder phase is selected from the group consisting of (i) alloys containing about 60 wt% to about 98 wt% Ni; about 2 wt% to about 35 wt% Cr; and up to about 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof; and (ii) alloys containing about 0.01 wt% to about 35 wt% Fe; about 25 wt% to about 97.99 wt% Ni, about 2 wt% to about 35 wt% Cr; and up to about 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof, the wt% in each instance based on the total weight of the alloy.
- cermet compositions suitable for use at elevated temperatures include:
- Preferred cermet compositions are the follows:
- the cermet compositions are made by general powder metallurgical techniques such as mixing, milling, pressing, sintering and cooling, employing as starting materials a chromium carbide ceramic powder and a binder powder in the volume ratio of 50:50 to 95:5 respectively.
- the chromium carbide powder is one Cr 23 C 6 or Cr 7 C 3 , although mixtures of these may be used.
- the binder is one of the alloy compositions set forth in Table 1.
- Ni Bal Balance
- These powders are milled in a ball mill in the presence of a sufficient amount of an organic liquid such as ethanol for a time sufficient to substantially disperse the powders in each other.
- the liquid is removed and the milled powder is dried, placed in a die and pressed into a green body.
- the green body is then sintered at temperatures above about 1200°C up to about 1600°C for times ranging from about 10 minutes to about 4 hours.
- the sintering operation is preferably performed in an inert atmosphere or a reducing atmosphere or under vacuum.
- the inert atmosphere can be argon and the reducing atmosphere can be hydrogen.
- the sintered body is allowed to cool, typically to ambient conditions.
- the cermet production according to the process described herein allows fabrication of bulk cermet bodies exceeding 5 mm in thickness.
- processing conditions result in the dispersion of the carbide or carbides in the binder. Additionally, the processing results in some compositional changes in the ceramic and binder. For example, when the ceramic employed is Cr 23 C 6 in the same binder there is substantially no change in the composition of the ceramic.
- the cermet can be characterized by a porosity in the range of 0.1 to 15 vol%.
- the volume of porosity is 0.1 to less than 10% of the volume of the cermet.
- the pores comprising the porosity is preferably not connected but distributed in the cermet body as discrete pores.
- the mean pore size is preferably the same or less than the mean particle size of the chromium carbide ceramic phase.
- cermets of the invention are their long term microstructural stability, even at elevated temperatures, making them particularly suitable for use in protecting metal surfaces against erosion at temperatures in the range of about 300°C to about 1000°C. This stability permits their use for prolonged time periods, for example greater than 2 years. In contrast many known cernets undergo transformations at elevated temperatures which result in the formation of phases which have a deleterious effect on the properties of the cermet.
- the long term microstructural stability of the cermets of the instant invention was confirmed by computational thermodynamics using calculation of phase diagram (CALPHAD) methods known to one of ordinary skill in the art of computational thermodynamic calculation methods. These calculations confirmed that the various carbide phases, their amounts, the binder amount and the respective chemistries lead to cermet compositions with long term microstructural stability. Further, lab experiments were conducted in which the cermet compositions of the instant invention were exposed at 800°C for 1000 hours in air. Analysis of the bulk microstructure of the resultant cermet after this 1000h high temperature exposure showed that the starting microstructure was substantially preserved as determined by SEM.
- CALPHAD phase diagram
- the cermet compositions of the instant invention can exhibit long term microstructural stability lasting at least 25 years when exposed to temperatures up to 1000°C.
- cermets of this invention have fracture toughness of greater than about 3 MPa ⁇ m 1/2 , preferably greater than about 5 MPa ⁇ m 1/2 , and most preferably greater than about 10 MPa ⁇ m 1/2 .
- Fracture toughness is the ability to resist crack propagation in a material under monotonic loading conditions. Fracture toughness is defined as the critical stress intensity factor at which a crack propagates in an unstable manner in the material. Loading in three-point bend geometry with the pre-crack in the tension side of the bend sample is preferably used to measure the fracture toughness with fracture mechanics theory.
- the binder phase of the cermet of the instant invention as described in the earlier paragraphs is primarily responsible for imparting this attribute.
- the high temperature stability of the cermets of the invention makes them suitable for applications where refractories are currently employed.
- a non-limiting list of suitable uses include liners for process vessels, transfer lines, cyclones, for example, fluid-solids separation cyclones as in the cyclone of Fluid Catalytic Cracking Unit used in refining industry, grid inserts, thermo wells, valve bodies, side valve gates and guides catalyst regenerators, and the like.
- liners for process vessels, transfer lines, cyclones for example, fluid-solids separation cyclones as in the cyclone of Fluid Catalytic Cracking Unit used in refining industry, grid inserts, thermo wells, valve bodies, side valve gates and guides catalyst regenerators, and the like.
- metal surfaces exposed to erosive or corrosive environments especially at about 300°C to about 1000°C are protected by providing the surface with a layer of the ceramic compositions of the invention.
- the cermets of the instant invention can be affixed to metal surfaces by mechanical means or by welding
- the volume percent of each phase, component and the pore volume (or porosity) were determined from the 2-dimensional area fractions by the Scanning Electron Microscopy method.
- Scanning Electron Microscopy SEM was conducted on the sintered cermet samples to obtain a secondary electron image preferably at 1000x magnification.
- X-ray dot image was obtained using Energy Dispersive X-ray Spectroscopy (EDXS).
- EDXS Energy Dispersive X-ray Spectroscopy
- the SEM and EDXS analyses were conducted on five adjacent areas of the sample.
- the 2-dimensional area fractions of each phase was then determined using the image analysis software: EDX Imaging/Mapping Version 3.2 (EDAX Inc, Mahwah, New Jersey 07430, USA) for each area.
- the arithmetic average of the area fraction was determined from the five measurements.
- the volume percent (vol%) is then determined by multiplying the average area fraction by 100.
- the vol% expressed in the examples have an accuracy of +/-50% for phase amounts measured to be less than 2 vol% and have an accuracy of +/-20% for phase amounts measured to be 2 vol% or greater.
- the weight percent of elements in the cermet phases was determined by standard EDXS analyses.
- the dried powder was compacted in a 40 mm diameter die in a hydraulic uniaxial press (SPEX 3630 Automated X-press) at 5,000 psi.
- the resulting green disc pellet was ramped up to 400°C at 25°C/min in argon and held for 30 min for residual solvent removal.
- the disc was then heated to 1450°C at 15°C/min in argon and held at 1450°C for 1 hour. The temperature was then reduced to below 100°C at -15°C/min.
- the resulting cermet comprises:
- Figure 1 is a SEM image of the cermet processed according to this example, wherein the bar represents 20 ⁇ m. In this image the chromium carbide phase appears light and the binder phase appears dark.
- Example 1 The mixing and pressing procedures of Example 1 was followed using 70 vol% of 14.0 ⁇ m average diameter of Cr 7 C 3 powder (99.5% purity, from Alfa Aesar) and 30 vol% of Ni-20Cr alloy binder powder (Alfa Aesar, screened below 325 mesh). The disc was then heated to 1400°C for 1 hour at 15°C/min in hydrogen. The temperature was then reduced to below 100°C at -15°C/min.
- the resulting cermet comprised:
- Figure 2 is a SEM image of the cermet processed according to this example, wherein the bar represents 20 ⁇ m. In this image the chromium carbide phase appears light and the binder phase appears dark.
- Example 2 The procedure of Example 2 was followed using 70 vol% of 14.0 ⁇ m average diameter of Cr 23 C 6 powder (99.5% purity, from Alfa Aesar) and 30 vol% of Ni-20Cr alloy binder powder (Alfa Aesar, screened below 325 mesh).
- the result cermet comprised of:
- Figure 3 is a SEM image of the cermet processed according to this example, wherein the bar represents 20 ⁇ m. In this image the chromium carbide phase appears light and the binder phase appears dark.
- Example 2 The procedure of Example 2 was followed using 85 vol% of 14.0 ⁇ m average diameter of Cr 3 C 2 powder (99.5% purity, from Alfa Aesar) and 15 vol% of Ni-20Cr alloy binder powder (Alfa Aesar, screened below 325 mesh).
- cermet comprised of:
- cermet compositions of examples 1,2 and 3 were exposed in air at 800°C for 1000 hours in a Lindberg box furnace. After exposure the samples were analyzed using SEM. No significant precipitation of new phases, change in the proportion of the original phase composition or change in the respective chemistry was observed in any of the 3 aforestated samples. Thus the cermet composition of example 1, 2 and 3 were determined to possess long term microstructural stability.
- a comparative example of a system that does not form a preferred thermodynamically stable cermet is prepared using the procedure of Example 1 and 70 vol% of 14.0 ⁇ m average diameter of Cr 3 C 2 powder (99.5% purity, from Alfa Aesar) and 30 vol% of 6.7 ⁇ m average diameter 304SS alloy binder powder (Osprey Metals, Fe(balance):18.5Cr:9.6Ni:1.4Mn:0.63Si, 95.9% screened below -16 ⁇ m). The disc was then heated to 1400°C at 15°C/min in argon and held at 1400°C for 1 hour. During heating, a significant vol% of Cr 3 C 2 phase is replaced by Cr 7 C 3 phase. As net result, carbide volume fraction increases and Cr content is depleted in the binder.
- the result cermet comprised of the non-equilibrium microstructure:
- this cermet comprises:
- Figure 4 is a SEM image of the cermet after heating in air according to this example, wherein the bar represents 10 ⁇ m.
- the chromium carbide phase appears light and the binder phase appears dark.
- This figure shows ⁇ 5 vol% 304SS and > 95 vol% chrome carbides after this relative short-term exposure to high temperature.
- the metal composition has become depleted in chromium content thereby decreasing the fracture toughness of the cermet.
- HEAT hot erosion and attrition test
- Each of the cermets of Examples 1 to 4 was subjected to a corrosion test and found to have a corrosion rate less than about 1.0x10 -11 g 2 /cm 4 s.
- the procedure employed was as follows:
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Materials Engineering (AREA)
- Mechanical Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Composite Materials (AREA)
- Manufacturing & Machinery (AREA)
- Powder Metallurgy (AREA)
- Physical Or Chemical Processes And Apparatus (AREA)
- Other Surface Treatments For Metallic Materials (AREA)
- Coating By Spraying Or Casting (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Cyclones (AREA)
Description
- The present invention relates to cermet compositions. More particularly the invention relates to chromium carbide containing cermet compositions and their use in high temperature erosion and corrosion applications.
- Abrasive and chemically resistant materials find use in many applications where metal surfaces are subjected to substances which would otherwise promote erosion or corrosion of the metal surfaces.
- Reactor vessels and transfer lines used in various chemical and petroleum processes are examples of equipment having metal surfaces that often are provided with materials to protect the surfaces against material degradation. Because these vessels and transfer lines are typically used at high temperatures protecting them against degradation is a technological challenge. Currently refractory liners are used to protect metal surfaces exposed at high temperature to erosive or corrosive environments. The lifespan of these refractory liners, however, is significantly limited by mechanical attrition of the liner, especially when exposed to high velocity particulates, often encountered in petroleum and petrochemical processing. Refractory liners also commonly exhibit cracking and spallation. Thus, there is a need for liner material that is more resistant to erosion and corrosion at high temperatures.
- Ceramic metal composites or cermets are known to possess the attributes of the hardness of ceramics and the fracture toughness of metal but only when used at relatively moderate temperatures, for example, from 25°C to no more than about 300°C. Tungsten carbide (WC) based cermets, for example, have both hardness and fracture toughness making them useful in high wear applications such as in cutting tools and drill bits cooled with fluids. WC based cermets, however, degrade at sustained high temperatures, greater than about 600°F (315°C).
- Chromium carbide has been a potentially suitable ceramic phase for use in cermets because its three crystallographic forms: the cubic (Cr23C6) the hexagonal (Cr7C3) and the orthorhombic (Cr3C2) have excellent oxidation resistance at elevated temperatures; yet cermets formed from these carbides typically undergo transformations at elevated temperatures which result in the formation of microstructural phases which have a deleterious effect on the properties of such cermets.
EP-A-0 641 869 relates to powders for use in spray-coating, comprising particles containing of metal carbide core (containing Cr3C2) and Ni-Cr alloys. - The object of the present invention is to provide new and improved cermet compositions.
- Another object of the invention is to provide chromium carbide containing cermet compositions suitable for use at high temperatures.
- Another object of the invention is to provide chromium carbide containing cermet compositions with long term microstructural stability suitable for long term service at high temperatures.
- Yet another object of the invention is to provide an improved method for protecting metal surfaces against erosion and corrosion under high temperature conditions.
- These and other objects will become apparent from the detailed description which follows.
- Broadly stated, the present invention is a cermet composition comprising a chromium carbide ceramic phase dispersed in a binder phase. The ceramic phase which constitutes about 50 vol% to about 95 vol% of the total volume of the cermet composition is a chromium carbide selected from the group consisting of Cr23C6, Cr7C3, and mixtures thereof.
- The binder phase is selected from the group consisting of (i) alloys containing about 60 wt% to about 98 wt% Ni; about 2 wt% to about 35 wt% Cr; and up to 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof; and (ii) alloys containing about 0.01 wt% to about 35 wt% Fe; about 25 wt% to about 97.99 wt% Ni, about 2 wt% to about 35 wt% Cr; and up to about 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof, the wt% in each instance based on the total weight of the alloy.
- This and other embodiment of the invention, including where applicable those preferred, will be elucidated in the detailed description which follows.
-
Figure 1 is a scanning electron microscopy (SEM) image of the surface of a cermet made with an initial Cr3C2 in 30 vol% Ni-20 Cr binder. Ni-20 Cr indicates 80 wt% Ni and 20 wt% Cr. -
Figure 2 is a SEM image of the surface of a cermet made with an initial Cr7C3 in 30 vol% Ni-20 Cr binder. -
Figure 3 is a SEM image of the surface of a cermet made with an initial Cr23C6 in a 30 vol% Ni-20 Cr binder. -
Figure 4 is a SEM image of the surface of a cermet made with an initial Cr3C2 in a 30vol% 304 stainless steel (304SS) binder after exposure to 800°C for 1000 hours. - In one embodiment the invention is a cermet composition comprising a chromium carbide ceramic phase dispersed in a continuous binder phase.
- The ceramic phase constitutes about 50 vol% to about 95 vol% of the total volume of the cennet composition, the ceramic phase being a chromium carbide selected from the group consisting of Cr23C6, Cr7C3, and mixtures thereof, where this group is intended to include sub and super stoichiometric variances thereof.
- The particle size diameter of the ceramic phase typically is below about 3 mm, preferably below about 100µm and more preferably below about 50µm. The dispersed ceramic particles can be any shape. Some non-limiting examples include spherical, ellipsoidal, polyhedral, distorted spherical, distorted ellipsoidal and distorted polyhedral shaped. By particle size diameter is meant the measure of longest axis of the 3-D shaped particle. Microscopy methods such as optical microscopy (OM), scanning electron microscopy (SEM) and transmission electron microscopy (TEM) can be used to determine the particle sizes.
- The binder phase is selected from the group consisting of (i) alloys containing about 60 wt% to about 98 wt% Ni; about 2 wt% to about 35 wt% Cr; and up to about 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof; and (ii) alloys containing about 0.01 wt% to about 35 wt% Fe; about 25 wt% to about 97.99 wt% Ni, about 2 wt% to about 35 wt% Cr; and up to about 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof, the wt% in each instance based on the total weight of the alloy.
- Illustration of cermet compositions suitable for use at elevated temperatures include:
- (1) about 50 vol% Cr7C3 in a binder comprising 78 wt% Ni, about 4 wt% Fe and 18 wt% Cr;
- (2) about 70 vol% Cr7C3 in a binder comprising 78 wt% Ni, about 4 wt% Fe and 18 wt% Cr;
- (3) about 94 vol% Cr7C3 in a binder comprising 75 wt% Ni, about 7 wt% Fe, and about 18 wt% Cr;
- (4) about 50 vol% Cr23C6 in a binder comprising 72wt% Ni, about 10 wt% Fe, and 18 wt% Cr;
- (5) about 50 vol% Cr23C6 in a binder comprising 67 wt% Ni, 15 wt% Fe and 18 wt% Cr; and
- (6) about 90 vol% Cr23C6 in a binder comprising 77 wt% Ni, 5 wt% Fe and 18 wt% Cr.
- Preferred cermet compositions are the follows:
- (1) 50 vol% to 90 vol% Cr23C6 in binder (i); and
- (2) 50 vol% to 90 vol% Cr7C3 in binder (i).
- The cermet compositions are made by general powder metallurgical techniques such as mixing, milling, pressing, sintering and cooling, employing as starting materials a chromium carbide ceramic powder and a binder powder in the volume ratio of 50:50 to 95:5 respectively. Preferably the chromium carbide powder is one Cr23C6 or Cr7C3, although mixtures of these may be used. Preferably the binder is one of the alloy compositions set forth in Table 1.
Table 1 Alloy Type Composition (wt%) NiCr Bal Ni:20 Cr NiCrSi Bal Ni:20.1 Cr:2.0 Si:0.4 Mn:0.09 Fe FeNiCr Bal Fe:> 12 Cr > 36 Ni Bal = Balance - These powders are milled in a ball mill in the presence of a sufficient amount of an organic liquid such as ethanol for a time sufficient to substantially disperse the powders in each other. The liquid is removed and the milled powder is dried, placed in a die and pressed into a green body. The green body is then sintered at temperatures above about 1200°C up to about 1600°C for times ranging from about 10 minutes to about 4 hours. The sintering operation is preferably performed in an inert atmosphere or a reducing atmosphere or under vacuum. For instance, the inert atmosphere can be argon and the reducing atmosphere can be hydrogen. Thereafter the sintered body is allowed to cool, typically to ambient conditions. The cermet production according to the process described herein allows fabrication of bulk cermet bodies exceeding 5 mm in thickness.
- These processing conditions result in the dispersion of the carbide or carbides in the binder. Additionally, the processing results in some compositional changes in the ceramic and binder. For example, when the ceramic employed is Cr23C6 in the same binder there is substantially no change in the composition of the ceramic.
- The volume percent of cermet phase (and cermet components) excludes pore volume due to porosity. The cermet can be characterized by a porosity in the range of 0.1 to 15 vol%. Preferably, the volume of porosity is 0.1 to less than 10% of the volume of the cermet. The pores comprising the porosity is preferably not connected but distributed in the cermet body as discrete pores. The mean pore size is preferably the same or less than the mean particle size of the chromium carbide ceramic phase.
- One feature of the cermets of the invention is their long term microstructural stability, even at elevated temperatures, making them particularly suitable for use in protecting metal surfaces against erosion at temperatures in the range of about 300°C to about 1000°C. This stability permits their use for prolonged time periods, for example greater than 2 years. In contrast many known cernets undergo transformations at elevated temperatures which result in the formation of phases which have a deleterious effect on the properties of the cermet.
- The long term microstructural stability of the cermets of the instant invention was confirmed by computational thermodynamics using calculation of phase diagram (CALPHAD) methods known to one of ordinary skill in the art of computational thermodynamic calculation methods. These calculations confirmed that the various carbide phases, their amounts, the binder amount and the respective chemistries lead to cermet compositions with long term microstructural stability. Further, lab experiments were conducted in which the cermet compositions of the instant invention were exposed at 800°C for 1000 hours in air. Analysis of the bulk microstructure of the resultant cermet after this 1000h high temperature exposure showed that the starting microstructure was substantially preserved as determined by SEM.
- The cermet compositions of the instant invention can exhibit long term microstructural stability lasting at least 25 years when exposed to temperatures up to 1000°C.
- Another feature of the cermets of this invention is that they have fracture toughness of greater than about 3 MPa·m1/2, preferably greater than about 5 MPa·m1/2, and most preferably greater than about 10 MPa·m1/2. Fracture toughness is the ability to resist crack propagation in a material under monotonic loading conditions. Fracture toughness is defined as the critical stress intensity factor at which a crack propagates in an unstable manner in the material. Loading in three-point bend geometry with the pre-crack in the tension side of the bend sample is preferably used to measure the fracture toughness with fracture mechanics theory. The binder phase of the cermet of the instant invention as described in the earlier paragraphs is primarily responsible for imparting this attribute.
- The high temperature stability of the cermets of the invention makes them suitable for applications where refractories are currently employed. A non-limiting list of suitable uses include liners for process vessels, transfer lines, cyclones, for example, fluid-solids separation cyclones as in the cyclone of Fluid Catalytic Cracking Unit used in refining industry, grid inserts, thermo wells, valve bodies, side valve gates and guides catalyst regenerators, and the like. Thus, metal surfaces exposed to erosive or corrosive environments, especially at about 300°C to about 1000°C are protected by providing the surface with a layer of the ceramic compositions of the invention. The cermets of the instant invention can be affixed to metal surfaces by mechanical means or by welding.
- The volume percent of each phase, component and the pore volume (or porosity) were determined from the 2-dimensional area fractions by the Scanning Electron Microscopy method. Scanning Electron Microscopy (SEM) was conducted on the sintered cermet samples to obtain a secondary electron image preferably at 1000x magnification. For the area scanned by SEM, X-ray dot image was obtained using Energy Dispersive X-ray Spectroscopy (EDXS). The SEM and EDXS analyses were conducted on five adjacent areas of the sample. The 2-dimensional area fractions of each phase was then determined using the image analysis software: EDX Imaging/Mapping Version 3.2 (EDAX Inc, Mahwah, New Jersey 07430, USA) for each area. The arithmetic average of the area fraction was determined from the five measurements. The volume percent (vol%) is then determined by multiplying the average area fraction by 100. The vol% expressed in the examples have an accuracy of +/-50% for phase amounts measured to be less than 2 vol% and have an accuracy of +/-20% for phase amounts measured to be 2 vol% or greater.
- The weight percent of elements in the cermet phases was determined by standard EDXS analyses.
- The following non-limiting examples are included to further illustrate the invention.
- 70 vol% of 14.0µm average diameter of Cr3C2 powder (99.5% purity, from Alfa Aesar) and 30 vol% of Ni-20Cr alloy binder powder (Alfa Aesar, screened below 325 mesh) were dispersed with ethanol in high density polyethylene milling jar. The powders in ethanol were mixed for 24 hours with yttria toughened zirconia balls (10 mm diameter, from Tosoh Ceramics) in a ball mill at 100 rpm. The ethanol was removed from the mixed powders by heating at 130°C for 24 hours in a vacuum oven. The dried powder was compacted in a 40 mm diameter die in a hydraulic uniaxial press (SPEX 3630 Automated X-press) at 5,000 psi. The resulting green disc pellet was ramped up to 400°C at 25°C/min in argon and held for 30 min for residual solvent removal. The disc was then heated to 1450°C at 15°C/min in argon and held at 1450°C for 1 hour. The temperature was then reduced to below 100°C at -15°C/min.
- The resulting cermet comprises:
- i) 63 vol% Cr3C2 with average grain size of 20 µm
- ii) 12 vol% Cr7C3 with average grain size of 20 µm
- iii) 25 vol% Cr-depleted alloy binder (87Ni:13Cr in wt%).
-
Figure 1 is a SEM image of the cermet processed according to this example, wherein the bar represents 20µm. In this image the chromium carbide phase appears light and the binder phase appears dark. - The mixing and pressing procedures of Example 1 was followed using 70 vol% of 14.0µm average diameter of Cr7C3 powder (99.5% purity, from Alfa Aesar) and 30 vol% of Ni-20Cr alloy binder powder (Alfa Aesar, screened below 325 mesh). The disc was then heated to 1400°C for 1 hour at 15°C/min in hydrogen. The temperature was then reduced to below 100°C at -15°C/min.
- The resulting cermet comprised:
- i) 67 vol% Cr7C3 with average grain size of 20µm
- ii) 33 vol% Cr-enriched alloy binder (76Ni:24Cr in wt%).
-
Figure 2 is a SEM image of the cermet processed according to this example, wherein the bar represents 20µm. In this image the chromium carbide phase appears light and the binder phase appears dark. - The procedure of Example 2 was followed using 70 vol% of 14.0µm average diameter of Cr23C6 powder (99.5% purity, from Alfa Aesar) and 30 vol% of Ni-20Cr alloy binder powder (Alfa Aesar, screened below 325 mesh).
- The result cermet comprised of:
- i) 67 vol% Cr23C6 with average grain size of 20µm
- ii) 33 vol% Cr-enriched alloy binder (69Ni:31Cr in wt%).
-
Figure 3 is a SEM image of the cermet processed according to this example, wherein the bar represents 20µm. In this image the chromium carbide phase appears light and the binder phase appears dark. - The procedure of Example 2 was followed using 85 vol% of 14.0µm average diameter of Cr3C2 powder (99.5% purity, from Alfa Aesar) and 15 vol% of Ni-20Cr alloy binder powder (Alfa Aesar, screened below 325 mesh).
- During heating, some Cr3C2 phase is replaced by Cr7C3 phase. As result, carbide volume fraction increases and Cr content is depleted in the binder. The result cermet comprised of:
- i) 80 vol% Cr3C2 with average grain size of 20µm
- ii) 7 vol% Cr7C3 with average grain size of 20µm
- iii) 13 vol% Cr-depleted alloy binder (85Ni:15Cr in wt%).
- The cermet compositions of examples 1,2 and 3were exposed in air at 800°C for 1000 hours in a Lindberg box furnace. After exposure the samples were analyzed using SEM. No significant precipitation of new phases, change in the proportion of the original phase composition or change in the respective chemistry was observed in any of the 3 aforestated samples. Thus the cermet composition of example 1, 2 and 3 were determined to possess long term microstructural stability.
- A comparative example of a system that does not form a preferred thermodynamically stable cermet is prepared using the procedure of Example 1 and 70 vol% of 14.0µm average diameter of Cr3C2 powder (99.5% purity, from Alfa Aesar) and 30 vol% of 6.7µm average diameter 304SS alloy binder powder (Osprey Metals, Fe(balance):18.5Cr:9.6Ni:1.4Mn:0.63Si, 95.9% screened below -16µm). The disc was then heated to 1400°C at 15°C/min in argon and held at 1400°C for 1 hour. During heating, a significant vol% of Cr3C2 phase is replaced by Cr7C3 phase. As net result, carbide volume fraction increases and Cr content is depleted in the binder.
- The result cermet comprised of the non-equilibrium microstructure:
- i) 8 vol% Cr3C2 with average grain size of 20µm
- ii) 72 vol% Cr7C3 with average grain size of 20µm
- iii) 20 vol% Cr-depleted alloy binder
- Next, the sintered disc was heated in air at 800°C for 1000 hours. After exposure to 800°C in air for 1000 hours this cermet comprises:
- i) >9.5 vol% Cr3C2
- ii) >85.5 vol% Cr7C3
- iii) <5 vol% Cr-depleted alloy binder (13.2Si:9.4Cr:8.9Fe:68.5Ni in wt%).
-
Figure 4 is a SEM image of the cermet after heating in air according to this example, wherein the bar represents 10µm. In this image the chromium carbide phase appears light and the binder phase appears dark. This figure shows < 5 vol% 304SS and > 95 vol% chrome carbides after this relative short-term exposure to high temperature. The metal composition has become depleted in chromium content thereby decreasing the fracture toughness of the cermet. - Each of the cermets of Examples 1 to 4 was subjected to a hot erosion and attrition test (HEAT) and was found to have an erosion rate of less than 1.0x10-6 cc/gram SiC erodant. The procedure employed was as follows:
- 1) A specimen cermet disk of about 35 mm diameter and about 5 mm thick was weighed.
- 2) The center of one side of the disk was then subjected to 1200g/min of SiC particles (220 grit #1 Grade Black Silicon Carbide, UK abrasives, Northbrook, IL) entrained in heated air exiting from a tube with a 0.5 inch diameter ending at 1 inch from the target at an angle of 45°. The velocity of the SiC was 45.7 m/sec.
- 3) Step (2) was conducted for 7 hrs at 732°C.
- 4) After 7 hrs the specimen was allowed to cool to ambient temperature and weighed to determine the weight loss.
- 5) The erosion of a specimen of a commercially available castable refractory was determined and used as a Reference Standard. The Reference Standard erosion was given a value of 1 and the results for the cermet specimens are compared in Table 2 to the Reference Standard. In Table 2 any value greater than 1 represents an improvement over the Reference Standard.
- Each of the cermets of Examples 1 to 4 was subjected to a corrosion test and found to have a corrosion rate less than about 1.0x10-11 g2/cm4s. The procedure employed was as follows:
- 1) A specimen cermet of about 10 mm square and about 1 mm thick was polished to 600 grit diamond finish and cleaned in acetone.
- 2) The specimen was then exposed to 100 cc/min air at 800°C in thermogravimetric analyzer (TGA).
- 3) Step (2) was conducted for 65 hours at 800°C.
- 4) After 65 hours the specimen was allowed to cool to ambient temperature.
- 5) Thickness of oxide scale was determined by cross sectional microscopy examination of the corrosion surface.
- 6) All the thickness of oxide scale formed on specimen surface was less than 1 µm, representing superior corrosion resistance.
Cermet {Example} | Starting Weight (g) | Finish Weight (g) | Weight Loss (g) | Bulk Density (g/cc) | Erodant (g) | Erosion (cc/g) | Improvement [(Normalized erosion)-1] |
Cr3C2 L 30 | 18.6737 | 15.0660 | 3.6077 | 7.350 | 5.04E+5 | 7.3766E-7 | 1.4 |
NiCr {1} | |||||||
Cr7C3 L 30 | 23.6681 | 21.0301 | 2.6380 | 7.360 | 5.34E+5 | 6.7121E-7 | 1.6 |
NiCr {2} | |||||||
Cr23C6 L | 23.5976 | 21.6016 | 1.9960 | 7.350 | 5.04E+5 | 5.3882E-7 | 1.9 |
30 NiCr {3} | |||||||
Cr3C2 L 15 | 19.6071 | 17.6609 | 1.9462 | 7.090 | 5.04E+5 | 5.4464E-7 | 1.9 |
NiCr {4} |
Claims (10)
- A cermet composition comprising a chromium carbide ceramic phase dispersed in a binder phase, said cermet composition comprising:(a) 50 vol% to 95 vol%, based on the total volume of the cermet composition, of a ceramic phase, wherein the ceramic phase being a chromium carbide selected from the group consisting of Cr23C6, Cr7C3 and mixtures thereof; and(b) the balance of the vol%, based on the total volume of the cermet composition, of a binder phase selected from the group consisting of(i) alloys containing, based on the total weight of the alloy, 60 wt% to 98 wt% Ni; 2 wt% to 35 wt% Cr; and up to 5 wt% of an element selected from the group consisting Al, Si, Mn, Ti and mixtures thereof; and(ii) alloys containing 0.01 wt% to 35 wt% Fe; 25 wt% to 97.99 wt% Ni, 2wt% to 35 wt% Cr; and up to 5 wt% of an element selected from the group consisting of Al, Si, Mn, Ti and mixtures thereof.
- The composition of claim 1 wherein the binder is (i).
- The composition of claim 1, wherein the binder is (ii).
- The composition of any of claims 1 to 3, wherein the chromium carbide is Cr23C6.
- The composition of any of claims 1 to 3, wherein the chromium carbide is Cr7C3.
- The composition of any of the preceding claims, wherein the ceramic phase is in the form of particles having a particle size diameter below 3 mm, preferably below 100 µm, more preferably below 50 µm.
- The composition of any one of the preceding claims having a long term microstructural stability lasting at least 25 years when exposed at temperatures up to 1000°C.
- A method for protecting a metal surface exposed to an erosive material at temperatures in the range of 300°C to 850°C, the method comprising providing the metal surface with a composition according to any of claims 1 to 7.
- The method of claim 8 wherein said surface comprises the inner surface of a fluid-solids separation cyclone.
- The composition of any of claims 1 to 7 or a method for protecting a metal surface according to any of claims 8 or 9, wherein the cermet composition is in the form of bulk cermet bodies exceeding 5 mm in thickness.
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US47178903P | 2003-05-20 | 2003-05-20 | |
US10/829,823 US7438741B1 (en) | 2003-05-20 | 2004-04-22 | Erosion-corrosion resistant carbide cermets for long term high temperature service |
PCT/US2004/015558 WO2004104250A1 (en) | 2003-05-20 | 2004-05-18 | Erosion-corrosion resistant carbide cermets for long term high temperature service |
Publications (2)
Publication Number | Publication Date |
---|---|
EP1631694A1 EP1631694A1 (en) | 2006-03-08 |
EP1631694B1 true EP1631694B1 (en) | 2009-04-15 |
Family
ID=33479298
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
EP04752554A Expired - Lifetime EP1631694B1 (en) | 2003-05-20 | 2004-05-18 | Erosion-corrosion resistant carbide cermets for long term high temperature service |
Country Status (9)
Country | Link |
---|---|
EP (1) | EP1631694B1 (en) |
JP (1) | JP2007530777A (en) |
KR (1) | KR20060012006A (en) |
AU (1) | AU2004242142A1 (en) |
BR (1) | BRPI0410404A (en) |
CA (1) | CA2523593A1 (en) |
MX (1) | MXPA05011604A (en) |
RU (1) | RU2005136135A (en) |
WO (1) | WO2004104250A1 (en) |
Families Citing this family (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US7842139B2 (en) | 2006-06-30 | 2010-11-30 | Exxonmobil Research And Engineering Company | Erosion resistant cermet linings for oil and gas exploration, refining and petrochemical processing applications |
DE102006045481B3 (en) * | 2006-09-22 | 2008-03-06 | H.C. Starck Gmbh | metal powder |
CN107794528A (en) * | 2017-10-23 | 2018-03-13 | 江西瑞曼增材科技有限公司 | A kind of preparation method of the wear-resisting antioxidant coating of high-temperature alloy surface |
WO2021087133A1 (en) * | 2019-11-01 | 2021-05-06 | Exxonmobil Chemical Patents Inc. | Bimetallic materials comprising cermets with improved metal dusting corrosion and abrasion/erosion resistance |
Family Cites Families (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4173457A (en) * | 1978-03-23 | 1979-11-06 | Alloys, Incorporated | Hardfacing composition of nickel-bonded sintered chromium carbide particles and tools hardfaced thereof |
WO1983001917A1 (en) * | 1981-11-27 | 1983-06-09 | Gte Prod Corp | Nickel-chromium carbide powder and sintering method |
US5137422A (en) * | 1990-10-18 | 1992-08-11 | Union Carbide Coatings Service Technology Corporation | Process for producing chromium carbide-nickel base age hardenable alloy coatings and coated articles so produced |
CA2129874C (en) * | 1993-09-03 | 1999-07-20 | Richard M. Douglas | Powder for use in thermal spraying |
JP3522590B2 (en) * | 1999-06-04 | 2004-04-26 | トーカロ株式会社 | High hardness carbide cermet thermal spray coating member and method of manufacturing the same |
-
2004
- 2004-05-18 AU AU2004242142A patent/AU2004242142A1/en not_active Abandoned
- 2004-05-18 MX MXPA05011604A patent/MXPA05011604A/en unknown
- 2004-05-18 WO PCT/US2004/015558 patent/WO2004104250A1/en active Application Filing
- 2004-05-18 EP EP04752554A patent/EP1631694B1/en not_active Expired - Lifetime
- 2004-05-18 RU RU2005136135/02A patent/RU2005136135A/en not_active Application Discontinuation
- 2004-05-18 KR KR1020057021892A patent/KR20060012006A/en not_active Application Discontinuation
- 2004-05-18 JP JP2006533190A patent/JP2007530777A/en not_active Withdrawn
- 2004-05-18 BR BRPI0410404-8A patent/BRPI0410404A/en not_active IP Right Cessation
- 2004-05-18 CA CA002523593A patent/CA2523593A1/en not_active Abandoned
Also Published As
Publication number | Publication date |
---|---|
MXPA05011604A (en) | 2006-01-23 |
BRPI0410404A (en) | 2006-05-30 |
CA2523593A1 (en) | 2004-12-02 |
JP2007530777A (en) | 2007-11-01 |
KR20060012006A (en) | 2006-02-06 |
RU2005136135A (en) | 2006-06-27 |
AU2004242142A1 (en) | 2004-12-02 |
WO2004104250A1 (en) | 2004-12-02 |
EP1631694A1 (en) | 2006-03-08 |
Similar Documents
Publication | Publication Date | Title |
---|---|---|
US7288132B2 (en) | Advanced erosion resistant carbide cermets with superior high temperature corrosion resistance | |
US20120177933A1 (en) | Multi-scale cermets for high temperature erosion-corrosion service | |
ZA200509370B (en) | Advanced erosion resistant carbonitride cermets | |
ZA200509374B (en) | Erosion-corrosion resistant carbide cermets for long term high temperature service | |
US7407082B2 (en) | Advanced erosion resistant carbonitride cermets | |
ZA200509371B (en) | Erosion-corrosion resistant nitride cermets | |
EP1631694B1 (en) | Erosion-corrosion resistant carbide cermets for long term high temperature service | |
AU2004242139B2 (en) | Advanced erosion-corrosion resistant boride cermets | |
ZA200509368B (en) | Multi-scale cermets for high temperature erosion-corrosion service | |
US20070107548A1 (en) | Erosion-corrosion resistant nitride cermets | |
ZA200509373B (en) | Advanced erosion resistant carbide cermets with superior high temperature corrosion resistance | |
MXPA05012059A (en) | Advanced erosion resistant carbide cermets with superior high temperature corrosion resistance |
Legal Events
Date | Code | Title | Description |
---|---|---|---|
PUAI | Public reference made under article 153(3) epc to a published international application that has entered the european phase |
Free format text: ORIGINAL CODE: 0009012 |
|
17P | Request for examination filed |
Effective date: 20051219 |
|
AK | Designated contracting states |
Kind code of ref document: A1 Designated state(s): AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LI LU MC NL PL PT RO SE SI SK TR |
|
DAX | Request for extension of the european patent (deleted) | ||
17Q | First examination report despatched |
Effective date: 20070323 |
|
RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: JIN, HYUN-WOO Inventor name: BANGARU, NARASIMHA-RAO, VENKATA Inventor name: LING, SHIUN Inventor name: CHUN, CHANGMIN Inventor name: PETERSON, JOHN, ROGER Inventor name: KOO, JAYOUNG, Y. Inventor name: FOWLER, CHRISTOPHER, JOHN Inventor name: ANTRAM, ROBERT, LEE Inventor name: THIRUMALAI, NEERAJ, SRINIVAS |
|
RIN1 | Information on inventor provided before grant (corrected) |
Inventor name: PETERSON, JOHN, ROGER Inventor name: ANTRAM, ROBERT, LEE Inventor name: FOWLER, CHRISTOPHER, JOHN Inventor name: KOO, JAYOUNG, Y. Inventor name: JIN, HYUN-WOO Inventor name: LING, SHIUN Inventor name: CHUN, CHANGMIN Inventor name: THIRUMALAI, NEERAJ, SRINIVAS Inventor name: BANGARU, NARASIMHA-RAO, VENKATA |
|
GRAP | Despatch of communication of intention to grant a patent |
Free format text: ORIGINAL CODE: EPIDOSNIGR1 |
|
GRAS | Grant fee paid |
Free format text: ORIGINAL CODE: EPIDOSNIGR3 |
|
GRAA | (expected) grant |
Free format text: ORIGINAL CODE: 0009210 |
|
AK | Designated contracting states |
Kind code of ref document: B1 Designated state(s): AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LI LU MC NL PL PT RO SE SI SK TR |
|
REG | Reference to a national code |
Ref country code: GB Ref legal event code: FG4D Ref country code: CH Ref legal event code: EP |
|
REG | Reference to a national code |
Ref country code: IE Ref legal event code: FG4D |
|
REF | Corresponds to: |
Ref document number: 602004020614 Country of ref document: DE Date of ref document: 20090528 Kind code of ref document: P |
|
NLV1 | Nl: lapsed or annulled due to failure to fulfill the requirements of art. 29p and 29m of the patents act | ||
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: PT Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090915 Ref country code: FI Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: ES Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090726 Ref country code: AT Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: NL Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: SI Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: PL Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: SE Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090715 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: MC Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20090531 |
|
REG | Reference to a national code |
Ref country code: CH Ref legal event code: PL |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: CZ Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: RO Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: LI Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20090531 Ref country code: DK Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: EE Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: CH Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20090531 |
|
PLBE | No opposition filed within time limit |
Free format text: ORIGINAL CODE: 0009261 |
|
STAA | Information on the status of an ep patent application or granted ep patent |
Free format text: STATUS: NO OPPOSITION FILED WITHIN TIME LIMIT |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: BE Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 Ref country code: SK Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 |
|
REG | Reference to a national code |
Ref country code: FR Ref legal event code: ST Effective date: 20100129 |
|
26N | No opposition filed |
Effective date: 20100118 |
|
GBPC | Gb: european patent ceased through non-payment of renewal fee |
Effective date: 20090715 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: BG Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090715 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: FR Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20090615 Ref country code: IE Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20090518 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: GB Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20090715 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: DE Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20091201 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: GR Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090716 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: IT Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: LU Free format text: LAPSE BECAUSE OF NON-PAYMENT OF DUE FEES Effective date: 20090518 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: HU Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20091016 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: TR Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 |
|
PG25 | Lapsed in a contracting state [announced via postgrant information from national office to epo] |
Ref country code: CY Free format text: LAPSE BECAUSE OF FAILURE TO SUBMIT A TRANSLATION OF THE DESCRIPTION OR TO PAY THE FEE WITHIN THE PRESCRIBED TIME-LIMIT Effective date: 20090415 |