EP3196327A1 - Stainless steel alloys, turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same - Google Patents
Stainless steel alloys, turbocharger turbine housings formed from the stainless steel alloys, and methods for manufacturing the same Download PDFInfo
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- EP3196327A1 EP3196327A1 EP16152144.8A EP16152144A EP3196327A1 EP 3196327 A1 EP3196327 A1 EP 3196327A1 EP 16152144 A EP16152144 A EP 16152144A EP 3196327 A1 EP3196327 A1 EP 3196327A1
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- EP
- European Patent Office
- Prior art keywords
- stainless steel
- turbocharger
- turbocharger turbine
- turbine housing
- steel alloy
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- 238000004519 manufacturing process Methods 0.000 title claims description 9
- 238000000034 method Methods 0.000 title claims description 6
- 229910001256 stainless steel alloy Inorganic materials 0.000 title description 24
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 56
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 31
- 239000000956 alloy Substances 0.000 claims abstract description 31
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims abstract description 28
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 25
- 239000011651 chromium Substances 0.000 claims abstract description 21
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 20
- 239000010955 niobium Substances 0.000 claims abstract description 19
- 229910052757 nitrogen Inorganic materials 0.000 claims abstract description 18
- 229910052758 niobium Inorganic materials 0.000 claims abstract description 17
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 claims abstract description 17
- 229910052804 chromium Inorganic materials 0.000 claims abstract description 16
- 229910052750 molybdenum Inorganic materials 0.000 claims abstract description 16
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims abstract description 15
- 229910000963 austenitic stainless steel Inorganic materials 0.000 claims abstract description 15
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 15
- 239000011733 molybdenum Substances 0.000 claims abstract description 15
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims abstract description 14
- 229910052710 silicon Inorganic materials 0.000 claims abstract description 14
- 229910052721 tungsten Inorganic materials 0.000 claims abstract description 14
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 13
- 239000010703 silicon Substances 0.000 claims abstract description 13
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims abstract description 13
- 239000010937 tungsten Substances 0.000 claims abstract description 13
- 229910052742 iron Inorganic materials 0.000 claims abstract description 10
- 239000011572 manganese Substances 0.000 claims description 20
- 229910052748 manganese Inorganic materials 0.000 claims description 12
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 10
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 abstract description 4
- 239000000463 material Substances 0.000 description 13
- 239000003570 air Substances 0.000 description 9
- 238000005260 corrosion Methods 0.000 description 9
- 230000007797 corrosion Effects 0.000 description 9
- 229910001220 stainless steel Inorganic materials 0.000 description 9
- 239000010935 stainless steel Substances 0.000 description 9
- 239000007789 gas Substances 0.000 description 8
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 7
- 230000006870 function Effects 0.000 description 7
- 239000012535 impurity Substances 0.000 description 6
- 229910000831 Steel Inorganic materials 0.000 description 5
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 5
- 238000002485 combustion reaction Methods 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 239000010959 steel Substances 0.000 description 5
- 230000008901 benefit Effects 0.000 description 4
- 229910052796 boron Inorganic materials 0.000 description 4
- 238000005266 casting Methods 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 3
- 229910001566 austenite Inorganic materials 0.000 description 3
- 239000011575 calcium Substances 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000005728 strengthening Methods 0.000 description 3
- 229910052717 sulfur Inorganic materials 0.000 description 3
- 239000011593 sulfur Substances 0.000 description 3
- 229910052684 Cerium Inorganic materials 0.000 description 2
- 239000005864 Sulphur Substances 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 230000002542 deteriorative effect Effects 0.000 description 2
- 239000000155 melt Substances 0.000 description 2
- 150000001247 metal acetylides Chemical class 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 229910021332 silicide Inorganic materials 0.000 description 2
- FVBUAEGBCNSCDD-UHFFFAOYSA-N silicide(4-) Chemical compound [Si-4] FVBUAEGBCNSCDD-UHFFFAOYSA-N 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 229910001018 Cast iron Inorganic materials 0.000 description 1
- 229910001141 Ductile iron Inorganic materials 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 1
- PCEXQRKSUSSDFT-UHFFFAOYSA-N [Mn].[Mo] Chemical compound [Mn].[Mo] PCEXQRKSUSSDFT-UHFFFAOYSA-N 0.000 description 1
- GAYPVYLCOOFYAP-UHFFFAOYSA-N [Nb].[W] Chemical compound [Nb].[W] GAYPVYLCOOFYAP-UHFFFAOYSA-N 0.000 description 1
- 238000005275 alloying Methods 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- YYXHRUSBEPGBCD-UHFFFAOYSA-N azanylidyneiron Chemical compound [N].[Fe] YYXHRUSBEPGBCD-UHFFFAOYSA-N 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 1
- BIJOYKCOMBZXAE-UHFFFAOYSA-N chromium iron nickel Chemical compound [Cr].[Fe].[Ni] BIJOYKCOMBZXAE-UHFFFAOYSA-N 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 230000005496 eutectics Effects 0.000 description 1
- BHEPBYXIRTUNPN-UHFFFAOYSA-N hydridophosphorus(.) (triplet) Chemical compound [PH] BHEPBYXIRTUNPN-UHFFFAOYSA-N 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 230000008569 process Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000007670 refining Methods 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 230000006641 stabilisation Effects 0.000 description 1
- 238000011105 stabilization Methods 0.000 description 1
- CADICXFYUNYKGD-UHFFFAOYSA-N sulfanylidenemanganese Chemical compound [Mn]=S CADICXFYUNYKGD-UHFFFAOYSA-N 0.000 description 1
- 230000003319 supportive effect Effects 0.000 description 1
- 238000010301 surface-oxidation reaction Methods 0.000 description 1
- 230000037303 wrinkles Effects 0.000 description 1
Images
Classifications
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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
- C22C38/38—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of manganese
-
- 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
- C22C38/001—Ferrous alloys, e.g. steel alloys containing N
-
- 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
- C22C38/002—Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
-
- 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
-
- 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
-
- 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
- C22C38/34—Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D25/00—Component parts, details, or accessories, not provided for in, or of interest apart from, other groups
- F01D25/005—Selecting particular materials
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2220/00—Application
- F05D2220/40—Application in turbochargers
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/10—Metals, alloys or intermetallic compounds
- F05D2300/13—Refractory metals, i.e. Ti, V, Cr, Zr, Nb, Mo, Hf, Ta, W
- F05D2300/132—Chromium
Abstract
Description
- The present disclosure generally relates to stainless steel alloys. More particularly, the present disclosure relates to stainless steel alloys used for casting applications, for example turbine and turbocharger turbine housings, exhaust manifolds, and combustion chambers, that exhibit oxidation resistance at elevated temperatures, and method for manufacturing the same.
- During operation, automotive or aircraft turbocharger housings are subjected to elevated operating temperatures. These housings must be able to contain a turbine wheel generating very high rotational speeds. Exhaust gas from the automotive or aircraft engine initially contacts the turbocharger in metal sections, such as the gas inlet area of the turbocharger, at elevated temperatures. As high-speed performance improves through exhaust temperature increase, there have been attempts to gradually raise the exhaust temperature of the engine. Due to these high temperatures, the thermal load on the parts such as the exhaust manifold and the turbine housing becomes very great and thermal fatigue resistance and brittleness are important factors.
- Various problems have been encountered by these increased exhaust gas temperatures contacting metal sections of the turbocharger. For example, one problem caused by the exhaust temperature rise is the problem of thermal deformation of the material, wherein the turbine housing and exhaust manifold, which alternates between regions of high temperature and low temperature is accompanied by thermal expansion and thermal shrinkage depending on the situation, which can cause surface oxidation wrinkles by such thermal deformation, and which can progress and develop into a penetration crack.
- In order to overcome the challenges associated with higher operating temperatures, prior art alloys used in turbocharger applications have included alloys of higher nickel content such as commercially available high nickel ductile iron casting alloys. Examples of these are NiResist™ developed by the International Nickel Company, or HK30, a chromium-nickel-iron stainless steel alloy containing approximately 25% chromium and 20% nickel, with the balance essentially iron. The HK series stainless steel alloys in general have about 18-22% nickel and are fully austenitic.
- The HK stainless steel alloys are strong stainless steel casting alloys, in terms of creep strength. However, while meeting the high temperature property requirements for turbocharger housings, they are quite technically expensive because of their high nickel content. Furthermore, it has been found advantageous to exclude some metal components so as to provide improved material properties including thermal fatigue resistance and lack of brittleness.
- Accordingly, there is a need for stainless steel alloys useful in turbocharger applications that are able to withstand the higher operating temperatures produced by modern engines, but that minimize the expensive nickel content. Furthermore, other desirable features and characteristics, such as material properties of the inventive subject matter will become apparent from the subsequent detailed description of the inventive subject matter and the appended claims, taken in conjunction with the accompanying drawings and this background of the inventive subject matter.
- The present invention in its various aspects is as set out in the appended claims.
- Stainless steel alloys, turbocharger turbine housings, and methods of manufacturing turbocharger turbine housings are provided.
- In an embodiment, by way of example only, an austenitic stainless steel alloy includes, by weight, about 22% to about 28% chromium, about 3.5% to about 6.5% nickel, about 1% to about 6% manganese, about 0.5% to about 2.5% silicon, about 0.3% to about 0.6% carbon, about 0.2% to about 0.5% nitrogen, and a balance of iron. Molybdenum, niobium, and tungsten are excluded.
- Niobium, in the presence of silicon can form niobium silicide which has a relatively low density, may affect thermal fatigue resistance and has low creep strength.
- In another embodiment, by way of example only, a turbocharger turbine housing includes an austenitic stainless steel alloy that includes, by weight, about 22% to about 28% chromium, about 3.5% to about 6.5% nickel, about 1% to about 6% manganese, about 0.5% to about 2.5% silicon, about 0.3% to about 0.6% carbon, about 0.2% to about 0.5% nitrogen, and a balance of iron. Molybdenum, niobium, and tungsten are excluded.
- In yet another embodiment, a method of fabricating a turbocharger turbine housing include forming the turbocharger turbine housing from an austenitic stainless steel alloy that includes, by weight, about 22% to about 28% chromium, about 3.5% to about 6.5% nickel, about 1% to about 6% manganese, about 0.5% to about 2.5% silicon, about 0.3% to about 0.6% carbon, about 0.2% to about 0.5% nitrogen, and a balance of iron. Molybdenum, niobium, and tungsten are excluded.
- This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
- The inventive subject matter will hereinafter be described in conjunction with the following drawing figures, wherein like numerals denote like elements, and wherein:
-
FIG. 1 is a system view of an embodiment of a turbocharged internal combustion engine in accordance with the present disclosure. - The following detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. As used herein, the word "exemplary" means "serving as an example, instance, or illustration." Thus, any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. Furthermore, as used herein, numerical ordinals such as "first," "second," "third," etc., such as first, second, and third components, simply denote different singles of a plurality unless specifically defined by language in the appended claims. All of the embodiments and implementations of the stainless steel alloys, turbocharger turbine housings, and methods for the manufacture thereof described herein are exemplary embodiments provided to enable persons skilled in the art to make or use the invention and not to limit the scope of the invention, which is defined by the claims. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary, or the following detailed description.
- The turbocharger turbine housing, usually a cast stainless steel or cast iron, is the most expensive component of the turbocharger. Reduction in cost of the housing will have a direct effect on the cost of the turbocharger. In order to withstand the high operating temperatures commonly produced by exhaust gasses impinging on the turbine housing, turbine housing materials are usually alloyed with elements such as chromium and nickel in addition to other carbide forming elements, which may reduce optimal properties, particularly for use in turbocharger turbines and turbocharger turbine housings.
- Typical embodiments of the present disclosure reside in a motor vehicle equipped with a gasoline powered internal combustion engine ("ICE") and a turbocharger. The turbocharger is equipped with a unique combination of features that may, in various embodiments, provide efficiency benefits by relatively limiting the amount of (and kinetic energy of) secondary flow in the turbine and/or compressor, as compared to a comparable unimproved system.
- With reference to
FIGS. 1-2 , an exemplary embodiment of aturbocharger 101 having a radial turbine and a radial compressor includes a turbocharger housing and a rotor configured to rotate within the turbocharger housing around an axis ofrotor rotation 103 during turbocharger operation on thrust bearings and two sets of journal bearings (one for each respective rotor wheel), or alternatively, other similarly supportive bearings. The turbocharger housing includes aturbine housing 105, acompressor housing 107, and a bearing housing 109 (i.e., a center housing that contains the bearings) that connects the turbine housing to the compressor housing. The rotor includes aradial turbine wheel 111 located substantially within theturbine housing 105, aradial compressor wheel 113 located substantially within thecompressor housing 107, and ashaft 115 extending along the axis ofrotor rotation 103, through thebearing housing 109, to connect theturbine wheel 111 to thecompressor wheel 113. - The turbine housing 105 and
turbine wheel 111 form a turbine configured to circumferentially receive a high-pressure and high-temperatureexhaust gas stream 121 from an engine, e.g., from anexhaust manifold 123 of aninternal combustion engine 125. The turbine wheel 111 (and thus the rotor) is driven in rotation around the axis ofrotor rotation 103 by the high-pressure and high-temperature exhaust gas stream, which becomes a lower-pressure and lower-temperatureexhaust gas stream 127 and is axially released into an exhaust system (not shown). - The compressor housing 107 and
compressor wheel 113 form a compressor stage. The compressor wheel, being driven in rotation by the exhaust-gas driventurbine wheel 111, is configured to compress axially received input air (e.g.,ambient air 131, or already-pressurized air from a previous-stage in a multi-stage compressor) into a pressurizedair stream 133 that is ejected circumferentially from the compressor. Due to the compression process, the pressurized air stream is characterized by an increased temperature over that of the input air. - Optionally, the pressurized air stream may be channeled through a convectively cooled
charge air cooler 135 configured to dissipate heat from the pressurized air stream, increasing its density. The resulting cooled and pressurizedoutput air stream 137 is channeled into anintake manifold 139 on the internal combustion engine, or alternatively, into a subsequent-stage, in-series compressor. The operation of the system is controlled by an ECU 151 (engine control unit) that connects to the remainder of the system viacommunication connections 153. - Turbochargers can be designed to operate at a variety of temperatures, depending on the configuration of the turbocharger and the desired output. As used herein, the term operating temperature refers to the maximum temperature of exhaust gas designed to be experienced by the turbine housing and blade components of the turbocharger. Stainless steel 1.4826, well-known in the art, with its specification for nickel between 8% and 12% is an exemplary prior art material for turbine housing applications up to about 980°C. The present invention includes a turbocharger comprising the turbocharger turbine housing of the claimed compositions that operates at a temperature of up to about 980°C.
- The presence of carbide forming elements such as niobium (Nb), tungsten (W) and molybdenum (Mo) can be disadvantageous, particularly in the proposed end use. Thus alloys with other materials but that retain the same beneficial properties are desirable. TABLE 1, set forth below, provides the specifications for stainless steel 1.4826.
Table 1: Composition of 1.4826 Stainless Steel 1.4826 Elements Min (%) Max (%) Carbon 0.3 0.50 Silicon 1 2.50 Chromium 18 23.0 Nickel 8 12.0 Molybdenum 0 0.50 Manganese 0 2.00 Niobium 1.3 1.70 Phosphorous 0 0.04 Sulphur 0 0.04 Nitrogen - - Iron Rest - As such, embodiments of the present disclosure are directed to improvements over the currently available stainless steel alloys for use in turbochargers having operating temperatures up to about 980°C. In particular, embodiments of the present disclosure are directed to stainless steel alloys that have a nickel content that is less than stainless steel 1.4826 for cost considerations, and eliminates the need for other expensive materials such as W and Mo. The stainless steel alloys described herein include iron alloyed with various alloying elements, as are described in greater detail below in weight percentages based on the total weight of the alloy.
- In an embodiment, the stainless steel alloy of the present disclosure includes from about 0.3% to about 0.6% carbon (C), for example about 0.4% to about 0.5% C. C has a function of improving the fluidity and castability of a melt. C also has a function of improving the castability by forming eutectic carbides. To exhibit such functions effectively, the amount of C should be 0.3% or more. Further, C is effective for strengthening a material by solid solution strengthening. C is an element capable of improving the high-temperature strength and the thermal fatigue resistance. To maximize the corrosion resistance, the content of C is lowered to 0.6% or about 0.6% and below. As can be seen C has several advantageous properties, particularly thermal fatigue resistance in turbocharger components, whilst materials such as tungsten, niobium and molybdenum can bind C and hence limit the availability of C for that benefit. Whilst tungsten, niobium and molybdenum may be beneficial in some instances and for the alloys of the present invention, particularly when used for turbocharger turbine and turbocharger housings, there is a preferential benefit from the availability of C, at least between 0.3 and 0.6% in and the absence of niobium and preferably also of tungsten and molybdenum.
- In an embodiment, the stainless steel alloy of the present disclosure includes from about 0.5% to about 2.5% silicon (Si), for example about 1.0% to about 2.0% Si. Si has effects of increasing the stability of its metal structure and its oxidation resistance. Further, it has a function as a deoxidizer and also is effective for improving castability and reducing pin holes in the resulting cast products, when present in an amount greater than about 0.5%. If the content of Si is excessive, Si deteriorates the mechanical property such as impact toughness of steel. Therefore, the content of Si is preferably limited to about 2.5% and below.
- In an embodiment, the stainless steel alloy of the present disclosure includes from about 22% to about 28% chromium (Cr), for example about 23% to about 27% Cr, such as from about 24% to about 26% Cr. On the other hand, if it is added excessively, coarse primary carbides of Cr are formed, resulting in extreme brittleness. When the content of Cr increases, the corrosion resistance increases, but the content of expensive Ni should be also increased to maintain the volume fraction. As such, the content of Cr is preferably limited to a maximum of about 28% so as to maintain the volume fraction of the stainless steel and the corrosion resistance.
- In an embodiment, the stainless steel alloy of the present disclosure includes from about 3.5% to about 6.5% nickel (Ni), for example about 4.0% to about 6.0% Ni, such as from about 4.5% to about 5.5% Ni. Ni, together with manganese and nitrogen (which as described in greater detail below are included in the alloy of the present disclosure), is an element to stabilize the austenite phase. To reduce a production cost, if the content of expensive Ni is lowered, the decrement of Ni can be replaced by increasing the content of manganese and nitrogen that form the austenite phase. However, if the content of Ni is excessively lowered, manganese and nitrogen would be excessively needed so that the corrosion resistance and the hot formability characteristics are deteriorated. Thus, the content of Ni preferably ranges from about 3.5% to about 6.5%.
- In an embodiment, the stainless steel alloy of the present disclosure preferably excludes (or at least substantially excludes) molybdenum (Mo), which is a relatively expensive material, to reduce technical costs and potential brittleness.
- In an embodiment, the stainless steel alloy of the present disclosure includes from about 1.0% to about 6.0% manganese (Mn), for example about 1.5% to about 5.5% Mn, such as from about 2.0% to about 5.0% Mn. Mn is effective like Si as a deoxidizer for the melt, and has a function of improving the fluidity during the casting operation. To exhibit such function effectively, the amount of Mn is about 6.0% or less, preferably 5.0% or less. Mn generally has a content of greater than about 1.0% to adjust a metal flow rate. However, when the content of Mn is excessive, Mn is combined with sulfur of the steel and forms excessive levels of manganese sulfide, thereby deteriorating the corrosion resistance and the hot formability. Thus, the upper limit content of Mn is limited to 6.0%.
- In an embodiment, the stainless steel alloy of the present disclosure preferably excludes (or at least substantially excludes) tungsten (W), which is a relatively expensive material, to further reduce costs and may bind with carbon to reduce its availability to adjust other alloy properties.
- In an embodiment, the stainless steel alloy of the present disclosure preferably excludes (or at least substantially excludes) niobium (Nb), which is a relatively expensive material, such as to reduce or avoid niobium silicide and or carbide formation.
- Nitrogen (N) is an element capable of improving the high-temperature strength and the thermal fatigue resistance like C, and such effects can be obtained when the amount of N is 0.2% or more. Accordingly, in an embodiment, the stainless steel alloy includes, in various alternative embodiments, from about 0.2% to about 0.5% N, for example from about 0.3% to about 0.5% N, from about 0.4% to about 0.5% N, from about 0.3% to about 0.4% N, from about 0.2% to about 0.4%, or from about 0.2% to about 0.3%. To ensure the production stability and to avoid the brittleness due to the precipitation of Cr nitrides, the upper limit of N should be about 0.5%. N, together with Ni, is one of elements that contribute stabilization of an austenite phase. As the content of N increases, the corrosion resistance and high strengthening are achieved. However, when the content of N is too high, the hot formability of steel is deteriorated, thereby lowering the production yield thereof. Therefore, the content of N preferably ranges up to a maximum of about 0.5%.
- Certain impurities may also be present in the stainless steel alloy of the present disclosure. The amounts of such impurities are minimized as much as practical. In an embodiment, phosphorus (P) may be present in the alloy, but is minimized to about 0.03% or less. P is seeded in the grain boundary or an interface, and is likely to deteriorate the corrosion resistance and toughness. Therefore, the content of P is lowered as low as possible. Preferably, the upper limit content of P is limited to 0.03% in consideration of the efficiency of a refining process. The contents of harmful impurities, such as P are as small as possible. However, due to cost concerns associated with removal of these impurities, and the P content is limited to 0.03%.
- In an embodiment, sulfur (S) may be present in the alloy, but is minimized to about 0.03% or less. S in steels deteriorates hot workability and can form sulfide inclusions that influence pitting corrosion resistance negatively. It should therefore be limited to less than 0.03%. S deteriorates the hot formability, or forms MnS together with Mn, thereby deteriorating the corrosion resistance. Therefore, the content of S is lowered as low as possible. The contents of harmful impurities, such as S (sulfur), are as small as possible. However, due to cost concerns associated with removal of these impurities, the S content is limited to about 0.03%.
- Boron (B), calcium (Ca), and cerium (Ce) can optionally be added in very small quantities in steels to improve hot workability. The preferred levels are for B, Ca, and Ce are less than about 0.005%. In the presence of boron, molybdenum borosilicides may be formed which may is brittle and may not be desirable.
- TABLE 2 sets forth the composition of an exemplary embodiment of the present disclosure, in accordance with the description provided above.
Table 2. Composition of Exemplary Stainless Steel Alloy Elements Min (%) Max (%) Carbon 0.4 0.5 Silicon 1.0 2.0 Chromium 24.0 26.0 Nickel 4.5 5.5 Molybdenum - - Manganese 2.0 5.0 Tungsten - - Niobium - - Phosphorous 0.03 Sulphur 0.03 Nitrogen 0.3 0.5 Boron 0.005 Iron Rest - As such, embodiments of the present disclosure provide numerous benefits over the prior art, such as stainless steel 1.4826. For example, in accordance with the present disclosure, the presently described embodiments lower the nickel content in as compared to stainless steel 1.4826. Further, the amount of molybdenum, niobium, and tungsten are reduced to zero. Thus, due to lower cost, alloys in accordance with the present disclosure are a suitable lower cost option for turbine housing materials for operation up to about 980°C.
- While at least one exemplary embodiment has been presented in the foregoing detailed description of the inventive subject matter, it should be appreciated that a vast number of variations exist. It should also be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration of the inventive subject matter in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing an exemplary embodiment of the inventive subject matter. It being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope of the inventive subject matter as set forth in the appended claims.
Claims (15)
- An austenitic stainless steel alloy, comprising, by weight:about 22% to about 28% chromium;about 3.5% to about 6.5% nickel;about 1% to about 6% manganese;about 0.5% to about 2.5% silicon;about 0.3% to about 0.6% carbon;about 0.2% to about 0.5% nitrogen; anda balance of iron, with the proviso that molybdenum, niobium, and tungsten are excluded from the alloy.
- The austenitic stainless steel alloy of claim 1 comprising about 23% to about 27% chromium.
- The austenitic stainless steel alloy of claim 1 comprising about 4.0% to about 6.0% nickel.
- The austenitic stainless steel alloy of claim 1 comprising about 1.5% to about 5.5% manganese.
- The austenitic stainless steel alloy of claim 1 comprising about 1.0% to about 2.0% silicon.
- The austenitic stainless steel alloy of claim 1 comprising about 0.4% to about 0.5% carbon.
- The austenitic stainless steel alloy of claim 1 comprising about 0.3% to about 0.5% nitrogen.
- An turbocharger turbine housing comprising:an austenitic stainless steel alloy, wherein the austenitic stainless steel alloy comprises, by weight:about 22% to about 28% chromium;about 3.5% to about 6.5% nickel;about 1% to about 6% manganese;about 0.5% to about 2.5% silicon;about 0.3% to about 0.6% carbon;about 0.2% to about 0.5% nitrogen; anda balance of iron, with the proviso that molybdenum, niobium, and tungsten are excluded from the alloy.
- The turbocharger turbine housing of claim 8 comprising about 23% to about 27% chromium.
- The turbocharger turbine housing of claim 8 comprising about 4.0% to about 6.0% nickel.
- The turbocharger turbine housing of claim 8 comprising about 1.5% to about 5.5% manganese.
- The turbocharger turbine housing of claim 8 comprising about 1.0% to about 2.0% silicon.
- The turbocharger turbine housing of claim 8 comprising about 0.4% to about 0.5% carbon.
- The turbocharger turbine housing of claim 8 comprising about 0.3% to about 0.5% nitrogen.
- A method of fabricating a turbocharger turbine housing, the method comprising the step of:forming the turbocharger turbine housing from an austenitic stainless steel alloy, wherein the austenitic stainless steel alloy comprises, by weight:about 22% to about 28% chromium;about 3.5% to about 6.5% nickel;about 1% to about 6% manganese;about 0.5% to about 2.5% silicon;about 0.3% to about 0.6% carbon;about 0.2% to about 0.5% nitrogen; anda balance of iron, with the proviso that molybdenum, niobium, and tungsten are excluded from the alloy optionallyfurther comprising forming a turbocharger turbine using the turbocharger turbine housing.
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EP3816315A1 (en) * | 2019-10-30 | 2021-05-05 | Garrett Transportation I Inc. | Stainless steel alloys, turbocharger components formed from the stainless steel alloys, and methods for manufacturing the same |
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DE102020128884A1 (en) | 2020-11-03 | 2022-05-05 | BMTS Technology GmbH & Co. KG | Austenitic steel alloy and turbine housing or turbine housing component for an exhaust gas turbocharger |
DE102020128883A1 (en) | 2020-11-03 | 2022-05-05 | BMTS Technology GmbH & Co. KG | Austenitic steel alloy and turbine housing or turbine housing component for an exhaust gas turbocharger |
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