EP4345183B1 - Hitzebeständiger austenitischer fe-cr-ni-al stahl mit hohem nickelgehalt - Google Patents

Hitzebeständiger austenitischer fe-cr-ni-al stahl mit hohem nickelgehalt Download PDF

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EP4345183B1
EP4345183B1 EP23200470.5A EP23200470A EP4345183B1 EP 4345183 B1 EP4345183 B1 EP 4345183B1 EP 23200470 A EP23200470 A EP 23200470A EP 4345183 B1 EP4345183 B1 EP 4345183B1
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EP4345183A1 (de
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Begona GOMEZ-FERRER HERRAN
Justine ALLO
Antoine FACCO
Meriem ABIKCHI
Manuel ROUSSEL
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Manoir Pitres SAS
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C19/00Alloys based on nickel or cobalt
    • C22C19/03Alloys based on nickel or cobalt based on nickel
    • C22C19/05Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/058Alloys based on nickel or cobalt based on nickel with chromium without Mo and W
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2211/00Microstructure comprising significant phases
    • C21D2211/001Austenite
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C19/00Alloys based on nickel or cobalt
    • C22C19/03Alloys based on nickel or cobalt based on nickel
    • C22C19/05Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/053Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 30% but less than 40%

Definitions

  • the present invention relates to the field of austenitic alloys requiring good mechanical and environmental resistance at high temperatures, in particular for use in reforming furnaces for the direct reduction of iron ore or more generally as a structural material for very high temperature applications such as in heat treatment furnaces. It relates in particular to a high nickel austenitic alloy, which has excellent resistance to corrosion and creep at service temperatures greater than or equal to 1100°C.
  • the document US5997809A provides an alloy resistant to carburization and oxidation at high temperatures, consisting essentially, in weight percentage, of about 27 to 35 chromium, about 0 to 7 iron, about 3 to 4.4 aluminum, about 0 to 0.14 titanium, about 0.2 to 3 niobium, about 0. 12 to 0.5 carbon, about 0 to 0.05 zirconium, about 0.002 to 0.05 total cerium and yttrium, about 0 to 1 manganese, about 0 to 1 silicon, about 0 to 0.5 calcium plus magnesium, about 0 to 0.1 boron and the balance nickel plus incidental impurities.
  • the present invention provides a solution for achieving the above-mentioned objectives.
  • the invention relates to a refractory austenitic "aluminoforming" alloy, with high chromium and nickel contents, which has excellent resistance to the environment and to creep, at temperatures greater than or equal to 1100°C, typically between 1100°C and 1185°C.
  • the invention relates to a refractory austenitic alloy, intended for use at a service temperature greater than or equal to 1100°C.
  • the present alloy can be used for furnaces of reforming, which are subjected to refractory brick temperatures typically between 1100°C and 1185°C.
  • the refractory austenitic alloy according to the invention is mainly composed of nickel (between 50.0% and 61.0%), chromium (between 25.0% and 32.0%), iron (between 4.0% and 18.0%) and aluminum (between 1.0% and 6.0%).
  • chromium is required to ensure good corrosion resistance (oxidation) and to allow the formation of chromium carbides, which have a positive impact on the creep resistance of the alloy.
  • the maximum mass percentage of chromium is limited to 32.0%, in particular to limit the excessive integration of alphagenic elements tending to destabilize the austenitic structure. of the alloy.
  • the Cr content is defined between 26.0% and 31.0%, to further promote the protection of the alloy from the environment and its creep resistance.
  • the minimum nickel content is set at 50.0% to maintain a refractory alloy with an austenitic structure, as the alloy contains at least 25.0% chromium and other alphagenic elements that tend to destabilize the austenitic structure in favor of a ferritic structure.
  • the amount of nickel is limited to 61.0%, or even limited to 57.0%, or even 55.0% for economic reasons, as nickel is a major cost contributor.
  • the iron mass percentage balances the alloy components, so that the sum of the mass percentages of said components reaches 100%.
  • a content between 4.0% and 18.0% makes the balance on the other components more advantageous.
  • an iron content greater than or equal to 13.0% is desirable in order to reduce the costs of the grade.
  • Aluminum is present in the alloy at a medium to high content, between 1.0% and 6.0%. Such a content allows the formation of a continuous layer of aluminum oxide (alumina) on the surface of the alloy, in a wide range of oxygen partial pressure (from less than 5 particles per million to high partial pressures such as in air), and a wide range of temperatures (typically, temperatures above 1000°C). The surface layer of aluminum oxide then forms a very resistant and effective barrier to corrosion (oxidation, carburization, nitriding) of the alloy, at high temperatures, typically 1100°C and above.
  • alumina aluminum oxide
  • the surface layer of aluminum oxide then forms a very resistant and effective barrier to corrosion (oxidation, carburization, nitriding) of the alloy, at high temperatures, typically 1100°C and above.
  • the mass percentage of aluminum is greater than or equal to 2.0%, or even greater than or equal to 2.5%.
  • a higher aluminum content ensures the formation of an aluminum oxide layer in a wider range of environmental conditions. It also allows access to a larger aluminum "reservoir" and thus to preserve the properties of the alloy over longer periods, in very harsh environments where the aluminum oxide layers are consumed.
  • B2 according to Strukturbericht notation describes a phase comprising two types of atoms (here, Ni and Al) in equal proportion and whose crystallographic structure is "interpenetrated primitive cubic", that is to say that each of the two types of atom forms a simple body-centered cubic lattice, with an atom of one type at the center of each cube of the other type.
  • Carbon must be present in the alloy for its hardening effect, by precipitation and by solid solution.
  • the range of carbon mass percentage is defined between 0.05% and 0.60%.
  • a percentage greater than or equal to 0.16%, or even 0.25%, or even 0.35% allows the formation of a significant volume fraction of carbides and improves the castability of the alloy.
  • the niobium content of the alloy is defined between 0.15% and 1.50% to fix the carbon in the form of carbonitrides rich in niobium and/or titanium.
  • niobium in combination with titanium, prevents the formation of the G phase, a phase rich in silicon, which is unfavorable to creep properties.
  • the niobium content is greater than or equal to 0.2%, 0.4%, 0.5%, 0.8%, or even 1%; and the niobium content is less than or equal to 1.4%, 1.3%, or even 1.2%.
  • a reactive element within the meaning of the present invention is defined as one of the rare earths or hafnium.
  • the addition of at least one reactive element is beneficial to the growth, adhesion and protective character of the alumina layer. This or these element(s) promote the fragmentation of the chromium carbide network and yet have a beneficial effect with respect to creep resistance.
  • a total content (sum of the contents of all the reactive elements introduced) greater than 0.060% does not provide any additional effect while it implies a strong impact on the cost and on the eco-responsible character of the material.
  • a minimum total content of 0.010% is required to obtain the aforementioned benefits.
  • the total mass percentage of reactive elements is chosen to be greater than or equal to 0.020%.
  • the alloy also contains silicon to improve castability and increase corrosion resistance.
  • the amount of this element is nevertheless limited to 0.30%, or even 0.25%, in order to avoid the presence of G and ⁇ phases (intermetallic phase comprising Fe, Cr, Ni and Si), which are detrimental to creep.
  • the Si content is between 0.01% and 0.20%, or even between 0.05% and 0.20%.
  • Manganese is also present in the alloy, to improve weldability and for its beneficial effect in oxidation because it acts as a trap for sulfur. It also has a beneficial effect on creep because it increases the solubility of nitrogen in austenite and promotes the stability of the austenitic structure. However, its content is limited to 0.30% to limit the formation of the B2-NiAl intermetallic phase, which negatively impacts creep resistance.
  • the content in manganese is between 0.05% and 0.25%, or even between 0.05% and 0.20%, or even between 0.01% and 0.20%.
  • the alloy contains vanadium, up to a mass percentage of 1.0%.
  • This compound is known to improve the creep properties of austenitic stainless steels by its impact on the precipitation of chromium carbides, increasing their volume fraction.
  • Vanadium also aids in the precipitation of carbonitrides rich in niobium, titanium and/or vanadium, during aging, and it also has a solid solution hardening effect. Its content must be limited to 1.0% to maintain its beneficial effects and avoid degradation of the oxidation behavior of the grade.
  • the vanadium content is between 0.005% and 0.5%; it can optionally be greater than or equal to 0.010%, or even greater than or equal to 0.1%.
  • Titanium promotes the formation of fine intragranular carbonitrides and their subsequent evolution during aging (favorable to creep resistance). It can be included in the alloy in a mass percentage of up to 0.40%. Advantageously, the mass percentage of titanium is greater than 0.05%.
  • the alloy also contains nitrogen which, due to its gammagenic character (stabilizes the austenitic structure), improves creep properties. Its presence in the alloy also contributes to the formation of carbonitrides rich in niobium, titanium and/or vanadium which reinforce creep properties. Its content is limited to 0.20% to avoid the formation of phases unfavorable to creep and oxidation properties.
  • the mass percentage of nitrogen is greater than or equal to 0.015%, preferably greater than or equal to 0.040%, 0.045%, 0.048%, 0.060%, even more preferably greater than or equal to 0.10%, or even more preferably greater than or equal to 0.12%.
  • Sulfur is an undesirable element in the alloy, but can be found in trace form (impurity) in the grade. It is desirable to limit the presence of this element in order to degrade the protective character of the alumina layer as little as possible. Sulfur can therefore be present in the alloy but at contents strictly lower than 0.0060% (i.e. ⁇ 60 ppm).
  • the sulfur content is lower than 0.0050% ( ⁇ 50 ppm), or even lower than 0.0020% ( ⁇ 20 ppm), preferably lower than 0.00050% ( ⁇ 5 ppm).
  • the alloy may possibly be polluted by other trace impurities whose content is in the order of one part per million (ppm), and strictly less than 200 ppm, such as phosphorus, lead, tin, boron, magnesium or arsenic.
  • trace impurities whose content is in the order of one part per million (ppm), and strictly less than 200 ppm, such as phosphorus, lead, tin, boron, magnesium or arsenic.
  • composition of the alloy can be measured by spark spectrometry.
  • the table of the Figure 1 presents the composition of the austenitic alloy in accordance with the present invention.
  • the austenitic alloy according to the invention further complies with two criteria linking the mass percentages (x Cr , x Al , x C , x Si , x Mn , x Ti , x Nb , x N , x V , x S , x Ni ) of all or part of the compounds of said alloy.
  • the first criterion is an oxidation criterion, determined empirically. It links the chromium, aluminum, and sulfur contents of the alloy. The equation is built around acceptable values for these three compounds (26% for Cr, 2% for Al, and 30 ppm for sulfur). This equation gives a different weight to each element depending on the impact of its content on high-temperature oxidation resistance. For simplicity, the criterion has been standardized and must be greater than 1 to ensure good oxidation behavior.
  • the second criterion concerns the solvus temperature of a certain type of carbides, namely M 23 C 6 carbides.
  • M 23 C 6 carbides A relationship has been established between the mass percentages of certain elements which are linked to the solvus temperature of M 23 C 6 carbides. This temperature must be high (i.e. greater than or equal to 1070°C) to promote the secondary precipitation of Cr carbides. (M 23 C 6 ) at operating temperatures and to ensure optimum mechanical performance (creep resistance).
  • the second criterion is defined by: -17.64 + 19.61 x Al - 1.29 x Al 2 - 101.46 x N + 450.65 x N 2 - 5.8368 x N 3 + 9.68 x V + 43.12 x Ti + 30.02 x Si + 11.42 x Ni - 0.18 x Ni 2 + 35.05 x Nb + 47.92 x Cr - 0.34 x Cr 2 + 13.97 x Mn - 239.66 x C > 1070° C.
  • the service temperature is the temperature to which the alloy is intended to be subjected, during its use: for example, for an alloy forming a reformer tube in a direct iron ore reduction installation, the service temperature could be between 1050°C and 1175°C.
  • the applicant was able to determine that, in an austenitic alloy with a high nickel content, the creep resistance, at the service temperature, can achieve exceptional performance when it has not only a microstructure "favorable" for creep resistance but also very good resistance to oxidation at said temperature, hence the definition of the two criteria previously stated.
  • This synergistic effect is particularly true for the very high service temperatures targeted and represents the heart of this invention.
  • a microstructure optimized for the Creep resistance is a necessary but not sufficient condition for high creep resistance at very high temperatures (>1100°C), it turns out that the ability of the grade to self-protect from the environment plays a crucial role and is also necessary (criterion 1).
  • a “favorable" microstructure in this case means that, at the service temperature, the chemical composition of the alloy must be such that the solvus temperature of the M 23 C 6 carbides is equal to or greater than 1070°C, to favor the secondary precipitation of said carbides from the M 7 C 3 carbides present in the as-cast alloy.
  • the said maximum temperature of the stability domain can be seen as the limiting temperature below which there is a transformation in the alloy of the M 7 C 3 carbides (present in the alloy in the as-cast state) into M 23 C 6 carbides; this transformation leads to a secondary precipitation of desired chromium carbides, which improves the creep performance of the alloy. Such a transformation takes place over a temperature range corresponding to the stability domain of the M 23 C 6 phase.
  • the maximum temperature T max M 23 C 6 must be greater than or equal to 1070°C in order to favor secondary precipitation in the alloy subjected to the service temperature, during its use. This condition corresponds to the second criterion.
  • the maximum temperature T max M 23 C 6 can be defined as greater than or equal to 1100°C, or even greater than or equal to 1150°C.
  • Validation of the second criterion, linked to the maximum temperature of the stability domain of secondary carbides M 23 C 6, is however not sufficient to guarantee optimal creep performance at the service temperature.
  • f oxy is an oxidation function and x Cr , x Al and x S are the mass percentages of Cr, Al and S respectively in the alloy.
  • the oxidation function f oxy must be greater than 1 in order to guarantee good oxidation behavior of the alloy subjected to the service temperature, and to optimize, in a synergistic manner, the creep resistance of the alloy during its use.
  • the condition f oxy ⁇ 1 corresponds to the first criterion according to the present invention.
  • Performance tests focus on the resistance of alloys to accelerated aging, cyclic oxidation, and their creep resistance.
  • the table of the Figure 2 presents different alloys which have been studied by the applicant.
  • Alloys 1 to 4 are in accordance with the present invention.
  • Alloys 5 to 9 are counter-examples which do not satisfy all of the characteristics of the present invention.
  • FIG. 3 shows optical microscopy cross-sectional images of alloys 1 to 8 after they have undergone accelerated aging heat treatment at 1150°C for 125 h.
  • the scale on these images is 50 ⁇ m.
  • a dendritic structure with a network of chromium carbides of type M 7 C 3 and/or M 23 C 6 is observed located at the inter-dendritic spaces as well as at the surface of the samples. Note that the surface was protected with a copper deposit in the cases of alloys 1, 2 and 6, this deposit has a clear contrast on the optical microscopy images and it is observable in the form of spaced islands at the surface.
  • the chromium-rich carbide network is fully present up to the surface of the samples of alloys 1, 2, 3, 4 and 7. In contrast, a free layer of chromium carbides is observed near the surface of alloys 5 and 8, as well as an internal oxidation layer. In the case of alloy 6, the width of the decarburized layer is such that, in the image, the chromium carbide network is not observed; on the other hand, a significant internal oxidation layer is observed.
  • the large black contrast objects formed inside the sample of alloys 5, 6 and 8 are aluminum nitrides.
  • alloy 1 has formed a protective alumina layer on the surface.
  • the aluminum signal obtained by EDS shows a peak at the surface (see figure 4 (c) ) and the chrome profile ( figure 4 (d) ) shows a monotonous nominal concentration with peaks corresponding to the presence of chromium carbides.
  • FIG. 5a shows the mass evolution of alloys 2 and 5, during cyclic oxidation.
  • the graph shows the number of cycles on the abscissa, one cycle corresponding to the sequence: 45 min at 1150°C and 15 min at room temperature.
  • the Figures 5b presents cross-sectional images of these same alloys, having undergone 20 oxidation cycles in the case of alloy 2 ( Figure 5b (a) And (c)) and 10 cycles in the case of alloy 5 ( Figure 5b (b) And (d) ), at two different magnifications.
  • T being the test temperature expressed in kelvin
  • t R the time to rupture expressed in hours
  • C a constant characteristic of the alloy
  • Figure 6a groups together the results of creep tests on alloys 1 to 9.
  • the graph shows the applied stress on the ordinate and the Larson-Miller parameter on the abscissa.
  • high LMP test conditions correspond to low stresses and high temperatures
  • low LMP conditions correspond to high stresses and lower temperatures.
  • a superior performance (especially at high LMP) of alloys 1 to 4, in accordance with the invention, can be observed compared to alloys 5 to 9.
  • FIG. 6b shows in detail the results of creep tests carried out at 9MPa and temperatures of 1150°C and 1175°C on alloys 1 to 8. Alloys 1 to 4 reach an LMP value greater than 33.32, a relevant performance threshold for such a refractory austenitic alloy.

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Claims (8)

  1. Feuerbeständige austenitische Legierung, die dafür bestimmt ist, bei einer Betriebstemperatur von höher als oder gleich 1100 °C verwendet zu werden, umfassend sämtliche von folgenden Verbindungen als Massenanteil:
    - Chrom zwischen 25,0 % und 32,0 %,
    - Nickel zwischen 50,0 % und 61,0 %,
    - Aluminium zwischen 1,0 % und 6,0 %,
    - Niob zwischen 0,15 % und 1,50 %,
    - Kohlenstoff zwischen 0,05 und 0,60 %,
    - ein oder mehrere reaktive(s) Element(e) mit einem Gesamtgehalt zwischen 0,010 % und 0,060 %, wobei ein reaktives Element als eines unter den Seltenen Erden oder Hafnium definiert ist,
    - Silizium mit 0,30 % oder weniger,
    - Mangan mit 0,30 % oder weniger,
    - Titan mit 0,40 % oder weniger,
    - Stickstoff zwischen 0,015 % und 0,20 %,
    - Vanadium zwischen 0,005 % und 1,0 %,
    - Eisen zwischen 4,0 % und 18,0 % zum Ausgleichen der Legierungsverbindungen;
    wobei Zirkonium, Wolfram und Schwefel in der Legierung fehlen oder in Form von Verunreinigungen in Mengen von weniger als 0,030 %, weniger als 0,010 % beziehungsweise weniger als 0,0060 %, vorliegen,
    wobei die Legierung ferner zwei Kriterien erfüllt, die die Massenanteile (xCr, xAl, xC, xSi, xMn, xTi, xNb, xN, xV, xS, xNi) aller oder eines Teils der Verbindungen der Legierung verbindet:
    - ein erstes Kriterium, definiert durch: 1 K Al K S × 2 e 26 x Cr 0 , 26 + 1 + K Al × 2 e 2 x Al 0 , 4 + 1 + K S × 2 e x S 0 , 003 0 , 1 × x S + 1 1
    Figure imgb0011
    mit K Al = 0 , 1728 + 0 , 1293 × ln x Al und K S = 0 , 3089 × e 64 × s ;
    Figure imgb0012
    - und ein zweites Kriterium, definiert durch: - 17,64 + 19,61xAl - 1,29xAı 2- 101,46xN + 450,65xN 2 - 5,8368xN 3 + 9,68xV + 43,12xTi + 30,02xSi + 11,42xNi - 0,18xNi 2 + 35,05xNb + 47,92xCr - 0,34xCr 2 + 13,97xMn - 239,66xC ≥ 1070.
  2. Feuerbeständige austenitische Legierung nach dem vorstehenden Anspruch, wobei der Massenanteil von Vanadium größer als oder gleich 0,010 %, noch bevorzugter größer als oder gleich 0,10 %, ist.
  3. Feuerbeständige austenitische Legierung nach einem der vorstehenden Ansprüche, wobei der Massenanteil von Aluminium größer als oder gleich 2,0 %, bevorzugter größer als oder gleich 2,50 %, ist.
  4. Feuerbeständige austenitische Legierung nach einem der vorstehenden Ansprüche, wobei der Massenanteil von Schwefel kleiner als 0,0050 %, vorzugsweise kleiner als 0,0020 % oder noch bevorzugter kleiner als 0,00050 %, ist.
  5. Feuerbeständige austenitische Legierung nach einem der vorstehenden Ansprüche, wobei der Massenanteil von Stickstoff größer als oder gleich 0,060 %, noch bevorzugter größer als oder gleich 0,10 % oder sogar noch bevorzugter größer als oder gleich 0,12 %, ist.
  6. Feuerbeständige austenitische Legierung nach einem der vorstehenden Ansprüche, wobei der Massenanteil von Chrom zwischen 26 % und 31 % liegt.
  7. Feuerbeständige austenitische Legierung nach einem der vorstehenden Ansprüche, wobei der Massenanteil von Kohlenstoff größer als oder gleich 0,16 %, vorzugsweise größer als 0,25 % oder noch bevorzugter größer als 0,35 %, ist.
  8. Feuerbeständige austenitische Legierung nach einem der vorstehenden Ansprüche, wobei der Gesamtmassenanteil reaktiver Elemente größer als oder gleich 0,020 % ist.
EP23200470.5A 2022-09-30 2023-09-28 Hitzebeständiger austenitischer fe-cr-ni-al stahl mit hohem nickelgehalt Active EP4345183B1 (de)

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Publication number Priority date Publication date Assignee Title
FR2333870A1 (fr) 1975-12-02 1977-07-01 Pompey Acieries Alliage refractaire a base de nickel et de chrome possedant une resistance elevee a l'oxydation, a la carburation et au fluage a tres haute temperature
GB2017148B (en) 1978-03-22 1983-01-12 Pompey Acieries Nickel chromium iron alloys possessing very high resistantance to carburization at very high temperature
US5997809A (en) * 1998-12-08 1999-12-07 Inco Alloys International, Inc. Alloys for high temperature service in aggressive environments

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