JPS5819458A - Homogeneous ductile hard facing foil - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to hard facing metal parts.
cing) - relates to a homogeneous ductile material used especially for hardfacing.

Hardfacing is a method of depositing a wear- and corrosion-resistant layer by melting a suitable alloy in situ. Only the surface of the base metal to be hard faced is made to have a melting point, and the bar, wire or powder for hard facing is melted and applied to the surface of the base metal.

Hardfacing is a quick and economical method used to repair or reinforce worn parts, thereby reducing overall operating and downtime costs. Using this method, composite parts can be made that combine strength, toughness, and corrosion resistance at low cost. Suitable wear-resistant coverings and corrosion-resistant surface layers can be applied to components such as dies and tooling made of relatively inexpensive high-impact alloys (eg, plain carbon steel or low-alloy steel). Additionally, hardfacing is employed in structures that use a flexible core material to overcome stress and a hard casing to resist wear. Examples of structures of this type include injection screws and extrusion screws used in plastic processing and the like. Many parts that would otherwise be discarded are used again at less than cost.

It is understood that further savings can be made as the part can be remanufactured on site if necessary.

Common hardfacing methods include oxyacetylene method,
Tungsten inert gas welding (TIG), metal inert gas welding (MIG), immersion electric arc welding.

This includes plasma transfer electric arc welding. The hardfacing alloys used in these methods are substantially dense (
Contains about 1 to 11*amounts of metalloid elements such as boron, silicon or carbon.

As a result, these alloys are extremely brittle and can only be obtained in the form of rods or powders.

One of the most difficult problems with common hardfacing methods and materials is the difficulty in controlling the thickness and uniformity of one surface layer.

The tough rod-like structures used to extrude hardfacing material into the heating zone cannot be economically advantageously applied to continuous surface treatment methods. Hardfacing bars are typically applied manually using tungsten inert gas or oxyacetylene methods. These are discontinuous and inherently slow. Continuous hardfacing can be done using automatic tungsten dead ratio gas machines, where individual bars are fed by gravity, or plasma-transfer electric arc (PTA) machines, where the hardfacing material in powder form is fed into the heating zone.
) Achieved by welding method. Such methods require relatively expensive equipment and materials. Sara%CP
The excessive heat generated by the plasma in the TA welding process has an adverse effect on the fluidity of the hard facing master key,
Diluting the alloy with material from the base metal changes the compositional homogeneity of one surface layer. Therefore, there remains a need in the art for an economical continuous hardfacing method.

Ductile glassy alloys are disclosed in U.S. Pat. No. 3,856,516 (December 24, 1974 to H.S. Cheno et al.)
It is shown in the specification. These alloys have the formula M a Y
Included are compositions with J Z c. In the formula, M is a metal selected from the group consisting of iron, nickel, cobalt, vanadium and chromium, and Y is phosphorus.

2 is an element selected from the group consisting of boron and carbon, 2 is an element selected from the group consisting of aluminum, silicon, tin, dallmanium, indium, antimony and beryllium, and ``a'' is approximately 60 "C" ranges from about 10 to 30 atoms, and "C" ranges from about 0.1 to 15 atoms. Also shown is a glassy wire with the formula TiXj. In the formula, T is at least one transition metal, and X is phosphorus, boron, carbon, aluminum, silicon, tin, or germanium.

It is an element selected from the group consisting of indium, beryllium, and antimony, and has a range of about 70 to 87 atoms. Such materials are manufactured today using processing methods well known in the art. It is conveniently prepared by rapid cooling from a melt.Ultra hardfacing compositions are not shown here.

There remains a need in the industry for homogeneous hardfacing materials available in thin ductile filaments.

In accordance with the present invention, homogeneous ductile hard facing filaments useful as filler metal for hard faced metal articles are provided. The hard facing filament is made of a metastable material with at least 50% glassy structure and has a thickness of 0.004 mm ('10.
16 x 1σ3crIL] It is not very large, especially o
,ooos~0.04 inch (127 x 163~10.
16x1σ3m). It has been found that by using flexible thin homogeneous hardfacing filaments as described above, the hardfacing speed can be increased and the hardness of the deposited surface layer can be improved.

More specifically, the hard facing filament has a thickness of approximately 0.0005 to 0.004 inches (1,27 x 1
1j3~10.16×1σ3crrL). The filament of the present invention is generally expressed in the broadest concept as being of first order. Namely.

Used as the surface layer of hard-facing metal parts, it has a small amount of chromium (both have 50% glassy grooves fNk, and woody constituents of F: 60 atoms and 11'F chromium
Tungsten below 16 atoms.

Molybdenum below 5 atom%μ, boron at 2 to 25 atoms,
A small amount selected from the group consisting of silicon at 15 atomic percent 1M and carbon at 5 atomic percent Small (both one element and accompanying impurities, however, the total of iron, cobalt, nickel, chromium, tungsten, oyohimmolybdenum is in the range of 7U to 88 atoms, and hor') element, silicon and The total of carbon is 1
A homogeneous ductile hexa-dofacing foil consisting of a metastable material having a composition in the range of 2 to 60 atoms. Preferably, the filament consists essentially of 1 to about 25 atoms of cobalt and about 30 atoms of nickel.

From 0 to about 60% chromium, from 0 to about 5 tungsten, from 0 to about 4 molybdenum, from about 2 to about 25 boron, from 0 to about 15 silicon, and from U to about 5 carbon The remainder is iron and incidental impurities, with the sum of iron, cobalt, nickel, chromium, tungsten, and molybdenum ranging from about 70 to 88 atoms, and the sum of boron, silicon, and carbon being about 12
~60 atoms.

Another preferred hard facing filament composition is 1
Essentially 0 to about 25 atoms of cobalt, 0 to about 20 atoms of iron, 0 to about 15 atoms of chromium, and 0 to about 16 atoms of tungsten.
Molybdenum: 0 to about 5 atoms, Boron: about 2 to about 2
0 to about 10 atoms of silicon, and 0 to about 5 atoms of carbon, with the remainder being nickel and accompanying impurities; however, the total of iron, cobalt, nickel, chromium, tungsten, and molybdenum is about 70 ~88 atoms, with the total boron, silicon and carbon ranging from about 12 to 30 atoms.

Yet another preferred hard facing filament composition is 1 essentially 0 to about 62 atoms, 0 to about 1 iron.
0 atoms, chromium 0~30 atoms, tungsten 0~
About 2 atoms, molybdenum O ~ about 4 atoms, boron about 2 ~
About 25 atoms, silicon O ~ about 15 atoms, manganese 0 ~
The remainder is essentially cobalt and incidental impurities, with the total of iron, cobalt, nitrogen, chromium, tungsten, and molybdenum being approximately 7 U to 88 atoms. and the sum of boron, silicon and carbon ranges from about 12 to 30 atoms.

The homogeneous hard facing filaments of the present invention are produced by preparing a melt of the composition described above and quenching the melt on a rotating quench wheel at a rate of at least about 10°C/sec.

This interfill filament can be easily processed into a homogeneous ductile ribbon useful for hardfacing. Furthermore, the homogeneous ductile hard facing filaments of the present invention allow for reduced deposit thicknesses, resulting in less dilution from the substrate (and less expense in grinding the deposited layer).

The present invention will be more fully understood, and other advantages will become apparent, from the following detailed description of the preferred embodiments thereof.

The present invention provides a homogeneous ductile hardfacing material in foil form. This hard facing base has a thickness of 0.
004 inches (10,16X10 cIrL) or less, preferably about 0.004 to 0.002 inches (10,16x10 to 5.08x10 cIIL)
i and 1 essentially have the following composition.

1. Cobalt 0 to about 25 atoms, nickel 0 to about 30 atoms, chromium O to about 60 atoms qb, tungsten 0 to about 5 atoms, molybdenum U to about 4 atoms, boron about 2 to about 25 atoms , about 0° to about 15 atoms of silicon and 0 of carbon
~About 5 atoms. The remainder is iron and impurities to be removed;
However, the total of iron/cobalt, nickel, chromium, tungsten and molybdenum is in the range of about 70 to 88 atoms, and the total of boron, silicon and carbon is in the range of about 12 to 30
It is in the range of atomic chi.

2.0 to about 25 atoms of cobalt, 0 to about 20 atoms of iron,
Chromium: 0 to about 15 atoms, tungsten: 0 to about 16 atoms, molybdenum: 0 to about 5 atoms.

About 2 to about 20 atoms of boron, 0 to about 10 atoms of silicon, and 0 to about 5 atoms of carbon. The remaining 1-2 nickels are impurities to be removed, except for iron.

The sum of cobalt, di-nokel, chromium, tungsten and molybdenum ranges from about 70 to 88 atoms, and the sum of boron, silicon and carbon ranges from about 12 to 60 atoms.

6. Nickel 0 to about 62 atoms, iron 0 to about 10 atoms,
Chromium: 0 to about 30 atoms, tungsten: 0 to about 2 atoms, molybdenum: 0 to about 4 atoms.

About 2 to about 25 atoms qb of boron, about 15 qb of silicon O, 0 to about 2 qb of manganese, and 0 to about 5 qb of carbon, the remainder being cobalt and impurities to be removed, with the exception of iron,
cobalt, nickel.

The total of chromium, tungsten and molybdenum is approximately 70
~88 atoms, boron.

The total silicon and carbon ranges from about 12 to 60 atoms.

These compositions are suitable for doffing low carbon and low alloy steels with relatively high wear and corrosion resistance.

Homogeneous means that the produced foil has a substantially uniform composition in all directions; ductile means that the foil is produced without breaking to a radius of a circle 10 times the thickness of the foil. This means that it can be bent.

Examples of hard facing alloy compositions within the scope of the present invention are shown in Tables 1a, 1+ and lc below.

Wlo and wt%
means weight %.

The hardfacing foils of the present invention are capable of melting a melt of a desired composition at a rate of at least about 0° C./sec using alloy quenching techniques well known in the glass-like metal alloy art (e.g., U.S. Pat. No. 5,856,515 and U.S. Pat. No. 4.148,973 (see each specification).

Various techniques are used to process ribbons, wires, sheets, etc., with the purity of all compositions being that found in common commercial practice. As a representative example.

Select a specific composition and make 1 kill of powder or granules of the required elements in the desired proportions! The molten alloy is quenched to a homogeneous ratio on a cooling surface, such as a rapidly rotating metal cylinder.

Under this quenching condition, a metastable homogeneous ductile material is obtained. The metastable material may be glassy, in which case there is no extensive alignment. The X-ray diffraction diagram of the glassy alloy shows only diffuse halos similar to those of inorganic acid [arsenite glasses]. Glassy alloys of this type must be at least 50% glassy in order to be sufficiently ductile that they can be subsequently handled (for example, stamping intricate cedar shapes from alloy ribbons). To obtain excellent ductility.

The glassy alloy should preferably be at least 80% glassy, most preferably substantially (or entirely) glassy.

The metastable phase may be a solid solution of the constituent elements.

1 In the case of the alloys of the present invention, metastable solid solution phases of this type are not normally produced by conventional processing techniques used in the art of crystalline alloy processing. The X-ray diffraction diagram of the solid solution alloy shows sharp diffraction peaks typical of crystalline alloys, with some broadening of the peaks due to the desired fine-grained crystallites. This twisted metastable material is also ductile when produced under the conditions described above.

In accordance with the present invention, knot facing of the gold-based material is readily accomplished by feeding a continuous filament from a spool or other similar coiled source to the heating zone. The filaments thus provided are homogeneous and ductile and have a composition consisting essentially of at least 51 metastable materials with a glassy structure. "1. Cobalt 0 to about 25 atoms, nickel 0 to about 25 atoms
About 30 atoms, chromium 0 to about 60 atoms, tungsten O to about 5 atoms, molybdenum 0 to about 4 atoms, boron about 2 to about 25 atoms, silicon O to about 15 atoms, and carbon 0 to about 30 atoms. About 5 atoms. The remainder is iron and accompanying impurities, except iron.

:7 HaA/), the total of nickel, chromium, tungsten and molybdenum is in the range of about 7 U to 88 atomic units,
Sum of boron, silicon and carbon.

ranges from about 12 to 60 atoms.

2. Cobalt 0 to about 25 atoms, iron O to about 20 atoms,
Chromium U to about 15 atoms, tungsten 0 to about 16 atoms, molybdenum 0 to about 5 atoms.

Boron from about 2 to about 20 atoms, silicon O to about 10 atoms,
and carbon O to about 5 atoms. The remainder is nickel and associated strained substances, but the total of iron/cobalt, nickel, chromium, tungsten and molybdenum is approximately 70~
The total number of boron, silicon and carbon ranges from about 12 to 60 atoms.

6. Nickel 0 to about 32 atoms, iron 0 to about 10 atoms,
Chromium O to about 60 atoms, tungsten 0 to about 2 atoms, molybdenum 0 to about 4 atoms.

Boron about 2 to about 25 atoms, silicon 0 to about 15 atoms,
O to about 2 atoms of manganese and 0 to about 5 atoms of carbon. The remainder is cobalt and associated impurities, with the exception of iron,
cobalt, nickel.

The total of chromium, tungsten and molybdenum is approximately 70
-Boron in the range of -88 atoms.

The total silicon and carbon ranges from about 12 to 60 atoms.

Heat is applied to the filament in the zero-end thermal zone to melt the filament and deposit it onto the workpiece surface in close proximity to it. The workpiece surface is then allowed to cool, and the deposited filaments form a hard, adherent film on this surface.

In order to more fully understand the present invention, examples below are presented. The specific method conditions, material proportions and reported data presented to exemplify the principles and practice of the invention are exemplary and should not be construed as limiting the scope of the invention.

Example 1 Mel of specific composition (j) is ejected under heavy pressure of argon onto a rapidly rotating copper cooling wheel (surface velocity 3000-6000 ft/G, or 914.4-1828.8 m/min). By that.

Approximately 2.5 to 25.4 m (approximately 0.10 to 1.00 inch) wide and approximately 1'5 to 60 μm (approximately 0.0005 to 0.0
．． A ribbon of 0.0025 inches was prepared. The composition below (
A metastable, homogeneous ribbon of a substantially glassy alloy was obtained with a weight ratio of 1.5% and atomic%.

The compositions of the ribbons are shown in Tables na, n+ and 1c below.

6.35 by the following procedure using ribbons of various alloy compositions.
x 10 art) range IC. A ribbon
l5I 304 stainless steel sheet (thickness approx. +1 0.0625yt- [1,59x 10 crti]
) K opposite.

This composite material was individually processed in a vacuum furnace at 190°C depending on each alloy.
Heated to a temperature of U~2300'F (1038-1260C) for about 15 minutes. The samples were then removed from the furnace, cut, mounted, and hard faced and polished for microhardness measurements.

The composition and Knoop hardness load of each ribbon alloy tested was 100? , pressing time 15 seconds) are shown in Table 1a.

Shown in Ichiban and We.

2 FessNilgCr, oB, 6MosCol,
1835 Fe55Nt16CrB B1
6Mo4C false 6 4494 Fe5e-oN
ih,acrn-J3s4Sis-ecoa-s”4.
r 197Table 1K2 N1aaCr7Si21%6Fe3
175”) N15aCrs*B+yFe4Col
1Mo5 3979 N15t4Cru-a
sie-aBi4. tFlb, aaQ<s 14
54 CCbs-tF&-saw-ssissM)4
2405 CCka-+C1m, 5Ni
t, sF#-aBu-tsi+J40s-aVW-oQ
-s86 Although the present invention has been explained in more detail above, it is not necessary to strictly adhere to these detailed explanations. It will be appreciated that various changes and modifications may occur to those skilled in the art, all of which fall within the scope of the invention as defined in the claims.

Patent applicant Allied Corporation (2 others) Continued from page 1 Priority claim @July 22, 1981■United States (US)■
285883 ■July 22, 1981■United States (tJs)■28588
4 0 Inventor Nicholas John DeCristofaro 114 Hillside Avenue, Chatham, New Jersey, 07928 United States 1- Author Claude Henschel 10 Eddystone Court, Redwood City, California 94065, United States

Claims (1)

Claims: (1) having and essentially having a glass-like structure of at least 50 inches for use as a surface layer of a hard-facing metal article. The following members: Chromium with less than 30 atoms. Tungsten with less than 16 atoms, molybdenum with less than 5 atoms, etc. 2 to 25 atoms of boron. It contains at least one element selected from the group consisting of up to 15 atoms of silicon and up to 5 atoms of carbon, the remainder being at least one element selected from the group consisting of cobalt, nickel and iron and However, the total of iron, cobalt, nickel, chromium, tungsten, and molybdenum is within the range of 70 to 88 atoms, and the total of reed, boron, silicon, and carbon is within the range of 12
A homogeneous ductile hardfacing foil of a metastable material having a composition in the range of ~30 atoms. (2) Used as a surface layer of hard facing treated metal articles. having a glass-like structure of at least 50 inches;
and essentially the following members: up to 25 atoms of cobalt, up to 60 atoms of nickel, and up to 30 atoms of chromium. Tungsten with less than 5 atoms. Molybdenum with less than 4 atoms. 2 to 25 atoms of boron. Containing at least one element selected from the group consisting of silicon having 15 atoms or less and carbon having 5 atoms or less,
The remainder is iron and incidental impurities.
A homogeneous ductile hardfacing group consisting of a metastable material having a composition in which the sum of silicon and carbon ranges from 12 to 30 atoms. (3) the material is at least 80% glass-like; A hardfacing group according to claim 2. (4) The material is 100% glassy. A hardfacing group according to claim 2. (5) A hard-faced metal article that has been subjected to a hard facing treatment with the foil according to claim 1 or 2. and ductile;
having and essentially a glassy structure of at least 50%. The following members:' 25 atoms or less of cobalt. 30 atoms or less of nickel. Up to 30 atoms of chromium. Tungsten with less than 5 atoms. Molybdenum with less than 4 atoms. Boron with 2 to 25 atoms. It contains at least one element from the group consisting of 15 atoms or less of silicon and 5 atoms or less of carbon, the remainder being iron and repellent impurities. However, L cobalt, nickel, and chromium. The total of tungsten and molybdenum is in the range of 70-88 atoms and boron. The sum of silicon and carbon is a metastable material with a composition ranging from 12 to 30 atoms. b) apply heat to the filament in said heating zone to melt the filament and deposit it on the workpiece surface in close proximity to it, and C) cool the workpiece surface and melt the deposited filament onto the workpiece surface. The process consists of forming a hard adhesive film on the top. Method for facing metal substrates (7)/-Dfacing is used as a surface layer of metal articles. having and essentially a glassy structure of at least 50%. The following members: Cobalt, up to 25 atoms. 20 atoms or less of iron, 15 atoms or less of chromium, 16 atoms or less of tungsten. Boron with up to 5 atoms of molybdenum 2 2 to 20 atoms. Containing at least one element selected from the group consisting of 10 atoms or less of silicon, and 5 atoms or less of carbon,
The rA part is nickel and extermination impurities.
The sum of cobalt, nickel, chromium, tungsten and molybdenum ranges from 70 to 88 atoms, and the sum of boron, silicon and carbon ranges from 12 to 30 atoms. Ductility No. 1-
defacing foil. (8) The material is at least 80% glass-like. A knot facing foil according to claim 7. (9) I-dofacing foil according to claim f4E7, wherein the material is 100% glassy. 0(lll I.-
De-facing treated) Ivy-de facing treated ready-to-metal articles. Ql) a) Feed a continuous filament from a spool to the heating zone, the filament being homogeneous and ductile, having a glass-like structure of at least 50 cm, and essentially; The following members: Cobalt with less than 25 atoms. 20 atoms or less of iron, 15 atoms or less of chromium. Tungsten up to 16 atoms. Molybdenum with less than 5 atoms. 2 to 20 atoms of boron. Contains at least one element selected from the group consisting of 10 atoms or less of silicon, and 5 atoms or less of carbon,
The remainder is nickel and extermination impurities, but iron,
It consists of a metastable material with a composition in which the sum of cobalt, nickel, chromium, tungsten and molybdenum ranges from 70 to 88 atoms, and the sum of boron, silicon and carbon ranges from 12 to 30 atoms. b) applying heat to the filament in the heating zone to melt the filament and depositing it on the workpiece surface in close proximity thereto; and C) cooling this workpiece surface and melting the deposited filament onto the workpiece surface. A method of hardfacing metal substrates, which involves the process of forming a hard adhesive coating. (1) Used as a surface layer of hard-facing metal articles, having at least 50% glassy structure and essentially consisting of: 32 atoms of nickel or less; 10 atoms or less of iron. Chromium up to 30 atoms q6. Tungsten up to 2 at%. Molybdenum up to 4 atoms. Boron up to 2 to 25 atoms, silicon up to 15 at%. Manganese up to 2 atoms q6μ, and carbon up to 5 atoms. Contains at least one or both elements selected from the group consisting of Fc), with the remainder being cobalt and exterminating impurities.
LAA - cobalt, nickel, chromium. The sum of tungsten and molybdenum is in the range of 70 to 88 atoms, the sum of boron, silicon and carbon is 12
A homogeneous ductile hardfacing foil of a metastable material having a composition in the range of ~30 atoms. 03) The hardfacing foil of claim 12, wherein said material is at least 80% glass-like. 04) A hardfacing foil according to claim 12, wherein said material is 100-glass-like. (15) A hard-facing metal article that is hard-faced with the foil according to claim 12. (16) supplying a continuous filament from a spool to the heating zone, the filament being homogeneous and ductile, having a glass-like structure of at least 50 mm and essentially; The following members: 32 atoms or less of nickel, 10 atoms or less of iron. Chromium with less than 30 atoms. Tungsten less than 2 atoms. Molybdenum with 4 atoms or less, boron with 2 to 25 atoms. Contains at least one element selected from the group consisting of 15 atomic % or less silicon, 2 atomic % or less manganese, and 5 atomic % or less carbon,
The balance is cobalt and repellent impurities, with the total of iron, cobalt, nickel, chromium, tungsten and molybdenum ranging from 70 to 88 atoms. It is a metastable material with a composition in which the sum of boron, silicon and carbon ranges from 12 to 30 atoms. and C) cooling the workpiece surface so that the deposited filaments form a hard adherent coating on the workpiece surface. Hard 7 ace method for metal base materials.