TWI512118B - 雙硬度鋼材物件及其製造方法 - Google Patents

雙硬度鋼材物件及其製造方法 Download PDF

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Publication number
TWI512118B
TWI512118B TW101100729A TW101100729A TWI512118B TW I512118 B TWI512118 B TW I512118B TW 101100729 A TW101100729 A TW 101100729A TW 101100729 A TW101100729 A TW 101100729A TW I512118 B TWI512118 B TW I512118B
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Taiwan
Prior art keywords
steel alloy
hardness
air hardenable
weight
component
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TW101100729A
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English (en)
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TW201237189A (en
Inventor
Njall Stefansson
Ronald E Bailey
Glenn J Swiatek
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Ati Properties Inc
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Publication of TW201237189A publication Critical patent/TW201237189A/zh
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F41—WEAPONS
    • F41H—ARMOUR; ARMOURED TURRETS; ARMOURED OR ARMED VEHICLES; MEANS OF ATTACK OR DEFENCE, e.g. CAMOUFLAGE, IN GENERAL
    • F41H5/00—Armour; Armour plates
    • F41H5/02—Plate construction
    • F41H5/04—Plate construction composed of more than one layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/02—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling heavy work, e.g. ingots, slabs, blooms, or billets, in which the cross-sectional form is unimportant ; Rolling combined with forging or pressing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/02—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling heavy work, e.g. ingots, slabs, blooms, or billets, in which the cross-sectional form is unimportant ; Rolling combined with forging or pressing
    • B21B1/04—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling heavy work, e.g. ingots, slabs, blooms, or billets, in which the cross-sectional form is unimportant ; Rolling combined with forging or pressing in a continuous process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B21B1/227—Surface roughening or texturing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B21B1/24—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length in a continuous or semi-continuous process
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/22—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length
    • B21B1/24—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length in a continuous or semi-continuous process
    • B21B1/26—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling plates, strips, bands or sheets of indefinite length in a continuous or semi-continuous process by hot-rolling, e.g. Steckel hot mill
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/46—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling metal immediately subsequent to continuous casting
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/46—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling metal immediately subsequent to continuous casting
    • B21B1/463—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling metal immediately subsequent to continuous casting in a continuous process, i.e. the cast not being cut before rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B1/00—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations
    • B21B1/46—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling metal immediately subsequent to continuous casting
    • B21B1/466—Metal-rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling metal immediately subsequent to continuous casting in a non-continuous process, i.e. the cast being cut before rolling
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21B—ROLLING OF METAL
    • B21B3/00—Rolling materials of special alloys so far as the composition of the alloy requires or permits special rolling methods or sequences ; Rolling of aluminium, copper, zinc or other non-ferrous metals
    • B21B3/02—Rolling special iron alloys, e.g. stainless steel
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
    • B23K20/021—Isostatic pressure welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/02—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press ; Diffusion bonding
    • B23K20/023—Thermo-compression bonding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/04—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a rolling mill
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/06—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of high energy impulses, e.g. magnetic energy
    • B23K20/08—Explosive welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K20/00—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating
    • B23K20/22—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded
    • B23K20/227—Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating taking account of the properties of the materials to be welded with ferrous layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
    • B23K35/00—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting
    • B23K35/02—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
    • B23K35/0255—Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape for use in welding
    • B23K35/0261—Rods, electrodes, wires
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/01—Layered products comprising a layer of metal all layers being exclusively metallic
    • B32B15/011—Layered products comprising a layer of metal all layers being exclusively metallic all layers being formed of iron alloys or steels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/043—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of metal
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING 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
    • C21D1/00—General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
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    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING 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
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
    • C21D7/04—Modifying the physical properties of iron or steel by deformation by cold working of the surface
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING 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
    • C21D7/00—Modifying the physical properties of iron or steel by deformation
    • C21D7/13—Modifying the physical properties of iron or steel by deformation by hot working
    • C—CHEMISTRY; METALLURGY
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    • C21D—MODIFYING 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
    • C21D8/00—Modifying the physical properties by deformation combined with, or followed by, heat treatment
    • C21D8/02—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
    • C21D8/0221—Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips characterised by the working steps
    • C21D8/0226—Hot rolling
    • C—CHEMISTRY; METALLURGY
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    • C21D—MODIFYING 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
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    • C21D9/42—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for armour plate
    • C—CHEMISTRY; METALLURGY
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    • C21D9/50—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for welded joints
    • C—CHEMISTRY; METALLURGY
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    • 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
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    • C—CHEMISTRY; METALLURGY
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    • C—CHEMISTRY; METALLURGY
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    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40—Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44—Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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Description

雙硬度鋼材物件及其製造方法
本發明係關於雙硬度鋼材之領域及製造雙硬度鋼材之方法。
輥壓接合雙硬度鋼材裝甲為高效裝甲材料。此類型鋼材裝甲之一個實例為ATI-MIL雙硬度裝甲板，其可自ATI Defense,Washington,PA USA購得。ATI-MIL雙硬度裝甲作為一個實施例揭示於美國專利第5,749,140號中，該專利以全文引用的方式併入本文中。ATI-MIL雙硬度裝甲板為具有高硬度正面及較軟背面之輥壓接合材料。在使用中，裝甲之較硬正面破裂且使入射彈頭變扁平，且較軟背面捕獲並進一步吸收變形彈頭之能量。
儘管習知輥壓接合雙硬度鋼材裝甲具有相當大的彈道穿入阻力，但製造該材料較為困難且昂貴。需要複雜的後輥壓接合熱處理及其他處理來獲得習知輥壓接合雙硬度鋼材裝甲中的所需機械及彈道特性。特定言之，在輥壓接合之後必須將材料奧氏體化(austenitize)、油淬火及回火。另外，此等製程步驟一次僅可在輥壓接合板之一個較小區段上進行，原因在於該板可因兩個輥壓接合合金之熱膨脹係數及轉變溫度的差異而發生過度翹曲。
另外，在熱處理之後，習知雙硬度鋼材裝甲板必須經歷複雜的平化處理。僅有限數目的製造位置被適當裝備以進行平化處理。此外，在板上進行平化處理的需要實際上將習知輥壓接合雙硬度鋼材裝甲板之尺寸限制為不大於約20吋×20吋(50.8 cm×50.8 cm)的尺寸。較大板必須藉由將多個較小板結合在一起來製造，實質上增加部件成本及製造時間以及潛在地負面影響部件之完整性。
因此，存在對並不需要習知後輥壓接合步驟(諸如奧氏體化及油淬火)及/或減少針對許多應用之回火及複雜平化程序之需要的製造輥壓接合雙硬度鋼材裝甲之方法的需要。更一般而言，存在對製造雙硬度鋼材裝甲之改良方法的需要。
根據本發明之一個非限制性態樣，雙硬度鋼材物件包含具有第一合金硬度之第一空氣可硬化鋼材合金及具有第二合金硬度之第二空氣可硬化且自身回火之鋼材合金。在某些實施例中，第一合金硬度大於第二合金硬度。冶金接合區域存在於第一空氣可硬化鋼材合金與第二空氣可硬化鋼材合金之間。
根據本發明之另一非限制性態樣，雙硬度鋼材裝甲包含具有至少574 BHN之第一合金硬度的第一空氣可硬化鋼材合金及具有在477 BHN至534 BHN範圍內(包括477 BHN及534 BHN)之第二合金硬度的第二空氣可硬化鋼材合金。第一空氣可硬化鋼材合金包含0.42重量%至0.52重量%碳、3.75重量%至4.25重量%鎳、1.00重量%至1.50重量%鉻、0.22重量%至0.37重量%鉬、0.20重量%至1.00重量%錳、0.20重量%至0.50重量%矽、至多0.020重量%磷、至多0.005重量%硫、鐵及雜質。第二空氣可硬化鋼材合金包含0.22重量%至0.32重量%碳、3.50重量%至4.00重量%鎳、1.60重量%至2.00重量%鉻、0.22重量%至0.37重量%鉬、0.80重量%至1.20重量%錳、0.25重量%至0.45重量%矽、至多0.020重量%磷、至多0.005重量%硫、鐵及雜質。冶金接合區域存在於第一空氣可硬化鋼材合金與第二空氣可硬化且自身回火之鋼材合金之間。
根據本發明之另一態樣，製造雙硬度鋼材裝甲之方法包含：提供包含第一配合面且具有第一部件硬度之第一空氣可硬化鋼材合金部件；及提供包含第二配合面且具有第二部件硬度之第二空氣可硬化鋼材合金部件。第一部件硬度大於第二部件硬度。安置第一部件及第二部件以使第一配合面之至少一部分接觸第二配合面之至少一部分，且冶金固定第一部件及第二部件以形成冶金固定之組件。熱軋冶金固定之組件以提供第一配合面與第二配合面之間的冶金接合。
本文所述之方法的特徵及優點可參考隨附圖式更好地理解。
讀者在考察以下本發明之某些非限制性實施例的詳細描述後，將瞭解上述細節以及其他資訊。
應瞭解，本文所揭示之實施例的某些描述已經簡化以說明僅與清楚瞭解所揭示之實施例有關的彼等要素、特徵及態樣，同時出於清楚之目的除去其他要素、特徵及態樣。一般技術者在考察所揭示之實施例的本發明描述後將認識到在所揭示實施例之特定實施或應用中可能需要其他要素及/或特徵。然而，因為一般技術者在考察所揭示之實施例的本發明描述後可易於確定及實施該等其他要素及/或特徵，且因此不必完全瞭解所揭示之實施例，該等要素及/或特徵之描述不在本文中提供。因而，應瞭解，本文所闡述之描述僅例示及說明所揭示之實施例且不意欲限制由申請專利範圍所單獨界定的本發明之範疇。
在非限制性實施例之本發明描述中，除在操作實例中或另外指示以外，所有表示數量或特徵之數字應理解為在所有情況下均由術語「約」修飾。因此，除非與此相反地指出，否則以下描述中所闡述的任何數值參數均為可視吾人設法獲得之本發明標的物中所需特性而改變的近似值。至少，且不試圖限制相當於申請專利範圍範疇之準則的應用，各數值參數應至少根據所報導有效數位的數字且藉由應用常規捨入技術來理解。
此外，本文中所述任何數值範圍均意欲包括其中所包含的所有子範圍。舉例而言，範圍「1至10」意欲包括所述最小值1與所述最大值10之間(且包括所述最小值1及所述最大值10)的所有子範圍，亦即具有等於或大於1之最小值及等於或小於10的最大值。本文中所述之任何最大數值限制意欲包括其中所包含的所有較低數值限制，且本文中所述之任何最小數值限制意欲包括其中所包含的所有較高數值限制。因此，申請者保留修正本發明(包括申請專利範圍)的權利以明確敍述本文中明確敍述之範圍內所包含的任何子範圍。所有該等範圍均意欲固有地揭示於本文中，使得明確敍述任何該等子範圍之修正將遵從35 U.S.C. §112第一段及35 U.S.C. §132(a)的要求。
除非另有指示，否則如本文所用之語法冠詞「一種(個)(one/a/an)」及「該」意欲包括「至少一種(個)」或「一或多種(個)」。因此，冠詞用於本文中以指代一種(個)或一種(個)以上(亦即至少一種(個))冠詞的語法對象。舉例而言，「一種(個)組分」意謂一或多種(個)組分，且因此可能涵蓋一種(個)以上組分，且可在實施所述實施例中採用或使用。
據稱以全文或部分引用的方式併入本文中的任何專利、公開案或其他揭示材料僅在所併入之材料不與本發明中所闡述之現有定義、陳述或其他揭示材料衝突的程度上併入本文中。因此，且在必要限度上，本文所闡述之揭示內容替代任何以引用的方式併入本文中的衝突材料。據稱以引用的方式併入本文中但與本文中所闡述之現有定義、陳述或其他揭示材料衝突的任何材料或其部分僅在併入之材料與現有揭示材料之間不出現抵觸的程度上併入。
本發明包括各種實施例之描述。應瞭解，本文所述之所有實施例均為例示性、說明性且非限制性的。因此，本發明不為各種例示性、說明性及非限制性實施例的描述所限制。更確切而言，本發明係由申請專利範圍所單獨界定，申請專利範圍可經修正以敍述明確或固有地描述於本發明中或者明確或固有地為本發明所支持的任何特徵。
本發明之態樣包括雙硬度(dual hardness)或「雙硬度(dual hard)」鋼材及鋼材物件的非限制性實施例。本發明之鋼材物件的可能形式包括例如雙硬度鋼材裝甲板或其他包含空氣可硬化鋼材合金的形式。
如本文所用，「空氣可硬化」鋼材合金係指並不需要在液體中淬火以獲得其最終高硬度的鋼材合金。更確切而言，可藉由僅在空氣中自高溫冷卻來獲得氣硬鋼材合金的高硬度。因為空氣可硬化鋼材合金並不需要液體淬火來獲得高硬度，所以空氣可硬化鋼材之物件(諸如空氣可硬化鋼材板)不會遭受可因快速液體淬火而出現之扭曲及過度翹曲。本發明之空氣可硬化鋼材合金可使用習知之輥壓接合技術進行處理，且隨後空氣冷卻以形成雙硬度鋼材裝甲板或其他物件，而無需習知後輥壓接合熱處理及液體淬火來獲得高硬度。
裝甲鋼材合金一般可根據硬度分為以下群組：(i)輥壓均質裝甲(「RHA」)合金根據美國軍用規格MIL-A-12560H顯示出在212 BHN至388 BHN(布氏硬度數(Brinell Hardness Number))範圍內的硬度且亦稱為400 BHN鋼材裝甲合金；(ii)高硬度裝甲(「HHA」)合金根據美國軍用規格MIL-DTL-46100E顯示出在477 BHN至534 BHN範圍內的硬度，且亦稱為500 BHN鋼材裝甲合金；及(iii)超高硬度裝甲(「UHH」)合金根據美國軍用規格MIL-DTL-32332顯示出570 BHN之最低硬度，且亦稱為600 BHN鋼材裝甲合金。另外，空氣可硬化700 BHN鋼材裝甲合金正在研發中。根據某些非限制性實施例，由本文方法所製造用於形成雙硬度鋼材裝甲之空氣可硬化鋼材裝甲合金包括(但不限於)選自RHA合金、HHA合金、UHH合金及潛在700 BHN鋼材裝甲合金的合金。目前，本發明者未知曉空氣可硬化400 BHN及700 BHN鋼材裝甲的任何市售實例。
圖1A為本發明之雙硬度鋼材物件10之非限制性實施例的透視示意圖且圖1B為本發明之雙硬度鋼材物件10之非限制性實施例的截面示意圖。雙硬度鋼材物件10可用作雙硬度裝甲。雙硬度鋼材物件10包含具有第一合金硬度之第一空氣可硬化鋼材裝甲合金12的層及具有第二合金硬度之第二空氣可硬化鋼材合金14的層。在一個非限制性實施例中，第一合金硬度大於第二合金硬度。冶金接合區域16附接第一空氣可硬化鋼材裝甲合金12之至少一個區域及第二空氣可硬化鋼材裝甲合金14的至少一個區域。如本文所用，「冶金接合」係指合金藉由界面區域中合金之間的擴散、焊接、合金化或分子間或晶粒間引力進行接合。在冶金接合區域16中，第一空氣可硬化鋼材裝甲合金與第二空氣可硬化鋼材裝甲合金互相擴散，藉此使兩種合金固定在一起。一般技術者將瞭解可用於形成兩種鋼材合金之間的冶金接合區域以便將兩種鋼材合金固定在一起之技術的特性。在一個非限制性實施例中，冶金接合區域具有在約750 μm至約1500 μm範圍內的厚度。然而，應瞭解，可形成任何適當厚度的冶金接合區域以將第一空氣可硬化鋼材裝甲合金12與第二空氣可硬化鋼材合金14固定在一起。
在本發明之某些非限制性實施例中，第一空氣可硬化鋼材裝甲合金具有至少574 BHN的硬度。氣硬時具有至少574 BHN之硬度之空氣可硬化UHH鋼材裝甲合金或600 BHN鋼材裝甲合金的非限制性實例為ATI 600-超高硬度特殊鋼材裝甲，其可自ATI Defense,Washington,PA USA購得，且揭示於申請中之美國專利申請案第12/184,573號(該案以全文引用的方式併入本文中)中。ATI 600-超高硬度特殊鋼材裝甲包含0.42重量%至0.52重量%碳、3.75重量%至4.25重量%鎳、1.00重量%至1.50重量%鉻、0.22重量%至0.37重量%鉬、0.20重量%至1.00重量%錳、0.20重量%至0.50重量%矽、至多0.020重量%磷、至多0.005重量%硫、餘鐵及附帶雜質。在一個非限制性實施例中，根據美國軍用規格MIL-DTL-32332要求，雜質由殘餘元素組成。
在本發明之某些非限制性實施例中，第二空氣可硬化鋼材裝甲合金具有在477 BHN至534 BHN範圍內(包括477 BHN及534 BHN)的硬度。具有在477 BHN至534 BHN範圍內(包括477 BHN及534 BHN)之硬度之空氣可硬化鋼材合金裝甲的一個非限制性實例為ATI 500-高硬度特殊鋼材裝甲，其亦可自ATI Defense購得。ATI 500-高硬度特殊鋼材裝甲包含0.22重量%至0.32重量%碳、3.50重量%至4.00重量%鎳、1.60重量%至2.00重量%鉻、0.22重量%至0.37重量%鉬、0.80重量%至1.20重量%錳、0.25重量%至0.45重量%矽、至多0.020重量%磷、至多0.005重量%硫、餘鐵及附帶雜質。在一個非限制性實施例中，根據美國軍用規格MIL-DTL-46100E要求，雜質由殘餘元素組成。在本發明之某些非限制性實施例中，第一空氣可硬化鋼材裝甲合金具有至少574 BHN之硬度，且第二空氣可硬化鋼材裝甲合金具有在477 BHN至534 BHN範圍內(包括477 BHN及534 BHN)的硬度。
再次參照圖1A及圖1B，雙硬度鋼材物件10可呈例如由具有不同硬度值之空氣可硬化鋼材合金所製造之雙硬度鋼材裝甲板的形式。雙硬度鋼材裝甲物件或裝甲10之正面18包括第一空氣可硬化鋼材裝甲合金12，其具有相對較高的硬度值。正面18包括「衝擊面」，其為第一空氣可硬化鋼材裝甲合金12的外露面。彈道彈頭在接觸正面18時破裂及/或變扁平。背面19或雙硬度空氣可硬化鋼材裝甲板10之背板包含第二鋼材裝甲合金14，其顯示出比第一空氣可硬化鋼材裝甲合金12低的硬度。較軟且延性極高之背面19用來捕獲穿過正面18之彈頭的碎片且吸收彈頭衝擊衝擊面後衝擊彈頭的能量。雖然不希望受到任何特定操作理論約束，但咸信當彈道彈頭衝擊時背面19之存在及第一與第二空氣可硬化鋼材裝甲合金12、14之間的冶金接合抑制相對較硬之正面18的開裂及/或裂紋的蔓延。
在一個非限制性實施例中，雙硬度鋼材物件或裝甲10之正面18的第一空氣可硬化鋼材裝甲合金12具有58 Rc至65 Rc的洛氏C硬度(Rockwell C hardness)。在另一非限制性實施例中，構成雙硬度鋼材物件或裝甲10之背面19或背板的第二空氣可硬化鋼材裝甲合金14具有45 Rc至55 Rc的洛氏C硬度。在又一實施例中，第一空氣可硬化鋼材裝甲合金12與第二空氣可硬化鋼材裝甲合金14之洛氏C硬度之間的差值為約10 Rc點至15 Rc點。
在另一非限制性實施例中，雙硬度鋼材物件10之正面18的第一空氣可硬化鋼材裝甲合金12可符合美國軍用規格MIL-DTL-32332(MR)。在另一非限制性實施例中，構成雙硬度鋼材物件10之背面19或背板的第二空氣可硬化鋼材裝甲合金14符合美國軍用規格MIL-DTL-46100E(MR)。
將一般技術者現在或在下文中已知之不同空氣可硬化鋼材裝甲合金的任何適當組合冶金接合在一起以提供雙硬度鋼材物件屬於本發明之範疇內。舉例而言，在某些非限制性實施例中，空氣可硬化400 BHN鋼材裝甲合金可與空氣可硬化500 BHN鋼材裝甲合金或空氣可硬化600 BHN鋼材裝甲合金冶金接合。在任何該等情況中，較硬合金將用作第一空氣可硬化鋼材裝甲合金及第一側，其通常將暴露於彈道威脅下以便最先接觸入射彈道彈頭。
表1列出本發明之雙硬度物件的若干非限制性實施例，其可由包括將不同硬度之空氣可硬化鋼材裝甲合金的組合冶金接合在一起的方法進行製造。在表1所列出之空氣可硬化鋼材裝甲合金的每一該組合中，參照圖1A及圖1B中所說明之物件10的非限制性實施例，舉例而言，顯示出較高硬度之特定組合之合金將用作正面18中所包括的第一空氣可硬化鋼材裝甲合金12，且顯示出較低硬度的合金將用作背面19中所包括的第二空氣可硬化鋼材裝甲合金。表1中400、500、600及700分別係指空氣可硬化400 BHN鋼材裝甲合金、空氣可硬化500 BHN鋼材裝甲合金、空氣可硬化600 BHN鋼材裝甲合金及空氣可硬化700 BHN鋼材裝甲合金。在相同合金類型以第一及第二空氣可硬化鋼材裝甲合金之形式合併(例如「500/500」)的表1之組合中，第一空氣可硬化鋼材裝甲合金(其包括於板10之第一面18中)將比第二空氣可硬化鋼材裝甲合金(其包括於背面19中)具有更大的硬度。
參照表1，本發明之雙硬度鋼材裝甲板或其他雙硬度鋼材物件之某些非限制性實施例分別將以下兩種空氣可硬化合金類型組合為第一空氣可硬化鋼材合金及第二空氣可硬化鋼材合金：400 BHN鋼材合金(較高硬度)+400 BHN鋼材合金(較低硬度)、500 BHN鋼材合金+400 BHN鋼材合金、500 BHN鋼材合金(較高硬度)+500 BHN鋼材合金(較低硬度)、600 BHN鋼材合金+400 BHN鋼材合金、600 BHN鋼材合金+500 BHN鋼材合金、600 BHN鋼材合金(較高硬度)+600 BHN鋼材合金(較低硬度)、700 BHN鋼材合金+400 BHN鋼材合金、700 BHN鋼材合金+500 BHN鋼材合金、700 BHN鋼材合金+600 BHN鋼材合金及700 BHN鋼材合金(較高硬度)+700 BHN鋼材合金(較低硬度)。
在本發明之某些非限制性實施例中，第二空氣可硬化鋼材合金包含空氣可硬化自身回火鋼材。如本文所用，「自身回火鋼材」係指鋼材中之碳在空氣冷卻期間自馬氏體相(martensitic phase)之部分中部分沈澱、形成提高鋼材合金之韌性的碳化鐵於α鐵基質中之精細分散的鋼材。在本發明之某些非限制性實施例中，作為第二空氣可硬化鋼材合金包括的自身回火鋼材顯示出包括至少260千磅/平方吋(1,792 MPa)之拉伸強度、至少150千磅/平方吋(1,034 MPa)之屈服強度及至少13%之伸長率的室溫拉伸特性。在本發明之另一非限制性實施例中，作為第二空氣可硬化鋼材合金包括的自身回火鋼材顯示出包括至少240千磅/平方吋(1,655 MPa)之拉伸強度、至少140千磅/平方吋(965 MPa)之屈服強度及至少9%之伸長率的室溫拉伸特性。在某些非限制性實施例中，如根據ASTM A370-10中列出之標準試驗方法所量測，可用作本發明之雙硬度鋼材物件中之第二空氣可硬化鋼材合金的空氣可硬化自身回火鋼材具有表2中所列的最小夏比(Charpy)V形缺口衝擊特性。夏比V形缺口衝擊試驗為量測鋼材合金吸收能量之能力的快速應變率衝擊試驗，進而提供鋼材合金之韌性的量測。
在本發明之另一非限制性實施例中，可用作本發明之雙硬度鋼材物件中的第二空氣可硬化鋼材合金之空氣可硬化自身回火鋼材為ATI 500-高硬度特殊鋼材裝甲。在另一非限制性實施例中，可作為本發明之某些雙硬度鋼材物件中之第二空氣可硬化鋼材合金包括的空氣回火鋼材為AISI 4820等級鋼材合金(UNS G48200)，其具有0.18重量%至0.23重量%碳、0.50重量%至0.70重量%錳、至多0.035重量%磷、至多0.04重量%硫、0.15重量%至0.30重量%矽、3.25重量%至3.75重量%鎳、0.20重量%至0.30重量%鉬、鐵及附帶雜質的標稱組成範圍，且具有如ASTM A29/A29M-05中所列的特性。
在本發明之雙硬度鋼材物件的某些非限制性實施例中，第一空氣可硬化鋼材合金及第二空氣可硬化鋼材合金中之至少一者包含空氣可硬化鎳-鉬-鉻鋼材合金。在本發明之雙硬度鋼材物件的某些非限制性實施例中，第一空氣可硬化鋼材合金為鎳-鉬-鉻鋼材合金，其包含、基本上由以下組成或由以下組成：0.42重量%至0.52重量%碳、3.75重量%至4.25重量%鎳、1.00重量%至1.50重量%鉻、0.22重量%至0.37重量%鉬、0.20重量%至1.00重量%錳、0.20重量%至0.50重量%矽、至多0.020重量%磷、至多0.005重量%硫、鐵及雜質。在本發明之雙硬度鋼材物件的某些其他非限制性實施例中，第一空氣可硬化鋼材合金為鎳-鉬-鉻鋼材合金，其包含、基本上由以下組成或由以下組成：0.22重量%至0.32重量%碳、3.50重量%至4.00重量%鎳、1.60重量%至2.00重量%鉻、0.22重量%至0.37重量%鉬、0.80重量%至1.20重量%錳、0.25重量%至0.45重量%矽、至多0.020重量%磷、至多0.005重量%硫、鐵及附帶雜質。
本發明之一態樣係關於包含含有本發明之空氣可硬化鋼材合金的雙硬度鋼材合金物件或由包含本發明之空氣可硬化鋼材合金的雙硬度鋼材合金物件組成的製造物件。在某些非限制性實施例中，製造物件係選自裝甲、爆炸保護性車輛外殼、V形爆炸保護性車輛外殼、爆炸保護性車輛機腹及爆炸保護性外罩。
本發明之另一態樣係關於製造雙硬度鋼材物件(諸如呈板形式之雙硬度鋼材裝甲)或其他物件的方法。參照圖2之流程圖，用於製造雙硬度鋼材裝甲的本發明之方法20的一個非限制性實施例包括提供(圖2中步驟21)包含第一配合面且具有第一部件硬度的第一空氣可硬化鋼材合金部件及提供(22)包含第二配合面及具有第二部件硬度的第二空氣可硬化鋼材合金部件。在方法20之某些非限制性實施例中，第一部件硬度大於第二部件硬度。在方法20之各種非限制性實施例中，第一空氣可硬化鋼材合金部件及第二空氣可硬化鋼材合金部件各自獨立地選自空氣可硬化鋼材合金之板、厚塊、薄片及鑄件。再次參照圖2，放置(23)第一空氣可硬化鋼材合金部件及第二空氣可硬化鋼材合金部件，以使第一配合面之至少一部分接觸第二配合面之至少一部分。在一個非限制性實施例中，第一配合面之整個部分接觸第二配合面之整個部分。第一空氣可硬化鋼材合金部件與第二空氣可硬化鋼材合金部件冶金固定(24)以形成冶金固定之組件。熱軋(25)冶金固定之組件以得到第一配合面與第二配合面之全部或一部分之間的冶金接合區域，進而將第一空氣可硬化鋼材合金部件與第二空氣可硬化鋼材合金部件冶金接合在一起。冷卻(26)熱軋之組件。在某些非限制性實施例中，在放置步驟(23)之前視情況研磨第一配合面及第二配合面中之至少一者的至少一部分。
注意到，在圖2之方法20中，在熱軋之前，第一空氣可硬化鋼材合金部件冶金固定至第二空氣可硬化鋼材合金部件以形成冶金固定之組件。如本文所用，「冶金固定」係指合金利用合金之間或合金與焊接合金之間的擴散、合金化、分子間或晶粒間引力進行接合。由將第一及第二空氣可硬化鋼材合金部件冶金固定在一起所製造之中間物件為便於參考在本文中稱為冶金固定之組件或焊接件。在本發明方法之某些非限制性實施例中，冶金固定第一空氣可硬化鋼材合金部件與第二空氣可硬化鋼材合金部件包含藉由將第一配合面外圍的至少一個區域與第二配合面外圍的至少一個區域焊接在一起使第一與第二空氣可硬化鋼材合金部件固定在一起。在某些非限制性實施例中，冶金固定第一空氣可硬化鋼材合金部件與第二空氣可硬化鋼材合金部件包含將第一配合面之整個外圍與第二配合面之整個外圍焊接在一起。將第一與第二空氣可硬化鋼材合金部件冶金固定(24)在一起適當地放置兩個部件以使其可利用隨後的熱軋步驟冶金接合在一起。鑒於此事實，不需要將第一配合面之整個外圍與第二配合面之整個外圍焊接或冶金固定在一起。
在另一非限制性實施例中，冶金固定第一空氣可硬化鋼材合金部件與第二空氣可硬化鋼材合金部件以形成冶金固定之組件包含爆炸性接合第一配合面之至少一個區域與第二配合面之至少一個區域。金屬與金屬合金之爆炸性接合的方法為一般技術者所知且無需在本文中另外詳細描述。
在方法20之某些非限制性實施例中，在冶金固定第一與第二空氣可硬化鋼材合金部件(24)之前，可能有必要或需要藉由例如研磨一個或兩個表面之全部或一部分來製備第一及第二接合面。在方法20之某些非限制性實施例中，在熱軋冶金固定之組件之前，可能需要抽空冶金固定之組件中第一與第二接合面之間的空氣。此等額外步驟可更好的確保在熱軋冶金固定之組件時第一與第二空氣可硬化鋼材合金部件之間形成適當的冶金接合。一般技術者將能夠在無不當實驗之情況下確定該等預熱軋步驟是否為必要或所需的。
再次參照圖2，方法20包括熱軋(25)冶金固定之組件以形成第一空氣可硬化鋼材合金部件之第一配合面之至少一部分與第二空氣可硬化鋼材合金部件之第二配合面之至少一部分之間的冶金接合。在方法20之某些非限制性實施例中，熱軋(25)包含在約700℉(371.1℃)至約2100℉(1149℃)(包括700℉(371.1℃)及2100℉(1149℃))範圍內的熱軋溫度下熱軋冶金固定之組件。在一個非限制性實施例中，在最終熱軋期間離開軋機之熱軋之組件的最低溫度為約700℉(371.1℃)。在另一非限制性實施例中，冶金固定之組件的熱軋(25)在大於0.5 Tm 且至多第一及第二空氣可硬化鋼材合金部件不發生初熔之最高溫度的熱軋溫度下進行，其中Tm 為冶金固定之組件中具有最高熔融溫度之空氣可硬化鋼材合金部件的熔融溫度。進行冶金固定之組件的熱軋(25)以使第一與第二空氣可硬化鋼材合金部件沿其界面之全部或一部分冶金接合在一起，進而得到具有適當完整性的雙硬度鋼材合金部件。熱軋產生第一與第二空氣可硬化鋼材合金相互擴散的冶金接合區域。一般技術者在閱讀本發明後可在無不當實驗之情況下確定適合的熱軋溫度。另外，鑒於熱軋鋼材合金部件之組件以使部件沿界面冶金接合在一起的技術為一般技術者所知，本發明方法之熱軋步驟可在本文中無另外論述之情況下由一般技術者成功地進行。
在方法20之某些非限制性實施例中，熱軋冶金固定之組件(25)包含將組件熱軋成適用作雙硬度鋼材裝甲板或其他物件的適當厚度。可能物件厚度之非限制性實例在例如0.040吋(0.102 cm)厚度之薄片至3吋(7.62 cm)厚度之板範圍內。在方法20之其他非限制性實施例中，熱軋冶金固定之組件包含將組件熱軋成中等厚度，噴砂處理組件之至少一個外表面，及將噴砂處理之組件進一步熱軋成適用作雙硬度鋼材裝甲板或其他物件的適當厚度。該等其他物件包括例如選自爆炸保護性車輛外殼、V形爆炸保護性車輛外殼、爆炸保護性車輛機腹及爆炸保護性外罩的物件。
在方法20之某些非限制性實施例中，熱軋冶金固定之組件產生分別沿第一空氣可硬化鋼材合金及第二空氣可硬化鋼材合金之對置第一及第二配合面的實質上整個界面的冶金接合。在此情況下，所得雙硬度鋼材物件可具有例如示意性描繪於圖1A及圖1B中之物件10的結構，其中冶金接合區域16在熱軋時產生且沿第一空氣可硬化鋼材合金12與第二空氣可硬化鋼材合金14之間的實質上整個界面延伸。
隨著熱軋之組件的空氣可硬化鋼材合金在空氣中自熱軋溫度冷卻，合金硬化成所需硬度，無需後輥壓接合步驟來獲得高硬度。舉例而言，作為第一或第二空氣可硬化鋼材合金包括於熱軋之組件中的400 BHN鋼材合金將在環境空氣中自熱軋溫度冷卻時產生212 BHN至388 BHN之硬度。作為第一或第二空氣可硬化鋼材合金包括於熱軋之組件中的500 BHN鋼材合金將在環境空氣中自熱軋溫度冷卻時產生477 BHN至535 BHN之硬度。作為第一或第二空氣可硬化鋼材合金包括於熱軋之組件中的600 BHN鋼材合金將在環境空氣中自熱軋溫度冷卻時產生最小570 BHN之硬度。因為空氣可硬化鋼材裝甲合金(諸如400 BHN、500 BHN、600 BHN及700 BHN鋼材裝甲合金)並不需要後輥壓接合步驟(諸如奧氏體化及油淬火)，所以根據本發明方法製造之雙硬度鋼材合金物件可製造成僅為可用熱軋設備所限制的尺寸，同時維持所需彈道阻力特性。因為不需要油淬火之習知後熱軋步驟來獲得如本發明之物件及方法中所用之空氣可硬化合金所需的硬度，所以可不需要使由如本文所述方法製造的雙硬度鋼材合金物件變平。對於某些應用可能不需要回火本發明之物件，但對於其他應用仍可為所需的。回火可藉由增加物件之韌性來改良物件之效能。當需要平化時，所需程度將較小，其原因在於由本發明方法之實施例產生之熱處理扭曲將小於油淬火之材料。另外，由於本發明方法及物件中所用合金之空氣可硬化性質，故如本文所揭示之雙硬度鋼材合金物件的機械鋸法並不造成物件之翹曲。
以下實例意欲在不限制本發明範疇的情況下進一步描述某些非限制性實施例。一般技術者應瞭解以下實例之變化在由申請專利範圍所單獨界定之本發明範疇內為可能的。
實例1
在本發明之雙硬度空氣可硬化鋼材裝甲的一個非限制性實例中，ATI 600-超高硬度特殊鋼材裝甲合金用作裝甲之正面或衝擊面，且ATI高硬度特殊鋼材裝甲合金用作裝甲之背面或背板。鑄錠表面使用習知方法研磨。將兩個合金之鑄錠或連續鑄件「連續鑄錠(concast)」厚塊加熱至約1300℉(704℃)之第一溫度，等化，在第一溫度下保持6小時至8小時，以約150℉/小時(66℃/小時)加熱至約2050℉(1121℃)的第二溫度，且在第二溫度下保持每吋厚度約30分鐘或更長。如一實例，將ATI 600-鋼材裝甲合金鑄錠熱軋成過大的2.80吋(7.11 cm)厚度厚塊。將ATI 500-鋼材裝甲合金鑄錠熱軋成過大的3.30吋(8.38 cm)厚度厚塊。使厚塊在1250℉(676.7℃)下消除應力至少12小時。將各厚塊之圖案鋸割成相同寬度及長度用於組件匹配。使各厚塊變平且碾壓至標準尺寸。如一實例，將ATI 600-鋼材裝甲厚塊碾壓成2.50吋(6.35 cm)之厚度，且將ATI 500-鋼材裝甲厚塊碾壓成3.00吋(7.62 cm)之厚度。徹底清潔碾壓之鑄錠之表面以移除任何外來物質(諸如油及潤滑劑)。
在各厚塊之外圍邊緣上加工斜角以有助於焊接。厚塊使用習知程序珠粒噴擊。為了儲存，用紙覆蓋厚塊且儲存在室內以抑制氧化。將不在7天內焊接的厚塊再次珠粒噴擊以移除任何氧化。將ATI 600-鋼材裝甲厚塊置於ATI 500-鋼材裝甲厚塊上，且使用低氫焊棒或線(焊接名稱7018)將厚塊在對準之斜緣處焊接在一起以得到兩個厚塊之冶金固定的組件。
衝壓焊接(冶金固定)之組件以鑑定硬面(亦即ATI 600-鋼材裝甲面)，且將組件加熱至2200℉(1204℃)或較低溫度且在溫度下每吋組件保持30分鐘至45分鐘或更長時間(每公分組件11.8分鐘至17.7分鐘或更長時間)。隨後，將組件輥壓成厚度在3.5吋(8.9 cm)至5.0吋(12.7 cm)範圍內之具有ATI 600-鋼材裝甲面作為頂面的疊塊(reslab)。
輥壓之疊塊組件在硬面向上之情況下照慣例珠粒噴擊，且隨後加熱至1750℉(954.4℃)，每吋組件保持30至45分鐘(每公分組件11.8分鐘至17.7分鐘)且輥壓成最終厚度。輥壓之組件在1600℉±200℉(871.1℃±93℃)下正常化，空氣冷卻且必要時平化。如美國專利申請案第12/565,809號(該案以全文引用的方式併入本文中)中所揭示，平化可包括習知平化程序，或可包括向輥壓之組件施加足以在正常化處理期間維持平坦的拉伸或壓縮應力。在製造本發明之雙硬度鋼材之方法的某些非限制性實施例中可能需要或可能不需要平化。然而，即使在本文方法之某些實施例中需要平化，其亦可因本文方法之實施例中的熱處理扭曲減少而需要比習知方法中較小的程度。
輥壓之組件在175℉(79.4℃)與250℉(121℃)之間的溫度下回火30分鐘至120分鐘。由此製造之雙硬度空氣可硬化鋼材裝甲經珠粒噴擊及噴水或磨切成所需尺寸。
本發明已參照各種例示性、說明性及非限制性實施例書寫。然而，一般技術者應認識到所揭示之實施例(或其部分)之任一者的各種替代、修改或組合可在不背離由申請專利範圍所單獨界定之本發明範疇的情況下作出。因此，預期及瞭解本發明包含未明確闡述於本文中的其他實施例。該等實施例可例如藉由合併及/或修改本文所述之實施例之所揭示之步驟、成分、組分、組成、要素、特徵、態樣及其類似物的任一者來獲得。因此，本發明不為各種例示性、說明性及非限制性實施例之描述所限，而是僅為申請專利範圍所限制。據此，應瞭解申請專利範圍可在本專利申請案執行期間修正以向所主張之本發明添加本文中不同地描述之特徵。
10．．．雙硬度鋼材物件
12．．．第一空氣可硬化鋼材裝甲合金
14．．．第二空氣可硬化鋼材裝甲合金
16．．．冶金接合區域
18．．．正面
19．．．背面
圖1A為本發明之雙硬度鋼材物件之非限制性實施例的透視示意圖；
圖1B為圖1A中所示之雙硬度鋼材物件實施例的截面示意圖；及
圖2為本發明之製造雙硬度鋼材物件之方法之非限制性實施例的流程圖。
10．．．雙硬度鋼材物件
12．．．第一空氣可硬化鋼材裝甲合金
14．．．第二空氣可硬化鋼材裝甲合金
16．．．冶金接合區域
18．．．正面
19．．．背面

Claims (30)

  1. 一種雙硬度鋼材物件，其包含：預成型之第一空氣可硬化鋼材合金部件，其具有第一合金硬度並包含第一表面；預成型之第二空氣可硬化鋼材合金部件，具有第二合金硬度並包含第二表面，其中該第一空氣可硬化鋼材合金部件之硬度大於該第二空氣可硬化鋼材合金部件之硬度，及存在於該第一空氣可硬化鋼材合金部件之第一表面與該第二空氣可硬化鋼材合金部件之第二表面之間的冶金接合。
  2. 如請求項1之雙硬度鋼材物件，其中：該第一空氣可硬化鋼材合金部件具有至少574BHN之硬度；且該第二空氣可硬化鋼材合金部件具有在477BHN至534BHN範圍內(包括477BHN及534BHN)的硬度。
  3. 如請求項1之雙硬度鋼材物件，其中：該第一空氣可硬化鋼材合金部件及該第二空氣可硬化鋼材合金部件中之至少一者個別地選自由以下組成之群：400BHN鋼材合金、500BHN鋼材合金及600BHN鋼材合金。
  4. 如請求項1之雙硬度鋼材物件，其中該第一空氣可硬化鋼材合金部件及該第二空氣可硬化鋼材合金部件中之至少一者包含鎳-鉬-鉻鋼材合金。
  5. 如請求項1之雙硬度鋼材物件，其中該第二空氣可硬化鋼材合金部件包含自身回火鋼材合金。
  6. 如請求項1之雙硬度鋼材物件，其中該第一空氣可硬化鋼材合金部件包含：0.42重量%至0.52重量%碳；3.75重量%至4.25重量%鎳；1.00重量%至1.50重量%鉻；0.22重量%至0.37重量%鉬；0.20重量%至1.00重量%錳；0.20重量%至0.50重量%矽；至多0.020重量%磷；至多0.005重量%硫；及其餘為鐵與附帶雜質。
  7. 如請求項1之雙硬度鋼材物件，其中該第二空氣可硬化鋼材合金部件包含：0.22重量%至0.32重量%碳；3.50重量%至4.00重量%鎳；1.60重量%至2.00重量%鉻；0.22重量%至0.37重量%鉬；0.80重量%至1.20重量%錳；0.25重量%至0.45重量%矽；至多0.020重量%磷；至多0.005重量%硫；鐵；及 雜質。
  8. 如請求項1之雙硬度鋼材物件，其中該物件係選自雙硬度鋼材裝甲、雙硬度爆炸保護性外殼、雙硬度爆炸保護性V形外殼、雙硬度爆炸保護性車輛機腹及雙硬度爆炸保護性外罩。
  9. 如請求項1之雙硬度鋼材物件，其中該第二空氣可硬化鋼材合金部件具有45Rc至55Rc之第二合金硬度。
  10. 如請求項1之雙硬度鋼材物件，其中該第一空氣可硬化空氣鋼材合金部件具有大於該第二合金硬度10Rc點至15Rc點的第一合金硬度。
  11. 如請求項1之雙硬度鋼材物件，其中該第一空氣可硬化鋼材合金部件符合規格MIL-DTL-32332(MR)。
  12. 如請求項1之雙硬度鋼材物件，其中該第二空氣可硬化鋼材合金部件符合規格MIL-DTL-46100E(MR)。
  13. 一種雙硬度鋼材裝甲，其包含：預成型之第一空氣可硬化鋼材合金部件，其具有至少574BHN之第一合金硬度並含有第一表面，且包含：0.42重量%至0.52重量%碳、3.75重量%至4.25重量%鎳、1.00重量%至1.50重量%鉻、0.22重量%至0.37重量%鉬、0.20重量%至1.00重量%錳、0.20重量%至0.50重量%矽、至多0.020重量%磷、 至多0.005重量%硫、鐵及雜質；預成型之第二空氣可硬化鋼材合金部件，其具有在477BHN至534BHN範圍內之第二合金硬度並含有第二表面，且包含：0.22重量%至0.32重量%碳、3.50重量%至4.00重量%鎳、1.60重量%至2.00重量%鉻、0.22重量%至0.37重量%鉬、0.80重量%至1.20重量%錳、0.25重量%至0.45重量%矽、至多0.020重量%磷、至多0.005重量%硫、鐵及雜質，及存在於該第一空氣可硬化鋼材合金部件之第一表面與該第二空氣可硬化鋼材合金部件之第二表面之間的冶金接合區域。
  14. 一種製造雙硬度鋼材物件之方法，其包含：提供包含第一配合面且具有第一部件硬度之第一空氣可硬化鋼材合金部件；提供包含第二配合面且具有第二部件硬度之第二空氣可硬化鋼材合金部件，其中該第一部件硬度大於該第二 部件硬度；安置該第一空氣可硬化鋼材合金部件及該第二空氣可硬化鋼材合金部件，以使該第一配合面的至少一部分接觸該第二配合面的至少一部分；將該第一空氣可硬化鋼材合金部件冶金固定至該第二空氣可硬化鋼材合金部件，以形成冶金固定之組件；熱軋該冶金固定之組件，以形成該第一配合面與該第二配合面之間的冶金接合；及冷卻該熱軋的組件。
  15. 如請求項14之方法，其另外包含在該安置步驟之前研磨該第一配合面及該第二配合面中之至少一者的至少一部分。
  16. 如請求項14之方法，其中該第一空氣可硬化鋼材合金部件與該第二空氣可硬化鋼材合金部件冶金固定以形成冶金固定之組件包含將該第一配合面之外圍的至少一部分與該第二配合面之外圍焊接在一起。
  17. 如請求項14之方法，其中該第一空氣可硬化鋼材合金部件與該第二空氣可硬化鋼材合金部件冶金固定以形成冶金固定之組件包含將該第一配合面之至少一部分與該第二配合面之一部分爆炸性接合。
  18. 如請求項14之方法，其中熱軋該冶金固定之組件包含將該冶金固定之組件熱軋成適用於雙硬度鋼材裝甲之厚度。
  19. 如請求項14之方法，其中熱軋該冶金固定之組件包含將 該冶金固定之組件熱軋成中等尺寸，噴砂處理該冶金固定之組件的至少一個外表面，及將該噴砂處理之組件熱軋成適用於雙硬度鋼材裝甲之厚度。
  20. 如請求項14之方法，其中熱軋該冶金固定之組件包含在2100℉(1149℃)至700℉(371.1℃)範圍內之熱軋溫度下熱軋。
  21. 如請求項14之方法，其中熱軋包含在大於具有該第一或第二鋼材合金部件之較高熔融溫度之合金的熔融溫度之0.5倍且至多該第一或第二鋼材合金部件不發生初熔之溫度的溫度範圍中的熱軋溫度下熱軋。
  22. 如請求項14之方法，其中該雙硬度鋼材合金物件包含：具有至少574BHN之硬度的第一空氣可硬化鋼材合金區域；硬度在477BHN至534BHN範圍內(包括477BHN及534BHN)的第二空氣可硬化鋼材合金區域；及該第一空氣可硬化鋼材合金區域與該第二空氣可硬化鋼材合金區域之間的冶金接合。
  23. 如請求項14之方法，其中：該第一空氣可硬化鋼材合金部件及該第二空氣可硬化鋼材合金部件中之至少一者包含個別選自由以下組成之群的合金：400BHN鋼材合金、500BHN鋼材合金、600BHN鋼材合金及700BHN鋼材合金。
  24. 如請求項14之方法，其中該第一空氣可硬化鋼材合金部件及該第二空氣可硬化鋼材合金部件中之至少一者包含 鎳-鉬-鉻鋼材合金。
  25. 如請求項14之方法，其中該第二空氣可硬化鋼材合金部件包含自身回火鋼材合金。
  26. 如請求項14之方法，其中該第一空氣可硬化鋼材合金部件包含：0.42重量%至0.52重量%碳；3.75重量%至4.25重量%鎳；1.00重量%至1.50重量%鉻；0.22重量%至0.37重量%鉬；0.20重量%至1.00重量%錳；0.20重量%至0.50重量%矽；至多0.020重量%磷；至多0.005重量%硫；鐵；及雜質。
  27. 如請求項14之方法，其中該第二空氣可硬化鋼材合金部件包含：0.22重量%至0.32重量%碳；3.50重量%至4.00重量%鎳；1.60重量%至2.00重量%鉻；0.22重量%至0.37重量%鉬；0.80重量%至1.20重量%錳；0.25重量%至0.45重量%矽；至多0.020重量%磷； 至多0.005重量%硫；鐵；及雜質。
  28. 如請求項14之方法，其中：該第一空氣可硬化鋼材合金部件具有55Rc至65Rc之第一合金硬度；該第二空氣可硬化鋼材合金部件具有45Rc至55Rc之第二合金硬度；且該第一空氣可硬化空氣鋼材合金部件具有大於該第二合金硬度10Rc點至15Rc點的第一合金硬度。
  29. 如請求項14之方法，其中該第一空氣可硬化鋼材合金部件符合規格MIL-DTL-32332(MR)。
  30. 如請求項14之方法，其中該第二空氣可硬化鋼材合金部件符合規格MIL-DTL-46100E(MR)。
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