US2699992A - Alloy cast irons - Google Patents

Alloy cast irons Download PDF

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US2699992A
US2699992A US219227A US21922751A US2699992A US 2699992 A US2699992 A US 2699992A US 219227 A US219227 A US 219227A US 21922751 A US21922751 A US 21922751A US 2699992 A US2699992 A US 2699992A
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alloy
alloy cast
iron
corrosion
excess
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Spitz Karl
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C37/00Cast-iron alloys
    • C22C37/10Cast-iron alloys containing aluminium or silicon

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Preventing Corrosion Or Incrustation Of Metals (AREA)

Description

Jan. 18, 1955 K. sPrrz 9 ALLOY CAST IRONS 2 Sheets-Sheet 1 Filed April 4, 1951 Fm, L
INVENTOR. KARL SPrrz ATTORNEYS.
Jana a K, ALLOY CAST IRONS Filed April 4, 1951 2 Sheets-Sheet 2 ALLOY No.2.
ALLOY No. 5
GNN m WaeA-w \N GRAMS TM: 0: E x oguke \N Novas & CMT'LRDN' 5 k Loss in \NEJGHT m Gamma IN VEN TOR. K ARL Sp \'\'z FMG. A BY I United States Patent 9 ALLOY CAST IRONS Karl Spitz, Cleveland, Ohio Application April 4, 1951, Serial No. 219,227
7 Claims. (Cl. 75-124) This invention relates, as indicated, to alloy cast irons, but has reference more particularly to ferritic and austenitic alloy cast irons having improved mechanical and chemical properties.
As is well known, the atmospheric corrosion product of iron or steel, commonly known as rust, causes heavy losses, from the viewpoint of general economy.
Even irons containing fairly high percentages of nickel or copper, under attack from the oxygen and moisture contained in the atmosphere, have formed thereon a coating of hydrated iron oxide, in the form of porous and loose flakes of rust which are easily washed away by fluid streams, or rain, or are torn away by wind. As soon as the rust is removed, the underlying base metal is again subject to renewed attack. Moreover, rust may even enhance further corrosion of the ferrous base metal by the formation of electrolytic oxygen concentration cells.
This form of continuous rust formation is in contrast to the protective oxide coatings formed on the surface of metals, such for example as copper, aluminum and stainless steels, which coatings are insoluble, adhere firmly to the base metal, and protect the underlying base metal from i any continuing attack by atmospheric corroding agents.
I am aware that alloy cast irons having constituents similar to those present in the alloy cast irons of my in vention, have been employed in order to obtain improved wear resistance, as compared with unalloyed cast iron, but these are usually of low alloy content, and being, in general, of a ferritic character, do not withstand atmospheric attack, and are even less able to withstand chemical, and especially acid corrosion.
The present invention has, as its primary object the provision of alloy cast irons in which are combined high tensile strengths and impact values with improved corrosion resistance, particularly against certain atmospheric conditions and certain dilute acids. In general, the alloy cast irons of my invention are designed to prevent or at least minimize the types of atmospheric corrosion which have been described, as well as corrosion resulting from combustion gases, and chemical reagents, including acids.
Another object of my invention is to provide a series of alloy cast irons which are capable of being readily melted, poured and cast by means of conventional apparatus and equipment.
A further object of the invention is to provide alloy cast irons of the character described, which are adaptable for various uses, especially in the chemical and oil industries, and for products used in many other fields where improved wear and corrosion-resistance are a primary factor, as for example, cylinder linings for pumps, compressors, combustion engines, etc.
A further object of the invention is to provide alloy cast irons which are especially useful for products in the plumbing and drainage industries, wherein the products are subjected not onlyv to natural atmospheric corrosion,
but also to smoke, combustion gases, moist sulphur di-' oxide, salt spray. and industrial waste liquors containing acids, chemicals, and other corrodents. Among these products are roof drain domes, floor, ramp and trench drains and gratings, backwater valves, grease and oil interceptors, roof, floor, shower and area drains. Improved impact resistance is an especially important desideratum for floor, ramp and trench drains and gratings, because ihedsame dimensional construction will allow for heavier oa s.
2,699,992 Patented Jan. 18, 1955 A further object of the invention is to provide alloy cast irons which may be used as substitutes for nonferrous alloys, such as brass, bronze, nickel-silver, etc., whereby a saving in critical or strategic materials is effected.
A still further object of the invention is to reduce the weight of castings for the above purposes, by reason of the increased strength of the alloys.
Other objects and advantages of my invention will become apparent during the course of the following description.
For a graphic understanding of the. characteristics and properties of the alloy cast irons of my invention, reference may be had to the accompanying drawings, forming a part ofthis application, and in which Figs. 1, 2 and 3 are photomicrographs of specific alloys coming within the scope of my invention, and
Fig. 4. is a drawing illustrating graphically the results of moist sulphur dioxide tests on the above specific alloys, and on a conventional cast iron.
The alloy cast irons of my invention contain at least 50% iron, more than 1.7% to about 4% carbon, and four major alloying constituents or elements, namely, Qhromium, nickel, copper and molybdenum, each being present in an amount in excess of 0.40%, with at least one being present in an amount in excess of 1.00%. I have further found that the desired characteristics toward which my invention is directed are generally obtainable without having the chromium, nickel, copper and molybdenum present in an amount in excess of about 36% each, with the single reservation that in those cases where the amount of any one of the principal alloying constitutents, chromium, nickel, copper and molybdenum, is in excess of 18% each of the other three must be present in an amount in excess of 1%, in order to provide efiectively balanced alloys in accordance with the invention. The alloy cast irons also contain silicon. in amounts of from 1.25% to 5.6%, manganese in amounts of from .20% to 3.0%, sulphur in amounts of from .03% to 1.00%, phosphorus in amounts of .02% to 2.00%, and aluminum in amounts of .05% to 1.00%. These constituents, namely silicon, manganese, sulphur, phosphorus and aluminum, when present, are intended to be comprised or included within the expression the balance of the alloy being substantially iron, as hereinafter employed in the claims, since they are normally found in cast irons.
The alloy cast irons may be prepared by any of the usual methods employed for making alloys. Among these methods are:
1. Melting a conventional cast iron charge in an electric furnace, and adding the alloying constituents thereto in order to obtain the desired composition.
2. Melting a conventional cast iron charge in a cupola, transferring this unalloyed cast .iron to an electric or air furnace, and then adding the alloying'constituents to the cast iron, as usual in duplexing.
3. Melting a master alloy containing the alloying constituents in an electric furnace, and then adding this master alloy to the conventional cupola-melted cast iron, in a ladle, mixer, or at the spout of the cupola, to form the alloy of the desired composition.
The alloy cast irons of the present invention are generally characterized by high tensile strengths and impact values. They are wear-resistant and resistant both to atmospheric corrosion and to corrosion by dilute acids and other chemicals. They can be melted, poured and cast by means of conventional apparatus and equipment generally employed in steel mills and foundries for these purposes. They are well adapted for use in the chemical and oil industries and for products used in many other fields, where improved wear an tfcorrosion-resistance are primary considerations, as for example, cylinder linings forpumps, compressors, combustion engines, etc. They are especially useful for products in the plumbing and drainage industries, which are subjected not only to natural atmospheric corrosion, but also to smoke, combustion gases, moist sulphur dioxide, salt spray and industrial waste liquors containing acids and other corrodents.
(b) sulphuric acid:
Loss in grams in 1 hr 5.0353 1985 0178 5. 6605 (c) Moist sulphur dioxide (6% H2803) #1 #2 #2 Cast iron Gain in grams in 18 hrs 3234 7723 5405 6626 Gain in grams in 24 hrs 0079 7839 5513 1724 Gain or Loss in grams in 42 hrs 1293 7449 5477 4727 Gain or Loss in ams in 66 hrs l i 2472 5639 5074 2472 Gain or Loss in grams in 72 n hrs 3642 5549 4993 7550 The results of these moist sulphur dioxide tests are illustrated graphically in Fig. 4 of the drawings.
These show that conventional cast iron deteriorates rapidly within a test period of 72 hours, and that alloy No. 1 deteriorates to a lesser degree, but shows a markedly improved resistance, as compared with such conventlonal cast iron. The reason for this is that the film formed by the corroded metals (indicated by the gains in weight) is washed away and does not protect the underlying metal which, therefore, is steadily attacked, as indicated by loss of weight after 24 hours. Alloys Nos. 2 and 3 are attacked considerably during a period of 24 hours, as 1ndr cated by the gain in weight. In contrast, however, with the conventional cast iron, the film which is formed in alloys Nos. 2 and 3 apparently is not easily dissolved and protects the underlying metal, as indicated by the slow loss in weight between 24 hours and 72 hours. At that point, there already exists a difference in resistance between the cast iron (.7556) and alloy No. 3 (-|-.4993), whlch is of fundamental magnitude in favor of alloy No. 3. More specifically, the total change between 24 hours and 72 hours for the cast iron is and for the same period for alloy No. 3
In other words, the total corrosion of the cast iron during the 24-72 hour period is more than 1700% higher than that of alloy No. 3.
Humidity tests conducted in a humidity chamber for 72 hours at 100% humidity, and 100 F. showed markedly superior resistance of alloys Nos. 1, 2 and 3, as compared with conventional cast iron.
Salt spray tests in a 20% solution, at 95 F. resulted in improved performance of the alloys in the following order: Alloy No. 3, alloy No. 2, and No. 1, with the conventional cast iron least resistant.
Alloys Nos. 1, 2 and 3 were selected for the above tests, primarily because of the fact that they utilize in their composition relatively small amounts of the critical or strategic alloying metals.
It is apparent from the foregoing that I have provided two series or groups of alloy cast irons, all of which are corrosion-resistant, with one group having tensile strengths of from about 38,000 to about 50,000 p. s. i., and being well adapted for use in the plumbing and drainage fields, and the other group having tensile strengths in excess of 50,000 p. s. i., and being generally suitable for application or uses in the chemical industries, being heat and wear resistant, as well as corrosion-resistant; that one group utilizes minimum amounts of strategic metals, and that both groups are capable of being readily melted, poured and cast, by means of conventional apparatus and equipment.
It is to be understood that the particular alloy cast irons herein listed are exemplary and illustrative of desirable alloy compositions, and that slight changes may be made in the proportions of the alloys without departing from the spirit of the invention as defined in the subjoined claims.
Having thus described my invention, I claim:
1. A corrosion-resistant alloy cast iron containing about 3.32% carbon, about 0.60% chromium, about 1.03% nickel, about 0.45% copper, about 0.48% molybdenum, from 1.25% to 5.6% silicon, from 0.20% to 3.0% manganese, from 0.03% to 1.00% sulphur, from 0.02% to 2.00% phosphorus, from 0.05% to 1.00% aluminum, and the remainder being iron.
2. A corrosion-resistant alloy cast iron containing about 2.90% carbon, about 2.04% chromium, about 3.69% nickel, about 1.18% copper, about 0.88% molybdenum, from 1.25 to 5.6% silicon, from 0.20% to 3.0% manganese, from 0.03% to 1.00% sulphur, from 0.02% to 2.00% phosphorus, from 0.05% to 1.00% aluminum, and the remainder being iron.
3. A corrosion-resistant alloy cast iron containing about 3.25% carbon, about 12.40% chromium, about 17.60% nickel, about 5.70% copper, about 7.20% molybdenum, from 1.25% to 5.6% silicon, from 0.20% to 3.0% manganese, from 0.03% to 1.00% sulphur, from 0.02% to 2.00% phosphorus, from 0.05 to 1.00% aluminum, and the remainder being iron, but the iron being always in excess of 50%.
4. A corrosion-resistant alloy cast iron containing about 3.40% carbon, about 4.60% chromium, about 16.30% nickel, about 15.80% copper, about 5.20% molybdenum, from 1.25% to 5.6% silicon, from 0.20% to 3.0% manganese, from 0.03% to 1.00% sulphur, from 0.02% to 2.00% phosphorus, from 0.05 to 1.00% aluminum, and the remainder being iron, but the iron being always in excess of 50%.
5. A corrosion-resistant alloy cast iron containing more than 1.7% to about 4% carbon, chromium, nickel, copper and molybdenum, each in excess of 0.40%, but not in excess of 36%, with at least one in excess of 1%, silicon in amounts of from 1.25% to 5.6%, manganese in amounts of from 0.20% to 3.0%, sulphur in amounts of from 0.03% to 1.00%, phosphorus in amounts of from 0.02% to 2.00%, aluminum in amounts of from 0.05 to 1.00%, the remainder being iron, but the iron being always in excess of 50%.
6. A corrosion-resistant alloy cast iron, as defined in claim 5, in which if any one of the principal alloying ingredients, chromium, nickel, copper and molybdenum, is present in excess of 18%, all of the others are present in excess of 1%.
.7. A corrosion-resistant alloy cast iron containing more than 1.7% to about 4% carbon, chromium, nickel, copper and molybdenum, each in an amount in excess of 0.40%, but not in excess of about 36%, with at least one in an amount in excess of 1.00%, but each of the others in excess of 1.00%, when any one is in excess of 18%, silicon in amounts of from 1.25% to 5.6%, manganese in amounts of from 0.20% .to 3.0%, sulphur in amounts of from 0.03% to 1.00%, phosphorus in amounts of from 0.02% to 2.00%, aluminum in amounts of from 0.05% to 1.00%, the remainder being iron, but the iron being always in excess of 50%.
References Cited in the file of this patent UNITED STATES PATENTS 1,528,478 Hadfield Mar. 3, 1925 1,876,411 Gregg et a1. Sept. 2, 1932 2,214,652 Bancroft Sept. 10, 1940 FOREIGN PATENTS 150,367 Switzerland Jan. 2, 1932 593,298 Great Britain Oct. 14, 1947

Claims (1)

1. A CORROSION-RESISTANT ALLOY CAST IRON CONTAINING ABOUT 3.23% CARBON, ABOUT 0.60% CHROMIUM, ABOUT 1.03% NICKEL, ABOUT 0.45% COPPER, ABOUT 0.48% MOLYBDENUM, FROM 1.25% TO 5.6% SILICON, FROM 0.20% TO 3.0%
US219227A 1951-04-04 1951-04-04 Alloy cast irons Expired - Lifetime US2699992A (en)

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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11111819B2 (en) * 2016-08-24 2021-09-07 Cpt Group Gmbh Iron material for high-temperature-resistant bearing bushings, bearing bushing made of said material, and turbocharger having such a bearing bushing

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1528478A (en) * 1924-12-16 1925-03-03 Hadfield Robert Abbott Alloy
CH150367A (en) * 1929-05-11 1931-10-31 Ver Stahlwerke Ag Process for the manufacture of items made of steel or cast iron that have a low tendency to rust even in seawater and moist soil.
US1876411A (en) * 1932-09-06 of columbus
US2214652A (en) * 1940-06-28 1940-09-10 Perfect Circle Co Iron alloy
GB593298A (en) * 1945-06-05 1947-10-14 Paramount Alloys Ltd Improvements relating to metal alloys

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US1876411A (en) * 1932-09-06 of columbus
US1528478A (en) * 1924-12-16 1925-03-03 Hadfield Robert Abbott Alloy
CH150367A (en) * 1929-05-11 1931-10-31 Ver Stahlwerke Ag Process for the manufacture of items made of steel or cast iron that have a low tendency to rust even in seawater and moist soil.
US2214652A (en) * 1940-06-28 1940-09-10 Perfect Circle Co Iron alloy
GB593298A (en) * 1945-06-05 1947-10-14 Paramount Alloys Ltd Improvements relating to metal alloys

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US11111819B2 (en) * 2016-08-24 2021-09-07 Cpt Group Gmbh Iron material for high-temperature-resistant bearing bushings, bearing bushing made of said material, and turbocharger having such a bearing bushing

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