Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C33/00—Making ferrous alloys
  • C22C33/02—Making ferrous alloys by powder metallurgy
  • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
  • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
  • C22C33/0292—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with more than 5% preformed carbides, nitrides or borides
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F9/00—Making metallic powder or suspensions thereof
  • B22F9/02—Making metallic powder or suspensions thereof using physical processes
  • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
  • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
  • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C1/00—Making non-ferrous alloys
  • C22C1/04—Making non-ferrous alloys by powder metallurgy
  • C22C1/05—Mixtures of metal powder with non-metallic powder
  • C22C1/051—Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C29/00—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides
  • C22C29/02—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides
  • C22C29/06—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds
  • C22C29/067—Alloys based on carbides, oxides, nitrides, borides, or silicides, e.g. cermets, or other metal compounds, e.g. oxynitrides, sulfides based on carbides or carbonitrides based on carbides, but not containing other metal compounds comprising a particular metallic binder
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
  • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
  • C22C32/0052—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides
• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C33/00—Making ferrous alloys
  • C22C33/02—Making ferrous alloys by powder metallurgy
  • C22C33/0207—Using a mixture of prealloyed powders or a master alloy
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F9/00—Making metallic powder or suspensions thereof
  • B22F9/02—Making metallic powder or suspensions thereof using physical processes
  • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
  • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
  • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
  • B22F2009/086—Cooling after atomisation
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B22—CASTING; POWDER METALLURGY
  • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
  • B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
  • B22F2998/10—Processes characterised by the sequence of their steps
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S75/00—Specialized metallurgical processes, compositions for use therein, consolidated metal powder compositions, and loose metal particulate mixtures
  • Y10S75/95—Consolidated metal powder compositions of >95% theoretical density, e.g. wrought
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10S75/00—Specialized metallurgical processes, compositions for use therein, consolidated metal powder compositions, and loose metal particulate mixtures
  • Y10S75/956—Producing particles containing a dispersed phase

Definitions

• the present invention relates to a novel process of producing both ferrous and non-ferrous alloys and to the novel alloy compositions and structures resulting therefrom. While not being limited thereto, the present invention has particular applicablity in the production of materials such as high speed steels and cobalt-base cutting tool alloys.
• this invention consists of the steps of atomizing and consolidating a plurality of alloy materials as hereinafter set forth in detail, whereby both, the new alloys (in terms of composition) and alloys of novel metallurgical structure are readily and conveniently attained, both of said new materials illustrating considerably improved properties over known similar compositions of the prior art. Even more specifically, my invention is directed to alloy structures wherein there is a hard finely dispersed phase such as a carbide, but not being limited thereto, in a metallic or alloy matrix.
• Another important aspect of my invention involves the formation of a uniform dispersion of, for example, very fine carbide particles throughout the major alloy constituent such as a cobalt-base matrix.
• carbide phase is finely grained (as hereinafter defined) and it is most important that it be substantially uniformly dispersed throughout the matrix.
• a primary object of my invention is to provide for the uniform dispersion of finely dispersed phase hard particles such as, but not being limited to carbides, in an alloy matrix whereby considerable enhancement of metallurgical and physical properties result.
• Another object of my invention is to provide nonferrous alloys having exceptional properties.
• Still another object of my invention is to provide ferrous alloys having exceptional properties.
• a still further object of my invention is to provide a process of atomizing molten homogeneous alloy compositions and thereafter rapidly quenching the atomized homogeneous composition to form alloy powder which may be consolidated by known powder consolidation techniques.
• Still a further object of my invention is to provide a method whereby Wrought shapes may be fabricated of alloys heretofore considered unfabricable.
• Still another object of my invention is to provide wrought alloys h'aving greater volumes of hard dispersed phase, such as carbides, without a resulting loss of fabricability and toughness.
• This invention is applicable to high-speed steels, cobaltbase alloys and other alloys containing refractory hard compounds in a metallic matrix.
• the atomized powders are consolidated by methods such as canning followed by forging or hot rolling.
• the carbide phase forms as an ultrafine precipitate; care must be taken to avoid excessively high working temperatures so that the carbides do not become coarse.
• the jacketing material is removed and, in the case of high-speed steel, the material is hardened and tempcred.
• Atomizing techniques have also been used to prepare highly refined cobalt-chromium-tungsten-carbon alloys, commonly referred to as cast alloys.” Atomization and consolidation produce a hard, tough alloy having extreme ly fine carbides.
• one of the first and most important concepts involved is that of producing the initial form of the alloy as a powder by an atomizing process.
• This atomizing process involves the prerequisite of generating a molten stream of the alloy, in which all of the alloying components are included, and in which all of the alloying constituents or phases are understood to be either completely liquefied or dissolved.
• the molten stream is heated to a temperature that is at least about F. to 200 F. above the fusion temperature of the alloy. It is an important aspect of the invention that the dispersed phase carbides are dissolved in this molten stream and remain primarily in solution not only during atomizing fiuid (e.g. gas) impact on the stream but even after solidification of the resultant powders. The fact that such carbides are clearly submicroscopic in size and presumably in solid solution is borne out by subsequent examinations of the powders. The consolidated alloy (which is formed by a process necessarily effecting some increase in the dispersed carbide particle size) still has extremely minute carbide particle sizes.
• fiuid e.g. gas
• any sort of heating and/or pressure conditions over a given time period which would tend to consolidate a powder into a solid alloy mass would also tend to cause at least a limited or nominal amount of growth and/or agglomeration of dispersed phase carbides.
• the alloy powders of the invention (and their resulting consolidated alloys) are unique in that such growth and/ or agglomeration is extremely nominal and the dispersed phase does, in fact, remain substantially uniformly discrete and dispersed throughout the continuous phase constit uents forming the matrix of the present alloy. This result is made possible by the initial atomizing technique which has the net effect of distributing the dispersed phase carbides and the matrix elements in such a uniquely fine and uniform distribution that the unusual results of the invention are made possible.
• the gas or atomizing medium or fluid that is used is inert (to the material being atomized) and it may be preheated to extremely high temperatures so that it actually imparts sensible heat to the flowing stream of the alloy and thereby might assist in increasing the molten alloy temperature above that actually obtained in the crucible or container in which the alloying composition is initially melted, but this is generally neither necessary nor preferred.
• plasma or other atomized molten alloying composition generating devices which are known, may be used; but presently the most practical procedure calls for a cooling inert gas.
• Such inert gas used is preferably argon, but the gas may be, as for example, N CO or, in fact, any of the known so-called gases which are elements of the group" of the Periodic System, which include helium, krypton, etc. It will be appreciated that the chemistry of this procedure suggests that the inert gas used be argon, unless for some reason any of the alloying elements or trace chemical elements present in the alloy has no peculiar sensitivity to nitrogen or CO which would then make one of these less expensive fluids more economical.
• argon is caused to impact or impinge against the free-flowing stream of molten onephase alloy under substantial pressure and at substantially great speeds.
• the speed is relatively difficult to measure and it is not practical to evaluate the impacting on the basis of speed alone, since the actual impact-impingement effect is based both upon speed and gaseous weight (which latter factor is in turn determined by the temperature).
• the argon (or other inert gas) is preferably used at ambient atmospheric temperatures for the reason that the inert gas functions essentially to impinge and impact against the stream, so as to break up the molten alloy stream and then to violently agitate the broken stream, which is in the form of droplets in the continuous highly agitated gaseous phase, to the extent that the droplets are reduced materially in size while retaining their initial homogeneous composition in such droplets before i actual solidification thereof, even though such solidification is so rapid essentially a solid single phase and/or supersaturated type of solid solution is actually obtained in this process.
• the alloying composition from a chemical point of view, is ordinarily given on the basis of chemical analysis reciting the individual elements and it is virtually impossible to attempt a composition definition in any other terms, because of the difiiculty of ascertaining exactly what type of chemical compounds, for example, might be formed in a given specific location of any particular alloy. Hence, the alloying composition and the composition per se of the alloys used herein will be given strictly speaking on the basis of the actual chemical elements employed.
• One chemical composition of the alloy contemplated for use in the practice of the instant invention may be described as consisting essentially of 10% to 45% Cr, 1% to 3.5% C, (40-20% W, x% M, remainder substantially Co, plus inherent trace amounts of impurities having selective preference to accumulate at phase boundaries, wherein at is a percent ranging from trace amounts to substantially 20% and M is an alloying metal selected from the group consisting of Fe, Ni, Cb, Ta and mixtures thereof. It is well known, of course, that M0 may be substituted for W in an approximate ratio of one part of M0 for two parts of W. Such substitution is within the scope of the invention.
• one alloy of the invention is considered to be a cobalt alloy (i.e., containing at least substantially 35% Co) containing substantial quantities of chromium, preferably within the range of about 14 to 35% by weight (and it will be apprecited that all percents herein are given by weight unless otherwise specified).
• this cobalt-chromium alloy contains a substantial quantity of tungsten, with trace or with comparatively minor amounts of the various other alloying metals previously specified.
• the instant alloy contains carbon, preferably in amounts above about l /z% and up to about 3%.
• Prior art alloys of the cobalt-chromium-tungsten type could not include carbon in proportions above about 1.5% without obtaining an as-cast alloy that was substantially completely unworkable, or was at least so difficultly workable that it had to be cast in approximately the shape ultimately contemplated for use and could then perhaps be forged or wrought only with considerable difficulty.
• Conventional prior art as-cast alloys of this type have been made using carbon contents above 2.5%, whereas the instant invention atfords unusual advantages in permitting the use of high carbon contents in workable alloys.
• the dispersed phase in the cobalt System will consist primarily of carbides. Also, it is generally understood that the dispersed phase in a cobalt-chromium-tungsten alloy, forming the subject matter of the instant alloy, will be predominantly tungsten carbide (but with some chromium carbide). Other alloying metals are included, however, and these various metals include such typical carbide formers as Mo and Cb. Although it is generally believed that substantially all of the Co remains in the continuous or matrix phase, it is believed that the other elements partition between the continuous phase and the carbide phases.
• molybdenum is readily compatible with the instant cobalt-chromium-tungsten-carbide system and the previously mentioned percentage indicated by x may consist substantially entirely of molybdenum (see alloy E hereinafter), because of its similarity to W in behavior in this system.
• alloy E hereinafter
• these relatively minor proportions of other alloying elements it is generally found that they are preferably used in amounts that are not substantially in excess of about 5%; and in those cases in which either iron or nickel is used as an alloying element it is generally preferable to use both materials, each in proportions less than substantially 5% and totalling less than substantially 9%.
• molybdenum is used in proportions as high as 7.5%, it may be used in an amount of at least 20% particularly as a substitute for its sister element W. It may also be used in lower proportions and in combinations with various of the other alloying materials such as iron and nickel hereinbefore described, the alloys which do contain iron and nickel ordinarily contain both of these elements and they are in amounts preferably of less than 4% in each instance.
• columbium which may be completely replaced by its sister element Ta
• columbium is not necessarily preferably used in combination with the other previously described relatively minor alloying metals such as molybdenum, iron and nickel.
• alloying metals used in x% need be used in measurable chemical quantities in the composition, although it must be understood that it is generally a practical impossibility to avoid at least trace proportions of at least some of these to appear in the alloy (as in the case of the alloy of alloy H on Table I), and it is for this reason that the percentage range for the figure x is indicated as ranging from trace amounts to substantially 20%.
• each of the alloys is described in terms of the identifiable chemical elements present therein, which are readily identified, and the remainder is described as being substantially cobalt, but with the obvious understanding to those skilled in the art that absolute purity in the case of any of these metallic elements is almost a practical impossibility and the remainder of substantially cobalt must be understood to contain inherently minor amounts (generally not totalling in excess of about 0.5%) of P, S, O, N or the like impurities as well as at least trace quantities (and perhaps as much as 2 /2%) of other compatible alloying metals, which are not identifiable readily in chemical composition and which substantially dissolve or otherwise disappear in the overall alloy structure, such that their presence, if it does exist, is not significant either from the point of view of chemical composition or from the point of view of the ultimate alloy structures here obtained.
• the total amount of molten alloying composition used was five pounds, heated in each case to a temperature of substantially 2800 F. and fed by gravity as a free falling stream of inch diameter through an orifice of inch diameter downwardly into the atomizing vessel, which was sealed against ambient atmosphere.
• a (conically) annular orifice aimed to impinge 2 to 3 inches below the alloy orifice exit, having an annular radial dimension of 0.05 inch through which argon at ambient temperature was fed using an argon back pressure on the orifice of 350 pounds per square inch, gauge.
• the overall volume of the gas space is the dispersion vessel is substantially 8 cubic feet and the vessel was sealed except for peripheral argon pressure bleed-ofi vents, at which the argon is bled from the vessel at substantially to to 10 pounds per inch gauge pressure.
• water is introduced initially at temperatures within the range of 33 F. to 50 F. to form a pool at a relatively low level but upon initiation of atomization the warm solidified particles appear to drive water liquid and/or vapor peripherally upward in the atomizing vessel.
• the coolant water circulates in the atomization vessel.
• the droplets are quenched in an extremely rapid manner so that all or substantially all of these droplets retain their minute discrete size and are non-agglomerative or non-tacky in character in the argon even before reaching the water.
• the total time which the molten alloy takes from the entrance of the molten stream via the orifice to the quench to non-agglomerative particles is very brief, such that the droplet formation in the discrete particle size desired (and ultimately measurable in the solid powder form) is obtained by the gaseous impact very rapidly and the agitation effect and quenching of the violent circulation of gases above the water pool is such as to generally cause uniform particle size formation, but not completely uniform size formation as the subsequent solidified powder mesh sizes indicate.
• the impact of the gases carries out the function of reduction to the very fine droplet size so that the quenching in the gases will also cause extremely rapid solidification and thus preclude agglomeration of the particles per se and also prevent excessive precipitation of the submicroscopic dispersed phase (i.e. carbides) in this particular alloy.
• the submicroscopic dispersed phase i.e. carbides
• the separation of the solidified powders from the water pool is, of course, a simple matter of passing these through a suitable strainer and/ or passing the wet powder into a suitable low temperature evaporator or drier, so that the powdered alloy particles are then obtained in a desired condition.
• the mesh sizes are indicated at the end of Table I.
• Typical mesh sizes are 10% above mesh, 70% in the range of 80 to 32:5, and 20% less than 325 mesh.
• Dispersed phase in the freeflowlng powders in the alloys A through M are of substantially submlcroscopic size.
• the nominal growth of the dispersed phase e.g. carbides
• the nominal growth of the dispersed phase has occurred to the extent that they are substantially within the range from micron to 3 microns.
• dispersed phase e.g. carbides
• dispersed phase e.g. carbides
• the consolidation of the separate alloys was carried out by a hot working technique protecting the alloy composition.
• only those powders from the tests passing the 80 mesh screen were collected separately in amounts of substantially 200 grams and sealed in a thin (i.e. about 0.1 inch) steel jacket (or Inconel" when preferred) that was functionally inert relative to the alloy powder but protective from ambient atmosphere, etc.; and the canned powder specimen was forged after heating to a billet temperature of 2175 F., and then hot rolled to substantially an alloy sheet of 0.060 inch thickness at hot working billet temperatures for such powder and resultant alloy sheet of substantiaally 2150 F.
• hot working involves a pressure as well as a temperature and time conditions, but the temperature can only be expressed as billet temperatures and should not be above substantially 2175 F., however, if there is an increase in the consolidation pressure a corresponding decrease in temperature will be most advantageous as this will prevent undue carbide growth and/ or agglomeration.
• the pressures being impractical to evaluate numerically, are those sufficient to the skilled worker to forge and/or roll the canned alloy thus heated to sheet thickness (or other shape, if such is desired) specified using conventional alloy hot working equipment and pressure ranges.
• the alloying composition in the liquefied droplets is heated or otherwise converted to a single metallurgical phase, in liquid form; and this effects, with the present rapid quenching, particles which contain minute submicroscopic dispersed carbide phases.
• the dispersed phase is characterized by a structure generally within substantially the size range of A1 or less up to slightly less than about 3 microns even after consolidation.
• dispersed phase of which the carbide phase has been considered in detail above refers to a material having a VPN of greater than 1200 and a melting point of greater than 3000 F.
• Such dispersed phase in the present alloy systems after consolidation, rarely or occasionally in the powders prior to consolidation, has a size ranging from 1 4 to 3 microns. Such phase is uniformly dispersed.
• Tantung-G a commercial alloy having approxlmatel 30% Cr, 15% W, 2.5% C with remainder substantially Co Tantung l44" a comrncrical alloy simiiar to alloy No. 7. GVgi v 1 5% M0, 4% Cr, 5% V, 1.4% C, remainder substan- 10 fi'yiawngfilizlgMo, 4% Or, 5% V, 1.7% O, remainder substan- 11 filagxg fig a'Mo, 4% Cr, 5% V, 1.7% C, remainder substan- 12 5233-11110, 4% Cr, 5% V, 1.55% C, remainder substan- 13 fi%islllt;,s fi%.Mo, 4% Cr, 5% V, 1.8% C, remainder substan- 14 6% W, 5% Mo, 4% Cr, 5% V, 1.8% C, remainder substantially Fe.
• mainder substantially Fe.
• mainder substantially Ni. 40 W, 10% Co 15% Cr, 3% Ti, 1.5% A1, 2% C, remainder substantially i. 41 16.8% Co, 20.15% Cr, 5% M0, 3.25% Ti, 3.72% 141,0.955 C,
• alloy compositions set forth in Tables I and III are specific examples of solid alloys prepared by hot consolidation of prcalloyed powders in accordance with the present invention.
• Alloy No. 38 all of the examples disclosed are alloys in which the base metal (M is cobalt, iron, nickel or a mixture thereof.
• Alloy N0. 38 consists essentially of 56 weight percent tungsten, 40 weight percent cobalt and 3.6 weight percent carbon and properly should be termed a tungsten carbide alloy rather than a cobaltbase alloy inasmuch as this alloy does not contain at least 50 percent cobalt.
• each of the other 57 alloys disclosed herein is a specific example of a class of iron group-base alloys (cobalt-, ironor nickel-base) which exhibit the following compositional characteristics:
• All of the examples of iron group-base alloys contain in the range of from 0.8 to 3.4% carbon.
• All of the examples of iron group-base alloys contain substantial amounts of carbide forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb and V. More than half of the alloys disclosed contain 30% or more carbide forming elements. All of the cobalt-base alloys contain in excess of 30% carbide formers and more specifically in the range of 45 to 54% carbide formers.
• All of the examples of iron group-base alloys contain in the range of from 43.5 to 81.2% base metal (M and in the range of from 0 to 35.45% chromium. In each example the amount of M exceeds the amount of chromium.
• All of the examples of iron group-base alloys which include chromium as an alloying constituent contain in the range of from 43.5 to 81.2% base metal, and in the range of from 7.6 to 38.3% carbide formers other than chromium. In each example the amount of M exceeds the total amount of carbide formers other than chromium.
• All of the examples of iron group-base alloys contain a total amount of base metal plus chromium in the range of from 50 to 87%. In each example the total amount of M plus chromium is at least 50%.
• An alloying process which comprises (2 generating an atomized dispersion of metallic droplets in an atomizing gas that is essentially chemically inert to the metallic droplets, wherein the metallic droplets each consist essentially of a substantially single metallurgical liquid phase of a liquefied alloying composition, and
• M is selected from the group consisting of Fe, Ni,
• Cb and Ta and x is a percent ranging from trace amounts to substantially 10%
• An alloying process which comprises (a generating an atomized dispersion of metallic droplets in an atomizing fluid that is essentially chemically inert to the metallic droplets, wherein the metallic droplets each consist essentially of a substantially single metallurgical liquid phase of a liquefied alloying composition,
• said alloying composition consisting essentially of 10% to 45% Cr 1% to 3.5% C (40z)% W (20z)% Mo x% M Balance Co wherein the Co content is at least substantially 35%, z ranges from to 20% M is selected from the group consisting of Fe, Ni,
• An alloying process which comprises (a;) generating an atomized dispersion of metallic droplets in an atomizing gas that is essentially chemically inert to the metallic droplets, wherein the metallic droplets each consist essentially of a substantially single metallurgical liquid phase of a liquefied alloying composition, and (a cooling substantially all of said metallic droplets rapidly to obtain solidified fine particles, each of which is a discrete solid alloy particle consisting substantially entirely of a single metallurgical solid phase under microscopic examination and wherein any second metallurgical phase is dispersed and is substantially entirely submicroscopic, said alloying composition consisting essentially of 10% to 45% Cr 1% to 3.5% C (40z)% W (z)% Mo x% M Balance Co 12 wherein the Co content is at least substantially 35%, z ranges from 0 to 20%, M is selected from the group consisting of Fe, Ni,
• Free-flowing powdered alloy formed essentially of generally discrete individual bodies of supersaturated solid solutions of an alloying composition, each of which particles consist of substantially entirely a single metallurgical solid phase under microscopic examination and wherein any second metallurgical phase is submicroscopic said alloying composition consisting essentially of 10% to 45% Cr 1% to 3.5% C
• M is selected from the group consisting of Fe, Ni, Cb and Ta and x is a percent ranging from trace amounts to substantially 10%; plus minute trace amounts of incidental impurities.
• a consolidated integral alloy body which is substantially dense formed of a hot worked super-saturated solid solution of an inherently alloying composition, said alloy body consisting essentially of a continuous metallurgical phase with a uniformly dispersed solid phase of minute dispersed phase particle sizes that are substantially entirely less than three microns in maximum dimension, said alloying composition consisting essentially of 10% to 45% Cr 1% to 3.5% C
• Co content is at least substantially 35%
• M is selected from the group consisting of Fe, Ni, Cb and Ta and x is a percent ranging from trace amounts to substantially 10%; plus minute trace amounts of incidental impurities.
• composition as claimed in claim 5 wherein said composition consists essentially of 14% to 35% Cr 15% to 38% W 1.5% to 3.5% C remainder substantially Co in an amount totalling at least 35%, plus incidental impurities comprising at least trace amounts each of O, S, N and P but the total amount of said impurities not exceeding substantially 0.5%.
• a method of producing a solid alloy suitable for forming into a cutting tool comprising, providing atomized pre-alloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of, from about 0.60% to about 5% carbon, at least 30% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, Zr, Hf and V and the remainder M and incidental impurities, wherein M is selected from the group consisting of cobalt, iron and nickel, and wherein the amount of M exceeds the amount of chromium, and the amount of M exceeds the total amount of carbide formers other than chromium, and the total amount of M plus chromium is at least 50%, compressing and mechanically hot working said powder to effect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method of producing a solid cobalt base alloy suitable for forming into a cutting tool comprising, providing atomized pre-alloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of from about 0.60% to about carbon, at least 30% carbideforming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, Zr, Hf and V, the remainder cobalt and incidental impurities and wherein the amount of cobalt exceeds the amount of chromium and the amount of cobalt exceeds the total amount of carbide formers other than chromium, and the total amount of cobalt plus chromium is at least 50%, compressing and mechanically but working said powder to efiect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid alloy suitable for forming into a cutting tool from pre-alloyed powder prepared under conditions of production which result in the substantial elimination of the formation of coarse crystals of dispersed phases comprising providing such pre-alloyed powder of an alloy having a composition consisting essentially of in the range of from 0.5 to 5.0 weight percent carbon, at least weight percent of a carbide-forming element selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, Zr, Hf, V and mixtures thereof and the remainder M and incidental impurities, wherein M is selected from the group consisting of cobalt, iron and nickel and mixtures thereof, and wherein the total amount of M is at least 30 weight percent, compressing and mechanically hot working said powder in an environment protected against admission of oxygen from outside said environment, to produce directly from said powder a solid material of a density substantially equivalent to the alloy in its cast state, said solid material having a hardening phase with a particle size predominantly less than 3 microns substantially uniformly dispersed throughout the major phase
• pre-alloyed powder is an atomized powder which is subjected to hot consolidation treatment while sealed within a container.
• An alloying process which comprises generating an atomized dispersion of metallic droplets in an atomizing gas that is essentially chemically inert to the metallic droplets wherein the metallic droplets each consist essentially of a substantially uniform homogeneous dispersion of alloying composition,
• alloying composition consisting essentially by weight of from about 0.5% to about 5.0% carbon, at least 10% of a hard phase-forming element selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, Zr, Hf, V and Al, and mixtures thereof, and the remainder base metal and incidental impurities, wherein said base metal is selected from the group consisting of cobalt, iron and nickel, and wherein the total amount of base metal is at least 30%.
• An alloying process which comprises generating an atomized dispersion of metallic droplets in an atomizing gas that is essentially chemically inert to the metallic droplets, wherein the metallic droplets each consist essentially of a substantially single metallurgical liquid phase of a liquefied alloying composition,
• Co content is at least substantially 35%
• M is selected from the group consisting of Fe, Ni, Cb and Ta
• x is a percent ranging from trace amounts to substantially 10%; plus minute trace amounts of incidental impurities.
• a method for producing a solid alloy suitable for forming into a cutting tool comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of from about 0.8% to about 3.4% carbon, at least 30% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, and the remainder base metal and incidential impurities, wherein said metal is selected from the group consisting of cobalt, iron and nickel, and wherein the amount of base metal exceeds the amount of chromium, and the amount of base metal exceeds the total amount of carbide formers other than chromium, and the total amount of base metal plus chromium is at least 50%, compressing and mechanically hot working said powder to elfect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid alloy suitable for forming into a cutting tool comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of from about 0.8% to about 3.4% carbon, in the range of from 30-54% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, and the remainder base metal and incidental impurities, wherein said base metal is selected from the group consisting of cobalt, iron and nickel, and wherein the amount of base metal exceeds the amount of chromium, and the amount of base metal exceeds the total amount of carbide formers other than chromium, and the total amount of base metal plus chromium is at least 50%, compressing and mechanically hot Working said powder to effect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid alloy suitable for forming into a cutting tool comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of from about 0.8% to about 3.4% carbon, in the range of from 30-54% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, and the remainder base metal and incidental impurities, wherein said base metal is selected from the group consisting of cobalt, iron and nickel, and wherein the amount of base metal is in the range of from 43.5-81.2%, the amount of chromium is in the range of from -35.45 the total amount of carbide formers other than chromium is in the range of from 7.6-38.3%, and the total amount of base metal plus chromium is in the range of from 50- 87%, compressing and mechanically hot working said powder to effect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid cobaltbase alloy comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25 diameter with a composition consisting essentially of 2.05% carbon, 52.95% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, and the remainder cobalt and incidental impurities, and wherein the amount of cobalt is 45%, the amount of chromium is 35.45%, the total amount of carbide formers other than chromium is 17.5%, and the total amount of cobalt plus chromium is 80.45%, compressing and mechanically hot working said powder to efiect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid iron-base alloy comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of 2.85% carbon, 32% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, and the remainder base metal and incidental impurities,
• said base metal consists of 57.15% iron and i 8% cobalt (based upon the total alloy composition), and wherein the total amount of base metal is 65.15%, the amount of chromium is 15%, the total amount of carbide formers other than chromium is 17%, and the total amount of base metal plus chromium is 80.15%, compressing and mechanically hot working said powder to effect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid nickel-base alloy comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of 2% carbon, 33% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, and the remainder base metal and incidental impurities, wherein said base metal consists of 53.5% nickel, cobalt and 1.5% aluminum (based upon total alloy composition), and wherein the total amount of base metal is 65%, the amount of chromium is the total amount 16 of carbide formers other than chromium is 18% and the total amount of base metal plus chromium is compressing and mechanically hot working said powder to effect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid cobalt-base alloy suitable for forming into a cutting tool comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of from about 2.05 to about 3% carbon, at least 30% carbideforming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, the remainder cobalt and incidental impurities, and wherein the amount of cobalt exceeds the amount of chromium, and the amount of cobalt exceeds the total amount of carbide formers other than chromium, and the total amount of cobalt plus chromium is at least 50%, compressing and mechanically hot working said powder to effect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid cobalt base alloy suitable for forming into a cutting tool comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of from about 2.05% to about 3% carbon, in the range of from 45-54% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, the remainder cobalt and incidental impurities, and wherein the amount of cobalt exceeds the amount of chromium, and the amount of cobalt exceeds the total amount of carbide formers other than chromium, and the total amount of cobalt plus chromium is at least 50%, compressing and mechanically hot working said powder to elfect a solid material of a density substantially equivalent to the alloy in its cast state.
• a method for producing a solid cobalt base alloy suitable for forming into a cutting tool comprising, providing atomized prealloyed powder of said alloy having a particle size of not more than .25" diameter with a composition consisting essentially of from about 2.05% to about 3% carbon, in the range of from 45-54% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, the remainder cobalt and incidental impurities, and wherein the amount of cobalt is in the range of from 43.552.5%, the amount of chromium is in the range of from 035.45%, the total amount of carbide formers other than chromium is in the range of from 15-38.3%, and the total amount of cobalt plus chromium is in the range of from 50-82.5%, compressing and mechanically hot working said powder to effect a solid material of a density substantially equivalent to the alloy in its case state.
• a consolidated integral alloy body which is substantially dense formed of a hot worked supersaturated solid solution of an inherently alloying composition, said alloy body consisting essentially of a continuous metaliurgical phase with a uniformly dispersed solid phase of minute dispersed phase particle sizes that are substantially entirely less than three microns in maximum dimension, said alloying composition consisting essentially of from about 0.8% to about 3.4% carbon, in the range of from 30-54% carbide-forming elements selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, and V, and the remainder base metal and incidental impurities, wherein said base metal is selected from the group consisting of cobalt, iron and nickel, and wherein the amount of base metal is in the range of from 43.5-81.2%, the amount of chromium is in the range of from 0-35.45 the total amount of carbide formers other than chromium is in the range of from 7.638.3%, and the total amount of base metal plus chromium is in the range of from 50-87%.
• a consolidated integral alloy body which is substantially fully dense formed of a hot worked supersaturated solid solution of an inherently alloying composition, said alloy body consisting essentially of a continuous metallurgical phase with a uniformly dispersed hard phase of minute dispersed hard phase particle sizes that are substantially entirely less than three microns in maximum dimension, said alloying composition consisting essentially by weight of from about 0.5% to about 5.0% carbon, at least 10% of a hard phase-forming element selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, Zr, Hf, V and Al, and mixtures thereof, and the remainder base metal and incidental impurities, wherein said base metal is selected from the group consisting of cobalt, iron and nickel, and wherein the total amount of base metal is at least 30%.
• a method for producing a consolidated, fully dense alloy from pre-alloyed powder prepared under conditions of production which result in the substantial elimination of the formation of coarse crystals of dispersed phases comprising providing such pre-alloyed powder of an alloy having a composition consisting essentially of in the range of from 0.5 to 5.0 weight percent carbon, at least 10 weight percent of a hard phase-forming element selected from the group consisting of Cr, W, Mo, Ti, Ta, Cb, Zr, Hf, V, Al, and mixtures thereof, and the remainder base metal and incidental impurties, wherein said base metal is selected from the group consisting of cobalt,

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• 1965
  • 1965-02-26 US US00435733A patent/US3746518A/en not_active Expired - Lifetime
• 1966
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