US3793160A - Method of forming case-hardened metals by electrolysis - Google Patents
Method of forming case-hardened metals by electrolysis Download PDFInfo
- Publication number
- US3793160A US3793160A US00098898A US3793160DA US3793160A US 3793160 A US3793160 A US 3793160A US 00098898 A US00098898 A US 00098898A US 3793160D A US3793160D A US 3793160DA US 3793160 A US3793160 A US 3793160A
- Authority
- US
- United States
- Prior art keywords
- metal
- boron
- salt bath
- alkali metal
- composition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Lifetime
Links
- 239000002184 metal Substances 0.000 title claims abstract description 101
- 229910052751 metal Inorganic materials 0.000 title claims abstract description 100
- 238000000034 method Methods 0.000 title claims abstract description 63
- 150000002739 metals Chemical class 0.000 title abstract description 29
- 238000005868 electrolysis reaction Methods 0.000 title description 3
- 150000003839 salts Chemical class 0.000 claims abstract description 73
- 229910052796 boron Inorganic materials 0.000 claims abstract description 51
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims abstract description 47
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 25
- 230000008569 process Effects 0.000 claims abstract description 25
- 239000010959 steel Substances 0.000 claims abstract description 25
- 229910001508 alkali metal halide Inorganic materials 0.000 claims abstract description 21
- 229910052783 alkali metal Inorganic materials 0.000 claims abstract description 18
- 150000001340 alkali metals Chemical class 0.000 claims abstract description 18
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 18
- 239000000956 alloy Substances 0.000 claims abstract description 18
- 150000008045 alkali metal halides Chemical class 0.000 claims abstract description 16
- 229910001615 alkaline earth metal halide Inorganic materials 0.000 claims abstract description 5
- 239000000203 mixture Substances 0.000 claims description 47
- -1 halide salt Chemical class 0.000 claims description 22
- 238000000576 coating method Methods 0.000 claims description 19
- 239000011734 sodium Substances 0.000 claims description 18
- DGAQECJNVWCQMB-PUAWFVPOSA-M Ilexoside XXIX Chemical group C[C@@H]1CC[C@@]2(CC[C@@]3(C(=CC[C@H]4[C@]3(CC[C@@H]5[C@@]4(CC[C@@H](C5(C)C)OS(=O)(=O)[O-])C)C)[C@@H]2[C@]1(C)O)C)C(=O)O[C@H]6[C@@H]([C@H]([C@@H]([C@H](O6)CO)O)O)O.[Na+] DGAQECJNVWCQMB-PUAWFVPOSA-M 0.000 claims description 15
- 229910052708 sodium Inorganic materials 0.000 claims description 15
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 claims description 14
- 239000011248 coating agent Substances 0.000 claims description 14
- 238000002844 melting Methods 0.000 claims description 14
- 230000008018 melting Effects 0.000 claims description 14
- KWGKDLIKAYFUFQ-UHFFFAOYSA-M lithium chloride Chemical compound [Li+].[Cl-] KWGKDLIKAYFUFQ-UHFFFAOYSA-M 0.000 claims description 12
- 229910001514 alkali metal chloride Inorganic materials 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 10
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 8
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 claims description 8
- 229910052721 tungsten Inorganic materials 0.000 claims description 8
- 239000010937 tungsten Substances 0.000 claims description 8
- 229910052750 molybdenum Inorganic materials 0.000 claims description 7
- 239000011733 molybdenum Substances 0.000 claims description 7
- 239000011780 sodium chloride Substances 0.000 claims description 7
- 229910000975 Carbon steel Inorganic materials 0.000 claims description 6
- 229910052715 tantalum Inorganic materials 0.000 claims description 6
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 claims description 6
- 239000003638 chemical reducing agent Substances 0.000 claims description 5
- KRHYYFGTRYWZRS-UHFFFAOYSA-M Fluoride anion Chemical compound [F-] KRHYYFGTRYWZRS-UHFFFAOYSA-M 0.000 claims description 4
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 claims description 4
- 239000010936 titanium Substances 0.000 claims description 4
- 229910052719 titanium Inorganic materials 0.000 claims description 4
- 229910000851 Alloy steel Inorganic materials 0.000 claims description 2
- 239000010962 carbon steel Substances 0.000 claims description 2
- 150000001638 boron Chemical class 0.000 abstract description 20
- 238000005271 boronizing Methods 0.000 abstract description 12
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 abstract description 10
- 230000001464 adherent effect Effects 0.000 abstract description 9
- 229910052799 carbon Inorganic materials 0.000 abstract description 9
- 230000007797 corrosion Effects 0.000 abstract description 5
- 238000005260 corrosion Methods 0.000 abstract description 5
- 238000004519 manufacturing process Methods 0.000 abstract description 2
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 9
- 238000007654 immersion Methods 0.000 description 6
- 230000035515 penetration Effects 0.000 description 6
- 239000000470 constituent Substances 0.000 description 5
- 238000001816 cooling Methods 0.000 description 5
- 150000004820 halides Chemical class 0.000 description 5
- 229910000788 1018 steel Inorganic materials 0.000 description 4
- 229910000640 Fe alloy Inorganic materials 0.000 description 4
- CWYNVVGOOAEACU-UHFFFAOYSA-N Fe2+ Chemical compound [Fe+2] CWYNVVGOOAEACU-UHFFFAOYSA-N 0.000 description 4
- ZLMJMSJWJFRBEC-UHFFFAOYSA-N Potassium Chemical compound [K] ZLMJMSJWJFRBEC-UHFFFAOYSA-N 0.000 description 4
- 230000008021 deposition Effects 0.000 description 4
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 230000000737 periodic effect Effects 0.000 description 4
- 229910052700 potassium Inorganic materials 0.000 description 4
- 239000011591 potassium Substances 0.000 description 4
- 229910001220 stainless steel Inorganic materials 0.000 description 4
- 150000001450 anions Chemical class 0.000 description 3
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 3
- 239000004327 boric acid Substances 0.000 description 3
- 150000001639 boron compounds Chemical class 0.000 description 3
- 150000001768 cations Chemical class 0.000 description 3
- 238000009792 diffusion process Methods 0.000 description 3
- 239000003921 oil Substances 0.000 description 3
- 235000006408 oxalic acid Nutrition 0.000 description 3
- 239000010935 stainless steel Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000011282 treatment Methods 0.000 description 3
- CURLTUGMZLYLDI-UHFFFAOYSA-N Carbon dioxide Chemical compound O=C=O CURLTUGMZLYLDI-UHFFFAOYSA-N 0.000 description 2
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 2
- 238000007547 Knoop hardness test Methods 0.000 description 2
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 230000002411 adverse Effects 0.000 description 2
- 229910052784 alkaline earth metal Inorganic materials 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 239000002585 base Substances 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000004020 conductor Substances 0.000 description 2
- 238000000354 decomposition reaction Methods 0.000 description 2
- 238000004141 dimensional analysis Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 230000004927 fusion Effects 0.000 description 2
- 238000010438 heat treatment Methods 0.000 description 2
- 239000001257 hydrogen Substances 0.000 description 2
- 229910052739 hydrogen Inorganic materials 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 239000012535 impurity Substances 0.000 description 2
- 229910052744 lithium Inorganic materials 0.000 description 2
- 229910052758 niobium Inorganic materials 0.000 description 2
- 239000010955 niobium Substances 0.000 description 2
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 239000000758 substrate Substances 0.000 description 2
- UONOETXJSWQNOL-UHFFFAOYSA-N tungsten carbide Chemical compound [W+]#[C-] UONOETXJSWQNOL-UHFFFAOYSA-N 0.000 description 2
- VZSRBBMJRBPUNF-UHFFFAOYSA-N 2-(2,3-dihydro-1H-inden-2-ylamino)-N-[3-oxo-3-(2,4,6,7-tetrahydrotriazolo[4,5-c]pyridin-5-yl)propyl]pyrimidine-5-carboxamide Chemical compound C1C(CC2=CC=CC=C12)NC1=NC=C(C=N1)C(=O)NCCC(N1CC2=C(CC1)NN=N2)=O VZSRBBMJRBPUNF-UHFFFAOYSA-N 0.000 description 1
- 238000012935 Averaging Methods 0.000 description 1
- 229910000521 B alloy Inorganic materials 0.000 description 1
- BTBUEUYNUDRHOZ-UHFFFAOYSA-N Borate Chemical compound [O-]B([O-])[O-] BTBUEUYNUDRHOZ-UHFFFAOYSA-N 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 1
- 241001397173 Kali <angiosperm> Species 0.000 description 1
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 1
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 1
- 229910020808 NaBF Inorganic materials 0.000 description 1
- 238000002441 X-ray diffraction Methods 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 229910001515 alkali metal fluoride Inorganic materials 0.000 description 1
- 150000001342 alkaline earth metals Chemical class 0.000 description 1
- 238000000137 annealing Methods 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- WDIHJSXYQDMJHN-UHFFFAOYSA-L barium chloride Chemical compound [Cl-].[Cl-].[Ba+2] WDIHJSXYQDMJHN-UHFFFAOYSA-L 0.000 description 1
- 229910001626 barium chloride Inorganic materials 0.000 description 1
- 239000011324 bead Substances 0.000 description 1
- 230000008901 benefit Effects 0.000 description 1
- 238000009835 boiling Methods 0.000 description 1
- 229910021538 borax Inorganic materials 0.000 description 1
- 229910052810 boron oxide Inorganic materials 0.000 description 1
- 150000001642 boronic acid derivatives Chemical class 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910001628 calcium chloride Inorganic materials 0.000 description 1
- 239000001110 calcium chloride Substances 0.000 description 1
- 239000001569 carbon dioxide Substances 0.000 description 1
- 229910002092 carbon dioxide Inorganic materials 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 238000001311 chemical methods and process Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 150000003841 chloride salts Chemical class 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 description 1
- 238000006073 displacement reaction Methods 0.000 description 1
- 238000003411 electrode reaction Methods 0.000 description 1
- 238000009713 electroplating Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 150000002431 hydrogen Chemical class 0.000 description 1
- 229910000039 hydrogen halide Inorganic materials 0.000 description 1
- 239000012433 hydrogen halide Substances 0.000 description 1
- 238000005470 impregnation Methods 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 239000011261 inert gas Substances 0.000 description 1
- 229910000765 intermetallic Inorganic materials 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 229910001092 metal group alloy Inorganic materials 0.000 description 1
- VUZPPFZMUPKLLV-UHFFFAOYSA-N methane;hydrate Chemical compound C.O VUZPPFZMUPKLLV-UHFFFAOYSA-N 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 239000000376 reactant Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 239000012279 sodium borohydride Substances 0.000 description 1
- 229910000033 sodium borohydride Inorganic materials 0.000 description 1
- 239000004328 sodium tetraborate Substances 0.000 description 1
- 235000010339 sodium tetraborate Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000011343 solid material Substances 0.000 description 1
- 239000006104 solid solution Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 230000004580 weight loss Effects 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C8/00—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
- C23C8/40—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using liquids, e.g. salt baths, liquid suspensions
- C23C8/42—Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using liquids, e.g. salt baths, liquid suspensions only one element being applied
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D11/00—Electrolytic coating by surface reaction, i.e. forming conversion layers
- C25D11/02—Anodisation
- C25D11/028—Borodising,, i.e. borides formed electrochemically
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D3/00—Electroplating: Baths therefor
- C25D3/66—Electroplating: Baths therefor from melts
Definitions
- a process of boronizing a metal article which comprises immersing the selected metal article in a fused bath composed of at least one alkali metal halide or alkaline earth metal halide and a boron salt of the empirical formula M .B,,F 2 wherein M is an alkali metal, and the ratio of x:y:z is 1:0.4 to 20:05 to 2.5 with y being preferably above 1 and z is preferably below 1.5, the fused bath being maintained at a temperature between 1200F to 1750F for a sufficient duration to impregnate the metal with boron.
- novel boron products, their process of manufacture and salt baths containing such boron products The process produces an extremely hard, uniform, adherent and corrosion resistant boride casing on metals such as carbon and alloy steels.
- This invention relates to boron salts, their preparation and use in a fused salt bath to case-harden metals.
- One of the processes used for the preparation of a boride coating on a metal comprises exposing the metal article to the vapors of a boron halide at a temperature sufficient to cause the halide to decompose and deposit a coating of boron on the metal. The metal is then heated to a still higher temperature to cause the boron to diffuse into and alloy with the metal. In the absence of a reducing gas, a displacement reaction occurs in which some of the metal replaces the boron in the boron halide. In the presence of hydrogen, the boron halide is reduced to boron and hydrogen halide.
- the rate of deposition of the boron is very dependent on the velocity of the boron halide over the surface and the temperature of the article being coated. Since these conditions are difficult to control, especially for large or irregular shaped articles, the coatings are usually not uniform over the entire surface.
- Boride coatings have also been deposited on ferrous alloys by electrolyzing a fused bath of a boron compound such as boron oxide, boric acid, borax, etc., using the ferrous alloy article as the cathode and graphite as the anode. Voltages of 4-40 volts and a current density of 50-100 amperes per square decimeter are required. Lower current densities permit the ferrous alloy to be dissolved in the bath at a rate faster than the boron is deposited on the alloy, so that there is a net weight loss. This effect is very noticeable with the boron compounds which are acidic such as boric acid or boron compounds containing boric acid as an impurity.
- boride coatings have been produced electrolytically using a fused bath composed of at least one alkali metal fluoride and at least one alkali metal fluoborate (NaBF This process is carried out in an electric cell in which an electric current is generated when an external electrical connection is made between a metal cathode and a boron anode.
- a fused bath composed of at least one alkali metal fluoride and at least one alkali metal fluoborate (NaBF
- NaBF alkali metal fluoborate
- Case hardening of metals by impregnation of metal surfaces with boron has also been carried out using a boronizing bath composed of one or more borates.
- the boron is either introduced into the bath as elemental boron or a metal is introduced into the bath e.g., calcium, which will in situ liberate boron from the borate base material in the bath.
- the boron liberating metal is introduced into the bath in ignot form under an inert atmosphere.
- a uniform, adherent, corrosion resistant boride coating can be produced by a simple process using a fused bath containing a boron salt of the empirical formula M,,B,,F wherein M is an alkali metal, B stands for boron, and F is the fluoride ion, which does not use any externally supplied electric current and is carried out under normal atmospheric conditions and temperatures at least as low as those previously employed in the prior art.
- one aspect of the present invention is to provide a relatively inexpensive, simple and effective diffusion process for boronizing a metal article using a fused salt bath containing a boron salt of the empirical formula M,B,,F, which does not require externally supplied electric current or special equipment or process conditions such as a boron anode, an inert atmosphere, highly purified chemicals and a specially designed electric cell.
- Another aspect of the present invention relates to novel boron salts of the empirical formula M B F in which the ratio ofx:y:z is 1:04 to 220.5 to 2.5 which are employed in a fused salt bath containing at least one alkali metal halide and/or alkaline-earth halide to produce a boronized metal article.
- Yet another aspect of the present invention relates to boronized metal articles such as carbon and alloy steels having a uniform, adherent, tough, corrosion resistant coating and a hardness comparable to tungsten carbide.
- a further aspect of the present invention relates to novel fused salt bath compositions for use in casehardening metal articles.
- An additional aspect of the invention relates to processes of producing the novel boron salts of the empiri-' cal formula M,,,B,,F' wherein the ratio of x:y: z is 110.4 to 2:0.5 to 2.5. a 7
- a uniform, non-porous, adherent, corrosion resistant coating can be formed on specific metals by a diffusion process employing a fused salt bath wherein an electrical circuit is formed through an electrical connection, which is external to the salt bath, between the pot containing the salt bath and the metal sample holder which holds the sample to be borided.
- This process produces boronized metal articles of extremely high hardness which is at least equal to and in many cases substantially greater than the hardness heretofore attainable in borided metals obtained in accordance with prior art processes.
- a boride case means any solid solution or alloy of boron and metal regardless of whether the metal forms an intermetallic compound with boron (e.g., FeB or Fe B in a boronized ferrous base alloy) in stoichiometric proportions which can be represented by a chemical formula.
- boronized metal means a metal article in which boron has been diffused into the core of the metal without forming a substantial overlying boron coating on the surface of the metal article.
- the boronizing process of my invention may be carried out in a stainless steel or silicon carbide pot.
- An electric circuit is formed external to the fused salt bath by using a conductor to join the pot containing the salt bath to the metal holder from which the sample is suspended into the bath.
- the salt bath contains at least one alkali metal halide and/or alkaline earth halide in addition to the selected novel boron salt.
- the boron products produced by the present invention have not been definitely proven to be chemical compounds as contrasted with mixtures and therefore will be referred to as chemical products.
- novel boron products of this invention conform to the empirical formula M B F in which M is an alkali metal e.g., sodium, lithium, potassium, etc., B is boron, F is a fluoride ion and the ratio of x:y:z is 120.4 to 2:05 to 2.5.
- the preferred products used in the fused salt bath have the empirical formula M B F wherein M is an alkali metal and the ratio of x:y:z is 1:1 to 210.5 to 1.5.
- novel boron salts may be produced by reducing an alkali metal fluoborate with a reducing agent such as amorphous boron.
- a reducing agent such as amorphous boron.
- Other reducing agents such as oxalic acid, sodium borohydride, metallic alkali metals, e.g., sodium, potassium, etc., mixtures of amorphous boron with metallic sodium, etc., can be employed suitably for reducing the alkali metal fluoborate.
- the foregoing process is carried out just above the melting point of the alkali metal fluoborate that is being used.
- alkali metal boron salts of the empirical formula M B F are the more desirable boron salts
- the drawback to using alkaline earth boron salts in place of al-' kali metal boron salts, particularly when treating ferrous alloys is that the alkaline earth boron salts have substantially higher melting and decomposition points than the corresponding alkali metals.
- the required operating temperatures would damage the ferrous alloy causing warpage, distortion, etc. which is obviously undesirable.
- boronizing metals such as tungsten, molybdenum and other metals which will not be damaged at thehigh temperature required for melting the alkaline earth boron salts in the fused bath
- such salts can be employed to good advantage.
- boron salts are employed in accordance with the invention in a fused salt bath composed of the selected boron salt and atleast one alkali metal halide and/or alkaline earth halide. Since it is desirable to use as low a temperature as practical to avoid damaging or distorting the metal article to be borided,
- alkali metals and alkaline earth metals mean those metals set forth in the periodic chart of elements which fall within these two classifications.
- the salt bath contains from about 10 to 40 percent by weight of the selected boron salt M B F preferably from 20 to 35 percent by weight.
- the predominant portion of the bath is made up of alkali metal and/or alkaline earth metal halides.
- the selected boron salt comprises about 10 to about 35 percent by weight of the alkali metal halide and/or alkaline earth halide salts present in the bath.
- alkali metal halides are used in the bath because they provide salt baths with lower fusion temperatures.
- At least two alkali metal halide salts are preferably used, with one of these salts comprising preferably at least about percent by weight of the salt bath.
- satisfactory results may also be obtained where no one alkali metal halide salt comprises at least 50 percent by weight of the bath composition.
- the selection of the particular combination of alkali metal halide salts for use in the salt bath is not critical. However, it has been found that optimum results are obtained when the cation portion of the predominant alkali metal halide or alkaline earth halide salt in the bath is the same as the cation portion of the boron salt in the bath. Results are further optimized if the cation portion of one of the alkali metal halides in the bath is of the next lower period, in the periodic table than the other alkali metal halide. Thus, if the one alkali metal halide is KCl, the other alkali metal halide is preferably NaCl. l
- the anion portion of the boron salt in the fused bath may be the same as or different from the anion portion of the alkali metal halide salts in the bath. Best results are obtained if the anion portion of the alkali metal or alkaline earth metal salts are chlorides, because this reduces the corrosive effects of the salt bath.
- the operating temperature of the fused salt bath is determined by numerous factors including the nature and characteristics of the metalto be borided and the melting temperature of the bath.
- a bath formed in accordance with the present invention is useful for boronizing at any temperature between its melting point and its boiling point provided that the selected metal to be boronized or the case obtained, is not damaged at the selected temperature.
- Temperatures should be avoided which will result in annealing of the product and which will damage or distort the metal article to be borided. With other metals to be case hardened such as tungsten, tantalum, niobium, molybdenum, etc., bath temperatures up to 2000F could be used.
- the thickness of the boride case and the degree of penetration is a function of immersion time in the bath, temperature of the salt bath, boron content of the bath, and the properties of the metal article to be treated.
- a good boride case has been obtained after about two hours immersion of a low carbon steel in the fused salt bath.
- the rate of boron diffusion is not the same for every metal.
- the treatment conditions necessary to obtain the desired case thickness and penetration may vary from one metal to another.
- ferrous alloys it has been found that the degree of penetration is higher in low carbon steels than in high alloy steels.
- the preferred time of immersion in the boronizing bath is variable and depends upon a number of factors including the thickness of the case desired, the bath temperature and the characteristics of the metal article being boronized.
- the current density generated by the external electrical connection between the pot and the specimen holder from which the specimen is immersed in the salt bath varies with the temperature of the bath, the specimen size and the percent boron in the product of the empirical formula M B F
- the current density lies between about 50 microamperes at l200F and 300 microamperes at about l600F using a rod three inches long and having a diameter of 0.5 inch.
- the process of this invention has produced boride cases having a thickness of at least 2 mils and thicknesses over mils have been obtained. It has been observed that the original dimensions of the treated metal article does not change substantially.
- the boronizing process of my invention is applicable to a large number of metals. Excellent case hardened products have been obtained with ferrous alloys such as low carbon steels and high alloy steels. With steels having a high carbon content, such as in 1080 steel, the penetration is somewhat less due to the higher carbon content.
- Other metals which may be borided by my process are those into which boron will diffuse such as metals having atomic numbers 22-28 inclusive, 41-46 inclusive, and 73-78 inclusive.
- This range of atomic numbers includes those metals included inthe periodic chart of the elements shown on pages 56 and 57 of Langes Handbook of Chemistry, 9th edition, l-landbook Publishers, Inc, Sandusky, Ohio, 1956, such as the group VB metals, which are'vanadium, niobium and tantalum, group VlB metals, which are chromium, molybdenum and tungsten, group VIIB metals such as manganese and group Vlll metals such as iron, cobalt and nickel.
- the fact that other metals may be the minor constituents of an alloy with the metals with which this invention is concerned does not prevent the formation of the desired boride case.
- These minor constituents may be any of the other metals of the periodic system, i.e., the metals of groups lA, "A, “B, lIlA, lllB, IVA, IVB, VA and VIA. These metals have atomic numbers 3-4 inclusive, 11-13 inclusive, 19-21 inclusive, 30-33 inclusive, 37-40 inclusive, 48-51 inclusive, 55-72 inclusive, -84 inclusive and 87-98 inclusive.
- the boronized metal is removed from the salt bath it is cooled.
- the selected method of cooling is not critical. However, care should be exercised to select a method of cooling that does not adversely affect previously established characteristics of the boronized metal. Air cooling or using a quenching oil have been found most satisfactory, but other cooling cycles may be used as necessary to obtain the desired substrate qualities.
- the boronized sample is cooled it is further treated by conventional techniques to remove residual salts that may be adhering to the metal surface.
- EXAMPLE 1 To 330 grams of sodium fluoborate placed in a steel crucible there was added 22 grams of amorphous boron, the mixture was heated just above the melting point of the sodium fluoborate which is 384C for approximately two hours. The crucible and its contents were cooled and the recovered product was foundto weigh 248 grams. The product removed was a cake-like solid mass which was pulverized into a powder-like material.
- EXAMPLE 2 To 330 grams sodium fluoborate placed in a steel crucible there was added 11 grams amorphous boron, the mixture was heated just above the melting point of the sodium fluoborate (i.e., 384) for approximately two hours. The recovered product was found to weigh 262 grams and upon analysis was indicated to have the empirical formula Na,,B,,F wherein the ratio of x:y:z is 1:0.83: 1.1.
- Example 3 The process of the Example 1 was repeated except that 44 grams of amorphous boron was used. The resulting product had the empirical formula Na B F wherein the ratio of x:y:z is l:l.7:0.95.
- EXAMPLE 4 To 330 grams sodium fluoborate in a steel crucible were added 46 grams metallic sodium beads and 22 grams of amorphous boron. The mixture was heated for two hours at a temperature above the melting point of sodium fluoborate, after which the crucible was cooled and the material removed. Upon analysis this material had the empirical formula Na B F, wherein the ratio of x:y:z is 1:0.8:l.8.
- EXAMPLE 7 A product having the empirical formula Na,,B,,F in which the ratio of x:y.'z is l:0.4:l.3 was produced by heating one mole sodium fluoborate with one mole of oxalic acid, in a steel crucible just above the melting point of the oxalic acid (i.e., 101C) for six hours driving off carbon dioxide, water and hydrofluoric acid.
- EXAMPLE 8 A product having the empirical formula Na B F in which the ratio of x:y:z is about l:0.9:1.2 was produced as described in Example 4 by mixing 330 grams sodium fluoborate, 115 grams metallic sodium and 66 grams amorphous boron.
- EXAMPLE 9 Into a steel vessel there was placed 1000 grams sodium chloride, 500 grams lithium chloride and 400 grams of the product of the empirical formula Na B F produced in Example 1. These materials were heated to a temperature of about 1400F to produce a clear fluid fused salt bath. In this bath there was suspended from stainless steel wire a rod (0.5 inch diameter X 3 inches long) of 1018 steel having a carbon content of 0.17 percent. The metal wire holder from which the rod is suspended was joined by a conductor to the pot handle thereby forming an electric circuit externalto the fused salt bath. This circuit operates as a selfgenerating cell. The rod remained immersed in the bath for about six hours, and was then removed from the bath and permitted to air cool.
- the sample had a hard, uniform, smooth, adherent boride layer which proved to be 3 mil thick upon photomicrograph examination.
- the microhardness was measured in accordance with the Knoop hardness test using a 100 gram load and found to be about 2000.
- This boride case is as hard as tungsten carbide and much harder than typical nitrided or carburized cases (300m 1000 Knoop value).
- Dimensional analysis showed that after immersion in the bath the original thickness of the rod changed less than 1 mil. 7
- the boron content of the case of this example was EXAMPLE 10 Into a stainless steel vessel there was placed 750,
- Example 8 grams sodium chloride, 750 grams lithium chloride and 400 grams of the product of the empirical formula Na,,B,,lproduced in Example 8. These materials were heated to a temperature of about 1600F In this bath there was immersed a rod (0.5 inch diameter X 3 inches long) of 1018 steel having a carbon content of 0.17 percent. An external electrical connection was made as previously described. The rod remained in the bath for 8 hours and was removed and oil quenched.
- the sample had a hard, uniform, smooth adherent boride layer which proved to be 6 mils thick upon photomicrograph examination.
- the microhardness was measured in accordance with the Knoop hardness test using a gram load and found to be about 2200. Dimensional analysis showed that after immersion in the bath the original thickness of the rod changed less than 2 mils.
- EXAMPLE 1 1 Into a stainless steel vessel there was placed 720 grams of calcium chloride, 465 grams of barium chloride, and 400 grams of the product having the empirical formula NaxByFz produced in Example 1. The bath was heated to about l600F at which point it was molten but carried a soft opaque crust of insoluble constituents. In this bath was immersed a rod one-half inch diameter and three inches long of 1018 steel. An external electrical connection was made as previously de-' scribed. The rod was allowed to remain immersed for about 6 hours, was then removed from the bath and oil quenched. The specimen had a hard borided layer which proved to be over 3 mils thick upon photomicrograph examination and the Knoop valuewas found to be about 2100 using a 100 gram load. The case was not as uniform as that obtained in Example 9 or Example 10.
- EXAMPLE 12 at 1600F for 8 hours.
- the nut was then removed from the salt bath, air cooled, split, mounted and examined metallographically.
- a hard, uniform hard borided case had been formed on the surface of the nut, including the roots, faces and crowns of the threads. Variations in the case thickness between the thread crowns and thread roots was less than 10 percent, a substantial improvement over electroplating of similar surfaces.
- thickness of the case was measured to be 3.5 mils average and the hardness varied from 2270 to 2470 Knoop, taken with a l gram load.
- EXAMPLE l3 In the salt bath described above in Example 9, heated to 1500F, there was placed a one-half inch by three inch long bar of l 137 steel. After 8 hours treatment in the salt bath, te specimen was removed, air cooled, sectioned and examined metallographically. A hard, smooth uniform borided case was formed on the surface of the specimen, averaging 4 mils thick and having a hardness of over 1900 Knoop, taken with a 100 gram load.
- EXAMPLE 14 In the salt bath described above in Example 9 there were placed 6 rods of4l40 steel, each having a diameter of one-half inch and length of three inches. The salt bath was maintained at 1600F throughout the length of the experiment. The 6 rods were singly withdrawn from the salt bath and allowed to air cool at two-hour intervals; e.g., the first was withdrawn after two hours in the salt bath, the second after four hours, etc., and the sixth after twelve hours immersion in the bath. Each sample was then sectioned and examined metallo graphically. A hard smooth uniform borided case had formed on each rod, of nearly equal hardness but with thickness of case varying according to the following table:
- EXAMPLE 17 Into the bath described above in Example 10, there was placed a Vs inch diameter tungsten rod. The salt bath was held at l700F for 4 hours. The rod was then withdrawn from the bath, air cooled, sectioned into several lengths and examined metallographically. A very hard case had formed on the rod which was 1.5 mils thick and had a hardness value of 4200 Knoop, taken with a 100 gram load.
- EXAMPLE 18 I obtained having a thickness of 1 mi] and a Knoop hardness value above 4200 using a gram load.
- a method of boriding a metal composition comprising immersing said metal composition in a fused salt bath composition maintained at a temperature above about 1200F and below the melting point of said metal composition, and forming an electrical circuit which comprises said metal composition, said fused salt bath and the container for said salt bath by making an electrical connection external to said salt bath between said container and said metal composition, said metal composition being immersed in said salt bath composition until the desired thickness of boride coating has formed said salt bath composition comprising (a) at least one halide salt selected from the class consisting of alkali metal halides and alkaline earth halides and (b) the product of the reduction of an alkali metal fluoborate with a reducing agent.
- said reducing agent comprises at least amorphous boron.
- halide salt comprises two different alkali metal chlorides.
- said metal composition is a member selected from the class consisting of a carbon steel, an alloy steel, molybdenum, tungsten, tantalum and titanium.
- alkali metal chlorides comprise at least 50 percent by weight of said fused salt bath.
- alkali metal chlorides are sodium chloride and lithium chloride.
- a method of boriding a metal composition comprising immersing said metal composition in a fused salt bath composition maintained at a temperature about l200F and below the melting point of said metal composition, and forming an electrical circuit which comprises said metal composition, said fused salt bath and the container for said salt bath by electrically connecting said container and said metal composition external to said salt bath, said metal composition being immersed in said salt bath composition until the desired thickness of boride coating has formed, said fused salt composition comprising (a) a product of the empirical formula M B F, wherein M is an alkali metal, B is boron, F is the fluoride ion and wherein the ratio ofx:y:z is 120.4 to 2:05 to 2.5 and (b) at least one halide salt selected from the class consisting of alkali metal halides and alkaline earth metal halides, said halide salts comprising at least 50 percent by weight of said fused salt bath composition.
- halide salts comprise two different alkali metal chlorides.
- alkali metal chlorides are sodium chloride and lithium chloride.
- a method according to claim 10 wherein the a ratio of xzyzz in said empirical formula is 1:1 to 2:0.5 to
- said metal composition is a material selected from the class consisting of carbon steels, alloy steels, tungsten, tantalum, titanium and molybdenum.
Abstract
Description
Claims (15)
- 2. A method according to claim 1 wherein said reducing agent comprises at least amorphous boron.
- 3. A method according to claim 2 wherein all of the electrical energy required to boride said metal composition is self-generated in said electrical circuit.
- 4. A method according to claim 3 wherein said halide salt comprises two different alkali metal chlorides.
- 5. A method according to claim 4 wherein said metal composition is a member selected from the class consisting of a carbon steel, an alloy steel, molybdenum, tungsten, tantalum and titanium.
- 6. A method according to claim 5 wherein said alkali metal chlorides comprise at least 50 percent by weight of said fused salt bath.
- 7. A method according to claim 6 wherein said alkali metal chlorides are sodium chloride and lithium chloride.
- 8. A method of boriding a metal composition, said method comprising immersing said metal composition in a fused salt bath composition maintained at a temperature about 1200*F and below the melting point of said metal composition, and forming an electrical circuit which comprises said metal composition, said fused salt bath and the container for said salt bath by electrically connecting said container and said metal composition external to said salt bath, said metal composition being immersed in said salt bath composition until the desired thickness of boride coating has formed, said fused salt composition comprising (a) a product of the empirical formula MxByFz wherein M is an alkali metal, B is boron, F is the fluoride ion and wherein the ratio of x:y:z is 1:0.4 to 2:0.5 to 2.5 and (b) at least one halide salt selected from the class consisting of alkali metal halides and alkaline earth metal halides, said halide salts comprising at least 50 percent by weight of said fused salt bath composition.
- 9. A method according to claim 8 wherein said halide salts comprise two different alkali metal chlorides.
- 10. A method according to claim 9 wherein said product of the empirical formula MxByFz comprises between 20 and about 35 percent by weight of said salt bath.
- 11. A method according to claim 10 wherein said alkali metal chlorides are sodium chloride and lithium chloride.
- 12. A method according to claim 11 wherein M is sodium.
- 13. A method according to claim 10 wherein the ratio of x:y:z in said empirical formula is 1:1 to 2:0.5 to 1.5.
- 14. A method according to claim 10 wherein said metal composition is a material selected from the class consisting of carbon steels, alloy steels, tungsten, tantalum, titanium and molybdenum.
- 15. A method according to claim 14 wherein all of the electrical energy required to boride said metal composition is self-generated in said electrical circuit.
- 16. A process according to claim 8 wherein said salt bath is maintained at a temperature between about 1200*F and 1700*F.
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US78243668A | 1968-12-09 | 1968-12-09 | |
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US5810990A (en) * | 1994-12-28 | 1998-09-22 | Yamaha Hatsudoki Kabushiki Kaisha | Method for plating and finishing a cylinder bore |
US20070098917A1 (en) * | 2005-09-22 | 2007-05-03 | Skaffco Engineering & Manufacturing, Inc. | Plasma Boriding Method |
US20080029305A1 (en) * | 2006-04-20 | 2008-02-07 | Skaff Corporation Of America, Inc. | Mechanical parts having increased wear resistance |
US20080233428A1 (en) * | 2007-03-22 | 2008-09-25 | Skaff Corporation Of America, Inc. | Mechanical parts having increased wear resistance |
US20110132769A1 (en) * | 2008-09-29 | 2011-06-09 | Hurst William D | Alloy Coating Apparatus and Metalliding Method |
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US3024176A (en) * | 1959-08-04 | 1962-03-06 | Gen Electric | Corrosion resistant coating |
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Cited By (10)
Publication number | Priority date | Publication date | Assignee | Title |
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US5810990A (en) * | 1994-12-28 | 1998-09-22 | Yamaha Hatsudoki Kabushiki Kaisha | Method for plating and finishing a cylinder bore |
US20070098917A1 (en) * | 2005-09-22 | 2007-05-03 | Skaffco Engineering & Manufacturing, Inc. | Plasma Boriding Method |
US7767274B2 (en) | 2005-09-22 | 2010-08-03 | Skaff Corporation of America | Plasma boriding method |
US20080029305A1 (en) * | 2006-04-20 | 2008-02-07 | Skaff Corporation Of America, Inc. | Mechanical parts having increased wear resistance |
US20080233428A1 (en) * | 2007-03-22 | 2008-09-25 | Skaff Corporation Of America, Inc. | Mechanical parts having increased wear resistance |
WO2008116159A2 (en) * | 2007-03-22 | 2008-09-25 | Skaff Corporation Of America, Inc. | Mechanical parts having increased wear-resistance |
WO2008116159A3 (en) * | 2007-03-22 | 2008-11-20 | Skaff Corp Of America Inc | Mechanical parts having increased wear-resistance |
US8012274B2 (en) | 2007-03-22 | 2011-09-06 | Skaff Corporation Of America, Inc. | Mechanical parts having increased wear-resistance |
US20120052315A1 (en) * | 2007-03-22 | 2012-03-01 | Skaff Corporation Of America, Inc. | Mechanical parts having increased wear-resistance |
US20110132769A1 (en) * | 2008-09-29 | 2011-06-09 | Hurst William D | Alloy Coating Apparatus and Metalliding Method |
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