Classifications

• • C—CHEMISTRY; METALLURGY
  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
  • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
  • B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
  • B29C70/06—Fibrous reinforcements only
  • B29C70/08—Fibrous reinforcements only comprising combinations of different forms of fibrous reinforcements incorporated in matrix material, forming one or more layers, and with or without non-reinforced layers
• • 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
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24893—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.] including particulate material
• • 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
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/29—Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
  • Y10T428/2913—Rod, strand, filament or fiber
  • Y10T428/298—Physical dimension
• • 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
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/31504—Composite [nonstructural laminate]
  • Y10T428/31678—Of metal
• • 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
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T442/00—Fabric [woven, knitted, or nonwoven textile or cloth, etc.]
  • Y10T442/20—Coated or impregnated woven, knit, or nonwoven fabric which is not [a] associated with another preformed layer or fiber layer or, [b] with respect to woven and knit, characterized, respectively, by a particular or differential weave or knit, wherein the coating or impregnation is neither a foamed material nor a free metal or alloy layer
  • Y10T442/273—Coating or impregnation provides wear or abrasion resistance

Definitions

• ABSTRACT Materials such as metals, alloys and other products are provided with improved wear-resistant surfaces comprised of a hard monocarbide phase in the form of filaments within the material matrix.
• This invention relates to improved wear resistant surface composite materials and to a method for their production.
• the invention relates to metals, particularly aluminum alloys with an especially wear-resistant duplex surface comprising a large area fraction of hard refractory metal monocarbide phases.
• the invention relates to the use of refractory metal monocarbide phases in the form of fibers, felts, tapes and woven fabrics and a method for composi'ting these materials in the surface of otherwise wear-prone materials such as aluminum alloys, to impart exceptionally high wear-resistance to the composite surface.
• the present invention teaches that the entire surface of the alloy need not be covered by the wear-improving phases. Instead, the utilization of the hard refractory mono-carbide phases, for example in the form of a woven tape permits the final surface to have a composite surface structure wherein up to 80 percent of the surface area is comprised of regions of the hard mononcarbide phase embedded within the matrix of the alloy. the fibrous nature of the wear-improving phase permits a continuous presence of the hard phase even in conditions of abrasive wear.
• the present invention represents a marked improvement over the prior art methods (e.g., plasma-sprayed powders) where a parti- 2 cle of hard phase, once removed during abrasive wear ceases to provide any wear-improving role.
• an object of this invention to provide improved wea resistant surface composite materials and to a methor for their production.
• a further object of the inventior is to provide materials with a duplex composite surfact which exhibit exceptionally improved wear resistanct in comparison to the untreated material surface.
• An other object of the invention is to employ refractory metal carbides in the form of filaments to provide a duplex composite surface having improved wear-resist ance.
• a still further object of this invention is to pro vide aluminum alloys with improved wear-resistance surfaces.
• Another object is to provide non-metallic materials such as epoxy and phenolic resins which have improved wear-resistant surfaces.
• this invention relates to improvec wear-resistant composite materials and to a process f0] their preparation.
• the composites are characterized by a surface which has a duplex composite structure comprised of (a) a matrix material of poor wear resistance and (b) not less than about 50 percent area fractior and up to about percent area fraction of a hard fibrous monocarbide phase.
• the monocarbide phase is represented by the general formula MC wherein M is 2 metal from the group tantalum, titanium or tungsten and C is carbon and is in the form of filaments of between about 2 and about 15 microns in diameter being present at the composite surface as sections of varying orientations, the remainder of the surface being comprised of matrix material.
• filaments as employed throughout the specification and appended claims is meant wover fabrics, tapes, felts, chopped fibers, and the like composed of the metallic monocarbides.
• These metallic monocarbides are prepared by the process disclosed ir U.S. Pat. No. 3,403,008.
• Illustrative materials include, among others, aluminum silver, copper, and their alloys, non-metallic matrices such as epoxy and phenolic resins, and the like.
• aluminum alloys which normally exhibit pooi wear-resistant properties include those based on the aluminum-silicon alloy system particularly hyper eutectic combinations which are commonly used a: casting grade aluminum alloys.
• silver and silver containing alloys such as those used for braz ing applications, copper and its alloys as well as othe matrices.
• the invention is alsr applicable to other non-metallic matrices such as epox resins and phenolic resins.
• the ability to produce the materials of this inventioi with exceptionally enhanced wear-resistance result from the discovery that when filaments of the monocar bides of the aforementioned refractory metals are i1 contact with materials such as aluminum and its alloy in the molten state, the filaments are rapidly wetted by the molten metal.
• a feature of this wetting reactioi is the formation of intermetallic phases at the interface between the individual fibers and filaments of th monocarbide phase and the adjacent metallic matrix
• the material of this invention can be onveniently prepared by a variety of methods.
• the ready wettability of the textile form of the efractory metal monocarbides by materials such as luminum and its alloys lends itself to a method of mbedding the wear-resistance-imparting monocarbide ito the material directly during the casting operation.
• the mold can be lined with the monocar ide filaments and the normal casting operation carried ut.
• the filaments can be em loyed in a variety of forms. The particular configuraion of the mold may, in part, determine the preferred arm of the filaments.
• filas in the form of tapes are convenient for lining the tterior surfaces of the mold.
• the thickness of the tape a not necessarily critical as long as sufficient metallic monocarbide filaments are present to improve the surace wear-resistant properties.
• marked improvements are obtained hen the surface composite structure is comprised of ot less than about percent area fraction and up to bout 90 percent area fraction of the hard fibrous ionocarbide phase.
• the present invention can rovide mechanically precise castings which have im- 35 roved wear-resistance.
• the overall configuration of the cast artile has the same dimensions as the cast article without EXAMPLE I
• a tape of satin-weave woven fabric comprised of tantalum carbide prepared by the process disclosed in US. Pat. No. 3,403,008 was used to create a composite surface on 6061 aluminum alloy.
• the filaments comprising the tape were 5,11. in diameter.
• the apparent molecular weight of the tantalum carbide was 191.4, showing that the material of the woven fabric approximated closely ideal stoichiometric TaC (molecular weight 192.96).
• a tape 0.5 inches wide by 3.0 inches long, was placed in an alumina crucible and a bar of 6061 aluminum alloy was placed over the tape. The crucible and contents were held in an argon atmosphere furnace at 700C for 5 minutes. Upon cooling, the as-cast 6061 alloy was found to have the said tape embedded fully within the lower surface of the ingot resulting in a composite surface.
• Blocks /4 inch wide X inch long X inch deep were cut from the sample of 6061 alloy with the composite matrix plus TaC fiber surface.
• the composite surface was tested for wear-resistance under varying loads in a standard Alpha model wear-testing machine. In this test the test surface is subject to wear against a 4620 steel ring hardened to a hardness of R 58 to 63.
• the relative wear parameter of test material is given by measuring the volume of the scar created on the surface by wear test. The results obtained are set forth in Table I below:
• the filaments employed in this invention are also seful for imparting improved wear-resistance to artiles prepared by hot pressing powdered matrix materi- Is.
• a tape, felt, woven fabric, or chopped bers of the metallic monocarbide can be placed on ne or more surfaces of a die, powdered matrix mateal added, and the composite hot pressed to form the esired article.
• the present invention thus provides a simple and onvenient technique for imparting improved wear- :sistance to surfaces of a variety of materials. Without ny complicated processing steps, other than those
• the wear scar volumes of the composite surface of the present invention are compared in Table I with the values for wear scar volumes for a typical aluminum alloy. It is evident that the composite surface of the present invention has wear characteristics which represent a thousand-fold improvement over the wear characteristics of conventional aluminum alloy surfaces.
• EXAMPLE 1 A tape of satin weave woven fabric comprising essentially of tantalum carbide was positioned into the bottom of a mold into which a Buehler No. 20-8133-001 Epoxy Resin was cast. Upon curing the resultant Epoxy block was found to have one surface with a duplex composite microstructure comprising area% TaC in Epoxy matrix. Blocks 8'4 inch wide, inch long and 4/8 inch deep were cut from these Expoxy blocks with matrix plus TaC fiber surface. The composite surface was tested for wear-resistance under varying loads in a standard Dow-Corning Alpha model Wear-testing Machine.
• Table 111 two (untreated) such state-of-the-art bulk composite materials produced via conventional powder metallurgy techniques: Ferro-TiC developed by Chromalloy Corporation EXAMPLE m and the Al graphite composite developed by Toyo Kogyo Co. as a wear-resistant rotor apex seal for the Comparisons were made between the wear resistance Hyundai automobiles rotary-piston engine.
• the Ferof the surface composite materials of this invention and ro-TiC material provides good wear-resistance but iS known materials using standard wear tests. very abrasive vis-a-vis the wear of the mating ring.
• the wear data was obtained using a LFW-l model weight loss values for tests with Ferro-TiC are a factor Wear-Testing Machine manufactured by the DO C0 of two higher than the comparable values for tests with ning Corporation. As described in ASTM Standard Surface Composite materials in 6061 and 2024 alloy Test Method D 2714-68, all tests were carried out on matrices.
• the A1 graphite composite material shows stationary re tangular inch d X 5 8 inch 1 g X higher values for both Ring Weight Loss and Wear Scar inch deep) test blocks pressed, with a pre-determined Volume when compared to the Surface Composite load, against a rotating ring.
• the wear properties mea- Materials thus clearly indicating the superior wear besured were: (i) Volume of Wear Scar on the test surhavior of the materials of this invention. face of wear block material; (ii) Weight change of the It should be noted that in addition to the wear propmating ring; and (iii) the friction force measured at erties of the Surface Composite materials being supeintervals during the test.
• An improved wear-resistant surface composite material the surface of which has a duplex composite structure comprised of (a) a matrix material of poor wear-resistance and (b) not less than about 50 percent area fraction and up to about 90 percent area fraction of a hard fibrous monocarbide phase, said monocarbide phase being represented by the general formula MC wherein M is a metal selected from the group consisting of tantalum, titanium or tungsten and C is carbon, said monocarbide phase being in the form of filaments between 2 and about 15 microns in diameter and being present at the composite surface as sections of varying orientations, the remainder of the surface being comprised of the matrix of the said material.
• woven fabric is present 2.
• said matrix material is aluminum.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Mechanical Engineering (AREA)
• Materials Engineering (AREA)
• Metallurgy (AREA)
• Organic Chemistry (AREA)
• Composite Materials (AREA)
• Manufacture Of Alloys Or Alloy Compounds (AREA)
• Laminated Bodies (AREA)
• Ceramic Products (AREA)
• Other Surface Treatments For Metallic Materials (AREA)
• Reinforced Plastic Materials (AREA)

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• 1973
  • 1973-05-04 US US35708073 patent/US3929427A/en not_active Expired - Lifetime
  • 1973-06-25 CA CA174,836A patent/CA973762A/en not_active Expired
  • 1973-07-09 JP JP7667073A patent/JPS548201B2/ja not_active Expired
  • 1973-07-09 SE SE7309634A patent/SE410200B/xx unknown
  • 1973-07-09 FR FR7325113A patent/FR2191996B1/fr not_active Expired
  • 1973-07-09 GB GB3265973A patent/GB1436768A/en not_active Expired
  • 1973-07-09 CH CH997473A patent/CH583629A5/xx not_active IP Right Cessation
  • 1973-07-09 IT IT6904673A patent/IT991760B/it active
  • 1973-07-10 DE DE2335112A patent/DE2335112C3/de not_active Expired

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