USRE33905E - Chromium carbide sintered body - Google Patents
Chromium carbide sintered body Download PDFInfo
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- USRE33905E USRE33905E US07/676,201 US67620191A USRE33905E US RE33905 E USRE33905 E US RE33905E US 67620191 A US67620191 A US 67620191A US RE33905 E USRE33905 E US RE33905E
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- sintered body
- chromium carbide
- sintering
- microns
- carbide sintered
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- UFGZSIPAQKLCGR-UHFFFAOYSA-N chromium carbide Chemical compound [Cr]#C[Cr]C#[Cr] UFGZSIPAQKLCGR-UHFFFAOYSA-N 0.000 title claims abstract description 37
- 229910003470 tongbaite Inorganic materials 0.000 title claims abstract description 37
- 239000013078 crystal Substances 0.000 claims abstract description 21
- 238000005245 sintering Methods 0.000 claims description 17
- 239000000843 powder Substances 0.000 claims description 15
- 238000000034 method Methods 0.000 claims description 13
- 229910019863 Cr3 C2 Inorganic materials 0.000 claims description 9
- 239000002245 particle Substances 0.000 claims description 8
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 claims description 4
- 239000012298 atmosphere Substances 0.000 claims description 4
- 238000001272 pressureless sintering Methods 0.000 claims description 3
- 229910052786 argon Inorganic materials 0.000 claims description 2
- 239000001307 helium Substances 0.000 claims description 2
- 229910052734 helium Inorganic materials 0.000 claims description 2
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 claims description 2
- 238000000465 moulding Methods 0.000 claims description 2
- 230000001590 oxidative effect Effects 0.000 claims description 2
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 claims 2
- 229910052757 nitrogen Inorganic materials 0.000 claims 1
- 230000015572 biosynthetic process Effects 0.000 description 6
- 239000000463 material Substances 0.000 description 5
- 229910052751 metal Inorganic materials 0.000 description 5
- 239000002184 metal Substances 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 4
- 229910010293 ceramic material Inorganic materials 0.000 description 3
- 230000000052 comparative effect Effects 0.000 description 3
- 238000005260 corrosion Methods 0.000 description 3
- 230000007797 corrosion Effects 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 208000010392 Bone Fractures Diseases 0.000 description 2
- 206010017076 Fracture Diseases 0.000 description 2
- 238000009694 cold isostatic pressing Methods 0.000 description 2
- 238000001513 hot isostatic pressing Methods 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229910010271 silicon carbide Inorganic materials 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
- -1 such as Co Substances 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000007088 Archimedes method Methods 0.000 description 1
- QYEXBYZXHDUPRC-UHFFFAOYSA-N B#[Ti]#B Chemical compound B#[Ti]#B QYEXBYZXHDUPRC-UHFFFAOYSA-N 0.000 description 1
- 229910052580 B4C Inorganic materials 0.000 description 1
- 229910019872 Cr4 C Inorganic materials 0.000 description 1
- 229910019869 Cr7 C3 Inorganic materials 0.000 description 1
- 229910018104 Ni-P Inorganic materials 0.000 description 1
- 229910018536 Ni—P Inorganic materials 0.000 description 1
- 208000013201 Stress fracture Diseases 0.000 description 1
- 229910033181 TiB2 Inorganic materials 0.000 description 1
- 229910034327 TiC Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 1
- WGLPBDUCMAPZCE-UHFFFAOYSA-N Trioxochromium Chemical compound O=[Cr](=O)=O WGLPBDUCMAPZCE-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 229910007948 ZrB2 Inorganic materials 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 230000003064 anti-oxidating effect Effects 0.000 description 1
- 238000010420 art technique Methods 0.000 description 1
- SJKRCWUQJZIWQB-UHFFFAOYSA-N azane;chromium Chemical compound N.[Cr] SJKRCWUQJZIWQB-UHFFFAOYSA-N 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- VWZIXVXBCBBRGP-UHFFFAOYSA-N boron;zirconium Chemical compound B#[Zr]#B VWZIXVXBCBBRGP-UHFFFAOYSA-N 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910000423 chromium oxide Inorganic materials 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
- 238000001816 cooling Methods 0.000 description 1
- PMHQVHHXPFUNSP-UHFFFAOYSA-M copper(1+);methylsulfanylmethane;bromide Chemical compound Br[Cu].CSC PMHQVHHXPFUNSP-UHFFFAOYSA-M 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000007676 flexural strength test Methods 0.000 description 1
- 238000007731 hot pressing Methods 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000007373 indentation Methods 0.000 description 1
- XEEYBQQBJWHFJM-UHFFFAOYSA-N iron Substances [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- VAKIVKMUBMZANL-UHFFFAOYSA-N iron phosphide Chemical compound P.[Fe].[Fe].[Fe] VAKIVKMUBMZANL-UHFFFAOYSA-N 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N magnesium oxide Inorganic materials [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- 239000000395 magnesium oxide Substances 0.000 description 1
- AXZKOIWUVFPNLO-UHFFFAOYSA-N magnesium;oxygen(2-) Chemical compound [O-2].[Mg+2] AXZKOIWUVFPNLO-UHFFFAOYSA-N 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- NFFIWVVINABMKP-UHFFFAOYSA-N methylidynetantalum Chemical compound [Ta]#C NFFIWVVINABMKP-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
- 229910003465 moissanite Inorganic materials 0.000 description 1
- 230000007935 neutral effect Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- ZTPQLYJGPLYBPS-UHFFFAOYSA-N phosphanylidynechromium Chemical compound [Cr]#P ZTPQLYJGPLYBPS-UHFFFAOYSA-N 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000010298 pulverizing process Methods 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 229910003468 tantalcarbide Inorganic materials 0.000 description 1
- 239000010936 titanium Substances 0.000 description 1
- 229910052719 titanium Inorganic materials 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Images
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
- C04B35/645—Pressure sintering
- C04B35/6455—Hot isostatic pressing
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/5607—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on refractory metal carbides
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/58—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
- C04B35/581—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on aluminium nitride
Definitions
- This invention relates to a chromium carbide sintered body. More particularly, it relates to a highly tough chromium carbide sintered body having superior corrosion resistance to molten metal or components of industrial furnaces, such as heating furnaces.
- a chromium carbide sintered body has been produced with addition of various sintering aids to chromium carbide.
- the sintering aids so far proposed include powders of metals, such as Co, Fe, Ni or Ni-P alloys, borides such as titanium boride or zirconium boride, carbides such as tantalum carbide, boron carbide or silicon carbide, oxides such as aluminum oxide, chromium oxide or magnesium oxide, phosphides such as iron phosphide, cobalt phosphide or chromium phosphide, and nitrides such as chromium nitride, titanium nitride or aluminum nitride.
- sintering aids are used in amounts of not more than 10 wt. % based on the weight of chromium carbide, and the sintering temperature is set so as not to be higher than 1500° C. (see Japanese Laid-open Patent Publication No. 107972/1984).
- the sintered body containing acicular crystals of chromium carbide cannot be obtained by this prior art technique.
- Concerning the structure of the chromium carbide sintered body although coarse-sized or granular crystals have been reported, examples of formation or utilization of the needle-shaped or columnar crystals have not been found (see for example "Some Properties of Chromium Carbide Ceramic Material", Nippon Tungsten Review, Vol. 19 (1986))
- chromium carbide type ceramic material Although a chromium carbide type ceramic material is known to have excellent anti-oxidation and anti-scaling properties, it has been reported that such material is not fully satisfactory in strength, hardness, fracture toughness and thermal impact resistance. Hence, the situation is that the usage of the material is restricted to skid rails or skid buttons in heating furnaces.
- the fiber reinforcing method has also been practiced for improving mechanical or thermal impact resistance which represents in general the most vulnerable points of the ceramic material.
- This method consists in uniformly dispersing whiskers having lengths of several tens to hundreds of microns or fibers of longer lengths into the interior of the sintered body. Although some effects may be realized by this method, it cannot be said that the method has gained widespread acceptance on account of elevated costs caused by the use of whiskers and difficulties in uniformly dispersing the whiskers or fibers.
- a chromium carbide sintered body having high toughness comprising 99.5 to 50% by weight of chromium carbide and 0.5 to 50% by weight of AlN, the sintered body containing acicular crystals of chromium carbide.
- FIG. 1 is a SEM photograph showing the crystal structure of the chromium carbide sintered body according to the Run No. 6 of the Example of the invention, with the magnification factor being 5,000.
- FIG. 2 is a SEM photograph similar to FIG. 1 showing the Run No. 1 of a Comparative Example.
- the sintered body of the present invention contains chromium carbide and AlN.
- Other components than chromium carbide and AlN, such as ZrB 2 , TiB 2 , TiC or SiC, may be contained in a starting powder material within the range that does not impair the properties of the sintered body, as for example within 20% by weight, preferably 10% by weight.
- the raw chromium carbide powders may preferably have purity of not less than 99% and mean particle size of not more than 5 microns and preferably not more than 1 micron.
- the raw AlN powders have purity of not less than 99% and mean particle size of not more than 10 microns and preferably not more than 5 microns.
- the starting powder material may be pulverized and mixed simultaneously.
- the particle size of the mixture may preferably be not more than 10 microns and preferably not more than 1 micron, in terms of the mean particle size.
- the wet type or dry type methods may be optionally employed for pulverizing the materials.
- the fine powder mixture prepared in the above described manner is molded by a cold press method in the case of pressureless sintering and the molded product is then sintered at around atmospheric pressure.
- Both hot pressing and pressureless sintering are carried out in a non-oxidizing atmosphere such as a neutral or reducing atmosphere such as in vacuum or in an argon, helium or nitrogen atmosphere, and the molded product is then sintered at atmospheric pressure.
- the sintering temperature is not lower than 1600° C., below which acicular crystals are not formed.
- the sintering time duration is advantageously 30 minutes to 12 hours.
- the HIP (Hot isostatic pressing) method is also effective for molding.
- the present invention resides in forming the acicular crystals of chromium carbide in the sintered body, whereby success has been realized in improving the impact resistance, thermal impact resistance, strength and hardness.
- the majority of the acicular crystals of chromium carbide more concretely, not less than 20% and preferably not less than 50% of the acicular crystals in the sintered body, may have 0.1 to 10 microns in diameter and about 0.2 to 30 microns in length, it is necessary that the ratio of AlN be in the range of from 0.5to 50% by weight and preferably 5 to 30% by weight, and that the sintering conditions be controlled appropriately. With the contents of AlN less than 0.5% by weight, satisfactory acicular crystals are not produced. On the other hand, with the contents in excess of 50% by weight, the properties inherent in chromium carbide are impaired.
- the sintered body of the present invention is excellent in corrosion resistance, hardness, strength and toughness and, inter alia, has a fracture toughness of not lower than 5 MPa m 1/2 at room temperature.
- the sintered body of the present invention is excellent in toughness, strength and thermal impact resistance, so that it can be used in a wider field of application than in the case of the conventional chromium carbide type ceramic sintered body.
- the sintered body of the present invention can be used as a protective tube for thermocouples on account of its excellent corrosion resistance against molten metal or components of industrial furnaces, such as heating furnaces. It can also be used as dies for metal forming on account of its high toughness and hardness, and as heaters or temperature sensors on account of its electrical conductivity.
- the sintered body of the invention can be worked by electric discharge machining, similarly to metals, so that the sintered body of a complex shape can be produced successfully.
- the resulting mixture was molded by the CIP (cold isostatic pressing) method at a pressure of 2.7 tons/cm 2 for three minutes and sintered at a temperature of 1650° C. for 360 minutes under a vacuum atmosphere.
- the physical properties of the so-produced sintered bodies are shown in Table 1.
- the SEM photos showing the crystal structure of the sintered bodies of the Run No. 6 (inventive) and the Run No. 1 (comparative), with the magnification factor of 5,000, are shown in FIGS. 1 and 2, respectively.
- the physical properties were measured in the following manner.
- the fracture toughness was measured by the IM (Indentation microfracture) method (at the room temperature).
- the thermal impact resistance was measured by the method of measuring the rapid cooling temperature.
- the flexural strength test piece of 3 ⁇ 4 ⁇ 40 mm in size was used as the sample.
- the test piece was heated to a predetermined temperature in an electrical furnace and maintained at this temperature for a predetermined time period (one hour).
- the test piece was then dropped into 0° C. water provided below the furnace and thereby cooled rapidly.
- the flexural strength of the test piece was measured by three point bend test, and the temperature difference between the heating temperature at which the strength of the test piece was lowered and the water temperature of 0° C. was found and designated ⁇ T.
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- Inorganic Chemistry (AREA)
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Abstract
A chromium carbide sintered body having high toughness contains 99.5 to 50% by weight of chromium carbide and 0.5 to 50% by weight of AlN. The sintered body contains acicular crystals of chromium carbide.
Description
This invention relates to a chromium carbide sintered body. More particularly, it relates to a highly tough chromium carbide sintered body having superior corrosion resistance to molten metal or components of industrial furnaces, such as heating furnaces.
A chromium carbide sintered body has been produced with addition of various sintering aids to chromium carbide. The sintering aids so far proposed include powders of metals, such as Co, Fe, Ni or Ni-P alloys, borides such as titanium boride or zirconium boride, carbides such as tantalum carbide, boron carbide or silicon carbide, oxides such as aluminum oxide, chromium oxide or magnesium oxide, phosphides such as iron phosphide, cobalt phosphide or chromium phosphide, and nitrides such as chromium nitride, titanium nitride or aluminum nitride. These sintering aids are used in amounts of not more than 10 wt. % based on the weight of chromium carbide, and the sintering temperature is set so as not to be higher than 1500° C. (see Japanese Laid-open Patent Publication No. 107972/1984). However, the sintered body containing acicular crystals of chromium carbide cannot be obtained by this prior art technique. Concerning the structure of the chromium carbide sintered body, although coarse-sized or granular crystals have been reported, examples of formation or utilization of the needle-shaped or columnar crystals have not been found (see for example "Some Properties of Chromium Carbide Ceramic Material", Nippon Tungsten Review, Vol. 19 (1986))
Although a chromium carbide type ceramic material is known to have excellent anti-oxidation and anti-scaling properties, it has been reported that such material is not fully satisfactory in strength, hardness, fracture toughness and thermal impact resistance. Hence, the situation is that the usage of the material is restricted to skid rails or skid buttons in heating furnaces.
The fiber reinforcing method has also been practiced for improving mechanical or thermal impact resistance which represents in general the most vulnerable points of the ceramic material. This method consists in uniformly dispersing whiskers having lengths of several tens to hundreds of microns or fibers of longer lengths into the interior of the sintered body. Although some effects may be realized by this method, it cannot be said that the method has gained widespread acceptance on account of elevated costs caused by the use of whiskers and difficulties in uniformly dispersing the whiskers or fibers.
It is a principal object of the present invention to provide a chromium carbide sintered body having high toughness.
It is another object of the present invention to provide a chromium carbide sintered body that is superior in impact resistance, thermal impact resistance, strength and hardness.
These and other objects of the invention will become apparent from the following description.
In accordance with the present invention, there is provided a chromium carbide sintered body having high toughness comprising 99.5 to 50% by weight of chromium carbide and 0.5 to 50% by weight of AlN, the sintered body containing acicular crystals of chromium carbide.
FIG. 1 is a SEM photograph showing the crystal structure of the chromium carbide sintered body according to the Run No. 6 of the Example of the invention, with the magnification factor being 5,000.
FIG. 2 is a SEM photograph similar to FIG. 1 showing the Run No. 1 of a Comparative Example.
The present invention will be explained in detail hereinbelow.
The sintered body of the present invention contains chromium carbide and AlN. Other components than chromium carbide and AlN, such as ZrB2, TiB2, TiC or SiC, may be contained in a starting powder material within the range that does not impair the properties of the sintered body, as for example within 20% by weight, preferably 10% by weight.
There are three species of the chromium carbide, namely Cr3 C2, Cr7 C3 Cr4 C, of which Cr3 C2 is most commonly employed. The raw chromium carbide powders may preferably have purity of not less than 99% and mean particle size of not more than 5 microns and preferably not more than 1 micron. Similarly, the raw AlN powders have purity of not less than 99% and mean particle size of not more than 10 microns and preferably not more than 5 microns.
Usually, a mixture of these fine powders may be obtained, respectively followed by uniformly mixing them together. However, the starting powder material may be pulverized and mixed simultaneously. The particle size of the mixture may preferably be not more than 10 microns and preferably not more than 1 micron, in terms of the mean particle size. The wet type or dry type methods may be optionally employed for pulverizing the materials.
For producing the sintered body of the present invention, the fine powder mixture prepared in the above described manner is molded by a cold press method in the case of pressureless sintering and the molded product is then sintered at around atmospheric pressure. Both hot pressing and pressureless sintering are carried out in a non-oxidizing atmosphere such as a neutral or reducing atmosphere such as in vacuum or in an argon, helium or nitrogen atmosphere, and the molded product is then sintered at atmospheric pressure. The sintering temperature is not lower than 1600° C., below which acicular crystals are not formed. The sintering time duration is advantageously 30 minutes to 12 hours. The HIP (Hot isostatic pressing) method is also effective for molding.
Briefly, the present invention resides in forming the acicular crystals of chromium carbide in the sintered body, whereby success has been realized in improving the impact resistance, thermal impact resistance, strength and hardness. For forming the acicular crystals of chromium carbide in the sintered body of the present invention, it is necessary to add a specified amount of AlN and to carry out the sintering at a temperature not lower than 1600° C. In order that the majority of the acicular crystals of chromium carbide, more concretely, not less than 20% and preferably not less than 50% of the acicular crystals in the sintered body, may have 0.1 to 10 microns in diameter and about 0.2 to 30 microns in length, it is necessary that the ratio of AlN be in the range of from 0.5to 50% by weight and preferably 5 to 30% by weight, and that the sintering conditions be controlled appropriately. With the contents of AlN less than 0.5% by weight, satisfactory acicular crystals are not produced. On the other hand, with the contents in excess of 50% by weight, the properties inherent in chromium carbide are impaired.
The sintered body of the present invention is excellent in corrosion resistance, hardness, strength and toughness and, inter alia, has a fracture toughness of not lower than 5 MPa m1/2 at room temperature. The sintered body of the present invention is excellent in toughness, strength and thermal impact resistance, so that it can be used in a wider field of application than in the case of the conventional chromium carbide type ceramic sintered body. More specifically, the sintered body of the present invention can be used as a protective tube for thermocouples on account of its excellent corrosion resistance against molten metal or components of industrial furnaces, such as heating furnaces. It can also be used as dies for metal forming on account of its high toughness and hardness, and as heaters or temperature sensors on account of its electrical conductivity. Also the sintered body of the invention can be worked by electric discharge machining, similarly to metals, so that the sintered body of a complex shape can be produced successfully.
Chromium carbide powders having a purity of not less than 99% and a mean particle size of 4 to 5 microns and AlN powders having a mean particle size of 3 to 4 microns, were separately metered out and mixed in a ball mill. The resulting mixture was molded by the CIP (cold isostatic pressing) method at a pressure of 2.7 tons/cm2 for three minutes and sintered at a temperature of 1650° C. for 360 minutes under a vacuum atmosphere. The physical properties of the so-produced sintered bodies are shown in Table 1. The SEM photos showing the crystal structure of the sintered bodies of the Run No. 6 (inventive) and the Run No. 1 (comparative), with the magnification factor of 5,000, are shown in FIGS. 1 and 2, respectively.
The physical properties were measured in the following manner.
(1) The fracture toughness was measured by the IM (Indentation microfracture) method (at the room temperature).
(2) The thermal impact resistance was measured by the method of measuring the rapid cooling temperature. The flexural strength test piece of 3×4×40 mm in size was used as the sample. The test piece was heated to a predetermined temperature in an electrical furnace and maintained at this temperature for a predetermined time period (one hour). The test piece was then dropped into 0° C. water provided below the furnace and thereby cooled rapidly. The flexural strength of the test piece was measured by three point bend test, and the temperature difference between the heating temperature at which the strength of the test piece was lowered and the water temperature of 0° C. was found and designated ΔT.
(3) The ratio of formation of the acicular crystals having a diameter of 0.1 to 10 microns and a length of 0.2 to 30 microns was classified through observation with SEM. In Tables 1 and 2, the marks ○, Δand X indicate the ratios of formation of not less than 50% by area, 49 to 20% by area and less than 20% by area, respectively.
(4) The relative density was measured by the Archimedes method.
TABLE 1
__________________________________________________________________________
Flexural
Strength
Fracture
Thermal
Composition
Relative
at Room
Toughness
Impact
Formation
Run (Wt. Part)
Density
Temp.
(K.sub.IC)
Resistance
of Acicular
No. Cr.sub.3 C.sub.2
AlN
(%) (MPa)
(MPa · m.sup.1/2)
ΔT (°C.)
Crystals
__________________________________________________________________________
Comp.
1 100 0 96.5 10 -- -- X
Ex. 2 40 60 82.3 55 3.0 200 Δ
3 20 80 75.5 30 2.5 200 X
Ex. 4 99.5
0.5
92.1 300 5.5 350 Δ
5 95 5 95.2 420 6.1 400 ◯
6 90 10 97.2 430 6.2 450 ◯
7 85 15 96.9 420 6.5 500 ◯
8 80 20 92.5 305 6.1 450 ◯
9 70 30 87.3 270 5.8 450 ◯
10 60 40 85.5 240 5.7 400 ◯
11 50 50 82.1 200 5.5 300 Δ
__________________________________________________________________________
It is seen from Table 1 that the Examples of the present invention (Run Nos. 4 to 11) are more excellent in toughness and thermal impact resistance than the Comparative Examples (Run Nos. 1 to 3).
Samples of the sintered bodies were produced in accordance with the Run No. 7 of the Example 1 with modified sintering temperatures and the ratios of formation of the acicular crystals were observed by SEM and classified in the same way as in Example 1. The results are shown in Table 2.
It is seen from Table 2 that the acicular crystals are not formed at the sintering temperature of lower than 1600° C.
TABLE 2
__________________________________________________________________________
Flexural
Sintering Strength
Fracture
Condition
Formation
Relative
at Room
Toughness
Run Temp.
Time
of Acicular
Density
Temp.
(K.sub.IC)
No. (°C.)
(Min.)
Crystals
(%) (MPa)
(MPa · m.sup.1/2)
__________________________________________________________________________
Comp.
12 1400
360 X 80.1 35 3.8
Ex. 13 1500
360 X 85.0 73 4.0
14 1550
360 X 90.2 105 3.7
Ex. 15 1600
360 ◯
99.3 420 5.9
16 1650
360 ◯
98.0 372 6.4
17 1700
360 ◯
96.4 280 5.8
18 1750
360 ◯
92.5 171 5.4
__________________________________________________________________________
Although the present invention has been described with reference to the specific examples, it should be understood that various modifications and variations can be easily made by those skilled in the art without departing from the spirit of the invention. Accordingly, the foregoing disclosure should be interpreted as illustrative only and is not to be interpreted in a limiting sense. The present invention is limited only by the scope of the following claims
Claims (8)
1. A chromium carbide sintered body having high toughness comprising 99.5 to 50% by weight of Cr3 C2 and 0.5 to 50% by weight of AlN, said sintered body being obtained by sintering Cr3 C2 powders .Iadd.and AlN powders .Iaddend.at a temperature of 1600° C. to 1750° C., and said sintered body containing not less than 20% by area of acicular crystals of Cr3 C2 as observed from an SEM photograph.
2. The chromium carbide sintered body according to claim 1 wherein the majority of the acicular crystals of Cr3 C2 has a diameter of 0.1 to 10 microns and a length of 0.2 to 30 microns.
3. The chromium carbide sintered body according to claim 1 wherein said sintered body is obtained by sintering Cr3 C2 powders having a purity of not less than 99% and a means particle size of not more than 5 microns and AlN powders having a purity of not less than 99% and a mean particle size of not ore than 10 microns.
4. The chromium carbide sintered body according to claim 1 wherein said sintered body is obtained by sintering Cr3 C2 powders and AlN powders for 30 minutes to 12 hours.
5. The chromium carbide sintered body according to claim 4 wherein the sintering is performed under a non-oxidizing atmosphere selected from the group consisting of vacuum, argon, helium and nitrogen.
6. The chromium carbide sintered body according to claim 4 wherein the sintering is performed by a hot press method.
7. The chromium carbide sintered body according to claim 4 wherein the sintering is performed by a cold press molding method followed by a pressureless sintering method.
8. The chromium carbide sintered body according to claim 2 wherein the acicular crystals of the Cr3 C2 of 0.1 to 10 microns in diameter and of 0.2 to 30 microns in length are contained in an amount of not less than 20%.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP25072987 | 1987-10-06 | ||
| JP62-250729 | 1987-10-06 |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US07/253,674 Reissue US4927791A (en) | 1987-10-06 | 1988-10-03 | Chromium carbide sintered body |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| USRE33905E true USRE33905E (en) | 1992-04-28 |
Family
ID=17212173
Family Applications (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US07/253,674 Ceased US4927791A (en) | 1987-10-06 | 1988-10-03 | Chromium carbide sintered body |
| US07/676,201 Expired - Lifetime USRE33905E (en) | 1987-10-06 | 1991-03-27 | Chromium carbide sintered body |
Family Applications Before (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| US07/253,674 Ceased US4927791A (en) | 1987-10-06 | 1988-10-03 | Chromium carbide sintered body |
Country Status (3)
| Country | Link |
|---|---|
| US (2) | US4927791A (en) |
| EP (1) | EP0311043B1 (en) |
| DE (1) | DE3874269T2 (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5435814A (en) * | 1992-08-13 | 1995-07-25 | Ashland Inc. | Molten metal decomposition apparatus |
Families Citing this family (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5567662A (en) * | 1994-02-15 | 1996-10-22 | The Dow Chemical Company | Method of making metallic carbide powders |
| US5580833A (en) * | 1994-10-11 | 1996-12-03 | Industrial Technology Research Institute | High performance ceramic composites containing tungsten carbide reinforced chromium carbide matrix |
| US5470807A (en) * | 1995-03-17 | 1995-11-28 | Industrial Technology Research Institute | Chromium carbide based ceramics composite block gauge |
| FR2894597B1 (en) * | 2005-12-12 | 2008-04-11 | Ceramique Plastique Sa | MASSIVE MECHANICAL PIECE, IN FRITTE CERAMIC MATERIAL, AND METHOD FOR MANUFACTURING SUCH A BRAKE |
| CN105517716A (en) * | 2013-09-05 | 2016-04-20 | 马勒工业股份有限公司 | Wire Alloys for Plasma Wire Arc Coating Treatment |
| CN110371978B (en) * | 2019-07-01 | 2022-10-11 | 武汉科技大学 | Chromium carbide-aluminum nitride composite powder based on chromium-aluminum-carbon and preparation method thereof |
Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB952554A (en) * | 1961-07-18 | 1964-03-18 | Norton Co | Improved refractory materials and method of making the same |
| JPS59107972A (en) * | 1982-12-09 | 1984-06-22 | 株式会社クボタ | Heat-resistant ceramic material |
| JPS60145954A (en) * | 1983-12-29 | 1985-08-01 | 株式会社クボタ | Chromium carbide sintered body for heated material supporting surface of heating furnace |
-
1988
- 1988-10-03 US US07/253,674 patent/US4927791A/en not_active Ceased
- 1988-10-05 EP EP88116474A patent/EP0311043B1/en not_active Expired
- 1988-10-05 DE DE8888116474T patent/DE3874269T2/en not_active Expired - Fee Related
-
1991
- 1991-03-27 US US07/676,201 patent/USRE33905E/en not_active Expired - Lifetime
Patent Citations (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB952554A (en) * | 1961-07-18 | 1964-03-18 | Norton Co | Improved refractory materials and method of making the same |
| JPS59107972A (en) * | 1982-12-09 | 1984-06-22 | 株式会社クボタ | Heat-resistant ceramic material |
| JPS60145954A (en) * | 1983-12-29 | 1985-08-01 | 株式会社クボタ | Chromium carbide sintered body for heated material supporting surface of heating furnace |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5435814A (en) * | 1992-08-13 | 1995-07-25 | Ashland Inc. | Molten metal decomposition apparatus |
Also Published As
| Publication number | Publication date |
|---|---|
| EP0311043B1 (en) | 1992-09-02 |
| DE3874269D1 (en) | 1992-10-08 |
| DE3874269T2 (en) | 1993-04-08 |
| EP0311043A1 (en) | 1989-04-12 |
| US4927791A (en) | 1990-05-22 |
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