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  • 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
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
  • C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
  • C04B35/46—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on titanium oxides or titanates
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  • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
  • C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
  • C04B35/48—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on zirconium or hafnium oxides, zirconates, zircon or hafnates
  • C04B35/486—Fine ceramics
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  • 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
  • C04B35/5805—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 borides
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  • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
  • C22C—ALLOYS
  • C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
  • C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
  • C22C32/0073—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only borides
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  • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
  • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
  • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
  • C04B2235/38—Non-oxide ceramic constituents or additives
  • C04B2235/3804—Borides
• • 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
  • Y10T428/2982—Particulate matter [e.g., sphere, flake, etc.]

Definitions

• the present invention is directed at hard phase materials, and more particularly at hard phase materials that may be used to increase the hardness and wear resistant characteristics of coatings and metallurgical products.
• aluminum boride compounds based upon A1B 8-16 are disclosed to increase the hardness of metal coatings when incorporated into the metal coating matrix.
• the invention herein also relates to methods of preparing the subject aluminum boride compounds as feedstock materials and their incorporation into metallic, ceramic or polymeric matrix materials.
• the invention herein also relates to selected incorporation of the subject aluminum boron compounds in specific identified alloy compositions and at various selected concentrations.
• Wear resistant materials are often used in coating or hardfacing applications to protect the underlying material from rubbing, impact, frictional wear and similar potentially damaging mechanical actions.
• Wear resistant coatings or hardfacings may include a layer of uniformly hard or wear resistant material.
• such materials are often expensive and may not be readily susceptible to forming coatings on their own.
• one strategy for developing wear resistant coatings is to incorporate a hard phase into a material that is more susceptible to coating or a hardfacing processes and that is more cost effective.
• producing an effective wear resistant coating material may require incorporating a high volume fraction of the hard phase into the coating material.
• the hard phase, or domains of wear resistant material dispersed in the wear resistant coating are often ceramic materials.
• Ceramic materials that are especially suitable generally have chemical structures that involve electron transfers leading to very strong ionic (although in some cases covalent) bonding. The result is very stable, strong and high melting point compounds.
• wear resistant coating materials are ceramic, metallic, or polymeric material incorporating the hard phase.
• the hard phase may be incorporated into an iron based alloy. The iron-based alloy allows the coating to be applied to a substrate while the hard phase provides the wear resistant characteristics.
• the hard phase may be provided as particles dispersed in the ceramic, metallic, or polymeric matrix.
• Carbides such as tungsten-carbide (WC), titanium-carbide (TiC), chromium- carbide (Cr 3 C ), and the like have been used as hard phases within ductile matrices such as cobalt, iron, or nickel.
• the ductile component allows a cost effective coating to be formed on a substrate, while the carbide material provided the desired wear resistance.
• Other wear resistant coatings have been developed from hard oxides. For example, titanium oxide (TiO 2 ), zirconium oxide (ZrO 2 ), aluminum oxide (Al O 3 ), etc. have all been used to form wear resistant coatings.
• oxide hard phases may be incorporated into a metal matrix.
• oxide based coatings have also been produced by densifying the hard oxides to form a ceramics.
• some use has also been made of titanium boride (TiB 2 ) and zirconium boride (ZrB 2 ).
• wear resistant coatings including titanium boride and zirconium boride are generally formed by providing a titanium boride or a zirconium boride hard phase in a metallic, ceramic, or polymeric matrix.
• a wear resistant material, or a metal coating, or a powder material, or a wire material, or a metallurgical product comprising aluminum boride.
• the aluminum boride is of the general formula AlB 8- ⁇ 6 , thereby including, e.g., A1B 8 , A1B 9 , AlBio, AlBu, AlB ⁇ 2 , A1B 13 , A1B 14 , AIB15 and A1B 16 , as well as other alternatives within said compositional range, and mixtures thereof.
• the present invention comprises a method for forming a wear resistant material comprising aluminum boride of the general formula A1B _ 16 comprising supplying aluminum boride of the general formula AlBg- t ⁇ , and incorporating said aluminum boride into one of a metallic material, a ceramic material, and a polymeric material.
• the present invention is directed at a method for forming a wear resistant coating comprising providing a material comprising aluminum boride of the general formula AlB 8- ⁇ 6 , melting said material, and applying said melted material onto a substrate and forming said coating.
• the present invention is directed at a method of increasing the hardness of iron based alloys comprising supplying an iron alloy having a hardness, adding aluminum boride to said iron alloy of the general formula AlB 8- i 6 , and increasing said hardness of said iron alloy by addition of said aluminum boride.
• the present invention is directed at the method of forming aluminum boride phases with the general formula A1B 8-16 in alloys in which the aluminum and boron were added as elements or in standard feedstock form (such as ferroboron for boron).
• the targeted aluminum boride phase with the general formula AlBg. 16 then forms through precipitation in the liquid, during solidification, and/or during subsequent solid state precipitation through post heat treatments.
• the present invention is directed at a method of making a powder feed stock comprising providing a metallic powder, providing aluminum boride of the general formula A1B 8-16 , and combining said metallic powder and said aluminum boride to form said powder feedstock.
• the present invention is directed at a method of forming a metallurgical product comprising supplying aluminum boride of the general formula A1B 8-16 in powder form and forming said aluminum boride into a selected shape.
• the present invention is directed at a hard phase material providing increased hardness and wear resistance when incorporated into matrix materials.
• the hard phase material of the present invention is an aluminum boride of the formula A1B 8 _ 16 .
• the aluminum boride is the binary compound having the structure AlB ⁇ 2 , however, the invention, while described with respect to AlB ⁇ 2 is not limited to this particular composition.
• aluminum boride may be incorporated into a matrix material via solid-solid mixing, solid liquid mixing of aluminum boride material with the matrix material.
• aluminum boride may be incorporated into the matrix material through precipitation of the aluminum boride from the aluminum and boron containing matrix material.
• the hardness of and density of a sampling of conventional hard phase materials are listed.
• the hardness and density of aluminum boride is also listed on Table 1.
• aluminum boride has a hardness of 26 GPa and a density of 2.58 g/cm 3 . While the hardness of aluminum boride is comparable to that of many conventional hard phase materials, the density is relatively lower than most other hard phase materials. The difference in density between aluminum boride and tungsten carbide is especially large.
• the relatively low density of aluminum boride as compared to many conventional hard phase materials allows a much lower weight percentage of aluminum boride to form a significant volume fraction of hard phase in a matrix material. A matrix material may, therefore, be more heavily loaded with aluminum boride for a given weight percentage as compared to many conventional hard phase materials.
• the beneficial effects of the incorporating the preferred low density aluminum boride phase, A1B 12 can be shown for example in Table 2.
• the aluminum boride hard phase may be preferably formed as a second phase precipitate in a metallic matrix.
• the aluminum boride hard phase may be preferably formed as a second phase precipitate in a metallic matrix.
• the ability of metallic systems, such as iron, nickel, and cobalt containing alloys, to dissolve large amounts of boron and aluminum (typically up to 50 atomic percent of aluminum plus boron) into the liquid phase of the metallic system may uniquely form aluminum boride hard phase in situ.
• the formation of an in situ aluminum boride hard phase may be accomplished by dissolving boron and aluminum as separate ingredients, i.e., not preformed aluminum boride, into the metallic system.
• the aluminum and boron may react with one another in the liquid phase metallic system to form aluminum boride.
• the aluminum boride may precipitate from the liquid phase metallic system, may form during solidification, or may form through solid state precipitation through subsequent heat treatment.
• the ability to form a hard phase in situ through second phase precipitation can be especially advantageous when used to create a hard phase in alloys that contain boron.
• Many nickel and iron based alloys common incorporate 15 to 20 at. % boron.
• Small amounts of aluminum may be added to such high boron alloys and may react with the boron in the alloy.
• aluminum boride precipitates can be formed from supersaturated solid solution in accordance with the present invention.
• the present invention provides method of improving wear resistance characteristics of materials.
• the relatively high hardness of aluminum boride enhances the hardness and wear resistance of a matrix, or base, material incorporating aluminum boride, and preferably, aluminum boride of the general formula AlB ⁇ 2 .
• Aluminum boride containing material may, consistent with a first aspect of the present invention, be incorporated into a matrix material using conventional incorporation techniques to enhance the wear resistance of the matrix material. Materials having improved wear resistance by the incorporation of aluminum boride may be used for hard-facing, or in specific application to reduce mechanical wear of the matrix material.
• a feedstock material including aluminum boride of the preferred AlBj 2 hard phase is provided. Generally, the feedstock material includes the preferred AlB ⁇ 2 particles incorporated into a metallic, ceramic, or polymeric matrix.
• the feed stock may ultimately be provided as a powder, wire, rod, etc. suitable for various subsequent processes.
• Example metallic materials include iron, nickel, and cobalt alloys.
• polymeric matrix materials include aromatic polyamides such as KevlarTM and polyolefin material, such as oriented polyethylene sold under the SpectraTM trademark.
• Example ceramic materials include alumina, titania, and zirconia ceramics. Consistent with this aspect, aluminum boride hard phase may be synthesized using appropriate chemical processes such as those which are used to make conventional oxide or carbide particles. Those having skill in the art will understand that various alternative processes may be used to produce raw aluminum boride hard phase.
• the particle size of the aluminum boride may be reduced to a desired size range, for example by grinding, high energy milling, etc.
• the preferred A1B 12 particles which will typically be in the size range from 0.5 micron to 500 micron may be incorporated with an appropriate matrix.
• a powder feedstock suitable for use in high-velocity oxygen-fuel (HVOF) thermal spay coating may be prepared by mixing the aluminum boride hard phase with a metallic binder such as iron, nickel, and cobalt containing metallic matrix alloys.
• the metallic binder may be provided as a powder, and may be mixed with the hard phase and a liquid to form a slurry.
• a liquid component may facilitate mixing and dispersion of the hard phase relative to the metallic binder.
• the slurry may then be dried, e.g., by spray drying, to produce a powder feedstock.
• a powder feedstock prepared using this technique may also be suitable for use with other know thermal spray coating applications, such as plasma spraying, flame spraying, etc.
• Another exemplary approach for preparing a feedstock including the preferred AlB ⁇ 2 hard phase includes adding elemental aluminum and boron to an alloy of the metallic matrix to be used in the coating system. The alloy may then be processed into a powder using conventional methods such as gas, water, or centrifugal atomization, etc.
• the desired aluminum boride phase may be formed in situ in the alloy by liquid state reaction during the melting atomization process, during solidification or subsequent cooling, or via precipitation from a supersaturated solid solution through a subsequent post heat treatment.
• Feedstock containing the preferred AlB ⁇ 2 phase may be processed according to a variety of techniques. For example, powder feedstock including aluminum boride may be applied to a substrate in order to produce a coating having improved wear resistance. Surface coatings may be applied to a substrate using conventional thermal spray methods, including plasma spraying, flame spraying, HVOF spraying etc. Similarly, wear resistant coatings may be applied to a substrate via weld-on hard facing, for example by plasma transfer arc welding and similar methods known in the art.
• powder shall be understood to mean particles in the micron size range.
• the particles will be sized and classified to develop feedstock powders which are of the appropriate size range for industrial processing.
• the high velocity oxy-fuel powder may be sized +15 to -53 microns
• the plasma spray powder might be sized +45 to -106 microns
• the plasma transferred arc weld overlay powder may be sized +53 to -150 micron etc.
• aluminum boride may be incorporated into a wire or rod.
• Aluminum boride powder, or powder feedstock containing aluminum boride or aluminum with boron in various forms, may be used to form the core of a wire or rod.
• the wire or rod having an aluminum boride core can be used for depositing coatings using processes including twin roll wire arc, activated arc, or high velocity arc processes. Additionally, hard face coatings can be developed though MIG, TIG, or stick welding processes using wire or rod feedstock including aluminum boride.
• aluminum boride powder or powder feedstock containing aluminum boride may be processed alone to form various powder metallurgy products.
• Aluminum boride containing powder feedstock is susceptible to known powder forming processes. Exemplary processes include press and sintering, powder forging, hot isotactic pressing (HIP), and metal injection molding.
• Each of these processes generally involve preforming a powder material into a perform having a desired near-net-shape.
• the powder is then heated to density the preform and consolidate the powder into a solid article. Often densifying and consolidating the powder is accomplished under pressure.
• solid products incorporating the preferred AlB ⁇ 2 may be formed through extrusion processes including hot extrusion and equal channel extrusion. Consistent with conventional profile extrusions, linear members having a constant cross-sectional profile may be produced. Consistent with yet another aspect of the invention, specific alloy compositions have been identified in which the incorporation or precipitation of aluminum boride provides especially advantageous improvements in hardness and wear resistance.
• the Superhard SteelTM alloy having the general composition Fe 5 . 3 Mn 2 Cr ⁇ 9 Mo 2 . 5 W ⁇ . 7 B ⁇ 6 C 4 Si 2 . 5 .
• the Superhard SteelTM alloys generally are iron based glass forming alloys which contain chromium, molybdenum, and tungsten.
• Aluminum boride may be easily incorporated into the Superhard SteelTM alloy either as particulate component mixed with the Superhard SteelTM alloy or through precipitation of an aluminum boride hard phase from as a second phase precipitate. Additionally, the formation of an aluminum boride phase may be advantageously achieved in nickel based alloy systems.
• Nickel contains several low melting point ( ⁇ 1150°C) eutectics at 17.0 at%, 10.0 at%, 39.5 at%, and 45.3 at% boron. These low melting point eutectics may allow very high concentrations of aluminum boride to precipitate out of supersaturated solid solution in an aluminum-boron-nickel based alloy system. Such precipitation of aluminum boride may allow the hard phase to be easily incorporated into the nickel alloy system. Aluminum and boron additions can be incorporated into existing commercial alloys such as Cu-Nickel monels, and nickel based superalloys such as 625 and 718. Examples of this will be given in the next section Additionally, the formation of an aluminum boride phase may be advantageously achieved in cobalt based systems.
• the hardness increases resulting from the further addition of aluminum in combination with the 15 at% aluminum/boron in a 1 to 12 ratio is believed to occur from the further aluminum additions reacting with boron in the SHS717 alloy.
• the reaction between the further aluminum additions and the boron native in the SHS717 alloy may produce additional aluminum boride hard phase (AlB ⁇ ) in the SHS717 matrix, thereby providing further hardness enhancements.
• AlB ⁇ additional aluminum boride hard phase
• microstructural refinements involve establishing amorphous structures and micro-crystalline domains as desired within the metallic structure.
• powder feedstock including a Superhard SteelTM alloy matrix incorporating aluminum boride hard phase is sprayed as a coating, it is contemplated herein that one can further increase the hardness of the coatings by refining the microstructure of the Superhard SteelTM alloy matrix.
• Table 3 Composition and Hardness for Iron Based Alloys with the Following Stoichiometry; [(Fe 523 Mn 2 Cn 9 Mo 25 W ⁇ 7 B ⁇ 6 C 4 Si 25 ) ⁇ oo-x- y + (AlB ⁇ 2 ) x + Al y ]
• Figure 1 SEM backscattered electron microstructure showing the microstructure of the DABX15Y1 ingot.
• the hard phases containing aluminum and boron along with dissolved tungsten, molybdenum, and chromium are shown as the white cubic phases.
• Figure 2 SEM backscattered electron microstructure showing the microstructure of the DABXO ingot.
• Nickel Based Alloys In expenmental settings, the addition of AIB12 to nickel based alloys have been demonstrated The addition of the aluminum boride produced sigmficantly enhanced hardness of the alloy.
• Table 4 the hardness is shown for pure nickel alloy which have been alloyed with simultaneous additions of aluminum and boron The three elements were placed at the stoichiometric ratios listed in Table 4, and then arc-melted into 5 gram ingots As shown, the hardness increased dramatically with the aluminum and boride additions up to an HVlOO hardness of 1462 Note that all hardness indentations are reported as an average of a minimum of 5 indentations. Also, note that nickel is a very soft face centered cubic element and the hardness of pure nickel is less than 200 HVlOO. Table 4 Alloy Composition and Hardness for (Nickel) ⁇ oo-x + (A1B 2 ) X
• HVlOO hardness is shown for aluminum and boron additions to an existing commercial alloy C-22 (Ni6 3 .oCr2 .6M ⁇ 8.2Fe 3 . 3 Wo.7Vo.2).
• the alloys were made by adding aluminum and boron additions to C-22 powder and then melting the feedstock into ingots using arc-melting.
• the arc-melted 15 gram ingots were then further processed into melt-spun ribbons by ejecting a liquid melt onto a rapidly moving copper wheel with a tangential velocity of 15 m/s.
• the ribbons were then metallographically mounted and polished and the cross sections of the approximately 135 micron wide ribbon were tested for hardness using Vickers at a 100 gram load.

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