WO2013172941A1 - Personnalisation de l'acier à un stade tardif - Google Patents

Personnalisation de l'acier à un stade tardif Download PDF

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Publication number
WO2013172941A1
WO2013172941A1 PCT/US2013/030724 US2013030724W WO2013172941A1 WO 2013172941 A1 WO2013172941 A1 WO 2013172941A1 US 2013030724 W US2013030724 W US 2013030724W WO 2013172941 A1 WO2013172941 A1 WO 2013172941A1
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WO
WIPO (PCT)
Prior art keywords
steel
product
substrate
composition
thickness
Prior art date
Application number
PCT/US2013/030724
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English (en)
Inventor
Daniel E. Bullard
Joseph Mcdermott
Original Assignee
Arcanum Alloy Design Inc.
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Arcanum Alloy Design Inc. filed Critical Arcanum Alloy Design Inc.
Publication of WO2013172941A1 publication Critical patent/WO2013172941A1/fr

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Classifications

    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D5/00—Heat treatments of cast-iron
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00—Layered products comprising a layer of metal
    • B32B15/18—Layered products comprising a layer of metal comprising iron or steel
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D11/00—Process control or regulation for heat treatments
    • 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
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/58—After-treatment
    • C23C14/5806—Thermal treatment
    • 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
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/06—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material
    • C23C16/16—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of metallic material from metal carbonyl compounds
    • 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
    • C23C18/00—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating
    • C23C18/16—Chemical coating by decomposition of either liquid compounds or solutions of the coating forming compounds, without leaving reaction products of surface material in the coating; Contact plating by reduction or substitution, e.g. electroless plating
    • C23C18/1601—Process or apparatus
    • C23C18/1633—Process of electroless plating
    • C23C18/1689—After-treatment
    • C23C18/1692—Heat-treatment
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/34—Pretreatment of metallic surfaces to be electroplated
    • C25D5/38—Pretreatment of metallic surfaces to be electroplated of refractory metals or nickel
    • C25D5/40—Nickel; Chromium
    • C—CHEMISTRY; METALLURGY
    • C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
    • C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
    • C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
    • C25D5/48—After-treatment of electroplated surfaces
    • C25D5/50—After-treatment of electroplated surfaces by heat-treatment

Definitions

  • This disclosure is related to the late-stage customization of steels, alloys, and other metals during the manufacturing process that starts with bulk materials such as coil, ore, and scrap metal.
  • the typical process of forming steel alloys includes the formation of a liquid alloy composition that has the approximate composition of the desired/final steel alloy. This process includes melting, casting, and rolling of large volumes of iron, nickel, chromium, tungsten and/or other alloying elements. The rolling of the steel alloys often requires multiple rolling/heat treatment steps to prevent the cracking and work hardening of the steel alloy. These repetitive steps add significant costs and time to the production of the steel alloy.
  • steel casting lines are typically operated in a continuous fashion. These continuous steel casting lines produce a single steel alloy. The production of a second steel alloy requires either a second casting line or shutting down the first line and restarting with a new alloy
  • Another tactic used to reduce the costs associated with manufacturing steel alloys is the standardization or grading of steel, (e.g., 316 Stainless, 403 Stainless).
  • the standardization allows the commoditization of the steel and the steel mill to produce, catalogue, and sell the commodity to a consumer. This prevents the consumer having input on the composition and/or performance of the offered product. That is, if the steel grades offered by a steel mill do not meet the consumer's demand either the steel mill or the consumer suffers.
  • This process can include receiving a product specification that can include performance or composition criteria;
  • Figure 1 depicts one embodiment of the steel customization process described herein.
  • Described herein is a metal customization process that provides a coated metal product which meets predefined product specifications that are typically based on whole thickness materials.
  • the metal customization process can be used with any commercially available substrates (e.g., aluminum bar, aluminum coil, steel bar, steel coil, and alloys thereof) but, preferably, the substrate is made of steel (e.g., carbon steel, low carbon steel or steel alloys).
  • steel e.g., carbon steel, low carbon steel or steel alloys.
  • steel is an alloy of iron and at least one other element.
  • steel refers to the alloy of iron and carbon of which many classes exist (e.g., pig iron, cast iron, carbon steel, low carbon steel, and very low carbon steel).
  • the steel customization process can include receiving a first product specification that includes criteria selected from the group consisting of performance criteria, composition criteria, thickness criteria, and a combination thereof.
  • the product specification/specifications is/are received from a purchaser.
  • the process further includes converting the first product specification to a first surface specification that includes a first surface alloy composition and a first surface alloy thickness, and a first core specification that includes a first core composition and a first core thickness.
  • the process can include converting the product specification to a deposition specification that includes the substrate composition, the substrate thickness, the coating composition, and a coating composition thickness.
  • the process additionally includes providing a plurality of substrates that individually have the same substrate composition and substrate thickness.
  • the plurality of substrates carbon steel. That is, the plurality of substrates have the same composition and are a carbon steel, low carbon steel, or very low carbon steel.
  • providing the plurality of substrates can include casting a molten metal or metal alloy to produce the plurality of substrates (e.g., casting and rolling a carbon steel to provide the plurality of substrates).
  • the process includes depositing at least one alloying element onto one of the plurality of substrates to form a first coating composition carried by that substrate.
  • the coating composition comprises alloying element(s), and the alloying element(s) can be selected from the group consisting of titanium, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, iron, cobalt, rhodium, nickel, copper, silver, zinc, aluminum, silicon, and a mixture thereof.
  • the alloying element(s) include(s) chromium.
  • the combined substrate thickness and coating composition thickness are, preferably, substantially similar to the product specification thickness criterion.
  • depositing the alloying element(s) can include a deposition process selected from the group consisting of chemical vapor deposition, physical vapor deposition, thermalspray, electrochemical deposition, electroless deposition, and a mixture thereof.
  • the process further includes annealing the first coating composition and the coated substrate to form a first product that meets the first surface specification and the first core specification.
  • annealing includes heating the first coating composition carried by that substrate to an annealing temperature for an annealing time which are sufficient to provide the first surface alloy composition and the first core composition.
  • the annealing provides a first surface alloy composition that is approximately equal to the first core composition.
  • the steel customization process can further include receiving a second product specification and producing a second product that meets that second specification by the above disclosed process. That is, the above process can further include converting a second product specification to a second surface specification that includes a second surface alloy composition and a second surface alloy thickness, and a second core specification that includes a second core composition and a second core thickness;
  • the process preferably, include producing a second product that is not the same as the first product. That is, the first product specification and the second product specification are not the same.
  • the difference between the first product specification and the second product specification is a difference in their compositions while the thicknesses can be the same.
  • the steel manufacturing process can include receiving an order for a stainless steel product that includes performance, thickness, and composition criteria; then providing a carbon steel substrate; depositing at least one alloying element selected from nickel and chromium onto the carbon steel substrate, at a temperature below an annealing temperature, thereby forming a coating composition that is carried by the carbon steel substrate; then annealing the coating composition and the carbon steel substrate to form a stainless steel product; and then satisfying the order by providing the stainless steel product.
  • the stainless steel product consists of a stainless steel layer carried by a core composition that is carbon steel.
  • the stainless steel product has an approximately consistent composition throughout the stainless steel product.
  • the carbon steel substrate has a thickness less than about 2 mm; and wherein the stainless steel product thickness is less than about 2 mm.
  • the herein described late-stage customization of steels, alloys, or other metals employs steel as a starting substrate and is therefore a steel customization process.
  • the steel customization process can include receiving a product specification that can include performance or composition criteria; converting the product specification to a surface specification that can include a surface alloy composition and a surface alloy thickness, and a core specification that can include a core composition and a core thickness.
  • the process can then include treating a substrate with a deposition composition (e.g., at a temperature below an annealing temperature) and thereby depositing at least one alloying element onto the substrate to form a coating composition carried by the substrate.
  • the process can include annealing the coating composition and the substrate to form a product that can include the surface specification and the core specification.
  • the process can include confirming that the product meets the product specification.
  • the steel customization process includes the production of multiple products (e.g., a first product and a second product) from, preferably, a single substrate stock.
  • the steel customization process first includes the steel customization process described above.
  • the process can include receiving a first product specification; converting the first product specification to a first surface specification that includes a first surface alloy composition and a first surface alloy thickness, and a first core specification that includes a first core composition and a first core thickness; treating a first substrate with a first deposition composition thereby forming a first coating composition that is carried by the first substrate; then annealing the first coating composition and the first substrate to form a first product that includes the first surface specification and the first core specification; and confirming that the first product meets the first product specification.
  • This example further includes receiving a second product specification that includes performance or composition criteria; converting the second product specification to a second surface specification that includes a second surface alloy composition and a second surface alloy thickness, and a second core specification that includes a second core composition and a second core thickness; treating a second substrate with a second deposition composition, at a temperature below an annealing temperature, thereby depositing at least one alloying element onto the substrate to form a second coating composition that is carried by the second substrate; annealing the second coating composition and the second substrate to form a second product that includes the second surface specification and the second core specification; and then confirming that the second product meets the second product specification.
  • the first surface alloy composition and the second surface alloy composition are not the same; but the first core composition and second core composition are the same (that is, have they have the same composition).
  • two products based on two product specifications are produced from substrates that have the same composition.
  • the substrates are parts cut from a single batch of substrate starting material (e.g., one batch of molten steel).
  • a third product or a plurality of products can be produced using following the procedures outlined above.
  • the first and the third product can have the same or substantially the same product specification.
  • the product specifications, and thereby the resultant products can have substantially different surface chemistries.
  • the substrate can be cut form a single batch of substrate starting material or produced on a continuous line (e.g., via continuous casting).
  • the product specification (or specifications) is received from a purchaser (or purchasers). That is, instead of offering or in addition to offering, a standard catalogue of products, the product specification can be customized for each purchaser. As such, the purchaser can specify performance or composition criteria, thicknesses, and even the amount or volume of the product.
  • the product specification includes a thickness criterion (e.g., the thickness can be the distance from a first major surface to a parallel and opposing second major surface of the product, or the diameter of a wire).
  • the process for receiving the product specification can be automated. For example, a purchaser interface can provide selection options that can be selected by the purchaser and that generate the product specification.
  • the purchaser interface can provide standardized or prearranged selection options that can correspond to standard grades of commercial materials (e.g. , 304SS, 314SS) in addition to selection options corresponding to size and shape criteria (e.g., thickness, volume, shape, length).
  • the purchaser interface can be, for example, a website or other electronic order form.
  • the purchaser interface can be configured to communicate with a production controller.
  • the production controller can include data on on-going and scheduled substrate production and substrate customization activities (e.g., processes), as well as, materials on hand, and material costs.
  • the production controller can provide estimates on, for example, the cost of a product meeting a purchaser-provided product specification, a time necessary to manufacture the product, and/or a delivery date based on a commitment to the purchase of the product.
  • the production controller can further provide steel mill operation control, which for example can automate the production of the customized steel product.
  • the steel customization process can further include converting the product specification to a deposition specification.
  • the deposition specification typically includes a substrate composition, a substrate thickness, and a coating composition thickness. Aspects of the deposition specification can be adapted or provided from results based on the deposition of volatile deposition agents onto substrates. Further aspects of the deposition specification can be determined directly from the product specification.
  • the deposition specification preferably includes the substrate composition, substrate thickness, coating composition, coating composition thickness, and processing requirements (e.g., annealing temperatures and annealing times).
  • the product specifications for, for example, wire and coil typically include a thickness criterion (e.g., the wire gage or foil/coil thickness).
  • the combination of the substrate thickness and the coating composition thickness is substantially similar to the product specification's thickness criterion.
  • the deposition specification included coating composition thickness can be determined from the substrate thickness and the product specification; that is, the product thickness is linearly/directly dependent on the combination of the substrate thickness and the coating composition thickness (e.g., the product thickness is the sum of the substrate thickness and the coating composition thickness).
  • the sum of the substrate thickness and the coating composition thickness may be substantially greater than the product thickness (e.g., the coating composition and/or the substrate may have a density less than the density of the product).
  • Further aspects of the process can include reforming the product after a coating composition is applied (e.g. , hot/cold rolling the coated substrate and/or the product) and correspondingly the product thickness may be significantly different from the combination of the substrate thickness and the coating composition thickness.
  • the steel customization process can include selecting the deposition composition from a predetermined class of volatile deposition agents and, optionally, a carrier gas.
  • the volatile deposition agent is selected from the group consisting of a metal alkyl, a metal alkylamide, a metal amine, a metal cyclopentadienyl, a metal acetylacetonate, a metal carbonyl, a metal hydride, and a mixture thereof. More preferably, the volatile deposition agent is selected from the group consisting of a metal carbonyl, a metal hydride and a mixture thereof. Even more preferably, the volatile deposition agent is a metal carbonyl. Examples of volatile deposition agents can be found in the Handbook of Chemical Vapour Deposition (CVD), Principles, Technology, and
  • metal carbonyls include, but are not limited to, Cr(CO) 6 , Mn(CO) 6 , Fe(CO) 5 , Co 2 (CO) 8 , Ni(CO) 4 , Mo(CO) 6 , or mixtures thereof.
  • the carrier gas can be selected from H 2 , CO, C0 2 , N 2 , Ar, or mixtures thereof.
  • the steel customization process includes casting molten steel to produce the substrate or substrates.
  • the casting process generally, includes heating iron to a temperature above its melting point, optionally to a temperature above a eutectic alloys melting point, when the metal being cast is a eutectic alloy.
  • the casting process can include any casting method; preferably the casting or casting process is selected from the group consisting of curved casting, horizontal casting, and thin strip casting.
  • the casting can be thin strip casting; or the casting can be curved casting followed by hot rolling.
  • the process can include the continuous casting of molten steel on one steel production line to form a plurality of steel substrates.
  • These steel substrates preferably, have substantially the same compositions and dimensions.
  • one steel production line can produce both the first substrate and the second substrate. That is, substrates cut from a continuous casting of molten steel should, and preferably do, have substantially the same composition independent of the time at which the substrates are cut from the casting. Thereby, a continuously casting, steel production line can produce a plurality of substrates with substantially the same composition and dimensions.
  • the substrate can have a substrate composition that includes iron.
  • the substrate composition can be carbon steel, preferably, low carbon steel, and more preferably very low carbon steel.
  • the product's core composition is essentially the same as the substrate composition. That is, the process described herein, preferably, can affect a surface of the substrate but does not change the composition of the material at a distance furthest from a surface (i.e., at the substrate's core).
  • the core composition can extend throughout the majority of the product, that is, the surface or surface composition extends a limited distance into the substrate, e.g., less than 1000 microns, 500 microns, 250 microns, 100 microns, 50 microns, 10 microns, 5 microns, 1 micron, or 0.5 microns.
  • the substrate can further be a spheroidite steel, coarse pearlite steel, annealed steel, normalized steel, martempered steel, tempered steel, or bainite steel.
  • the substrate is an annealed carbon steel.
  • the shape of the substrate can vary dependent on the desired product.
  • the substrate can be a bar, tube, wire, plate, or coil.
  • the substrate can alternatively be a finished metal object or have a finished shape, for example, a fastener, a casement (e.g., a cellphone or computer case), engine part (e.g., engine block, piston, valve, exhaust part), a wheel part, a bicycle frame, a gear wheel, or kitchen or eating utensil.
  • the substrate is a steel coil; more preferably, the substrate is an open steel coil.
  • the coating process generally, includes depositing a material onto the surface of the substrate to form a coating composition.
  • the coating composition can be a single layer of a pure element (e.g., nickel), can be a single layer of an alloy (e.g., nickel and chromium), or can be a plurality of layers (e.g., where each layer is the same element (i.e., multiple layers of, for example, nickel) or where layers include different elements or different compositions).
  • the coating composition includes a plurality of alloying element layers.
  • Each alloying element layer preferably, includes at least one alloying element selected from the group consisting of titanium, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, iron, cobalt, rhodium, nickel, copper, silver, zinc, aluminum, and silicon.
  • each alloying element layer is a layer of a single element (a pure alloying element) or an alloy of elements (a plurality of different alloying element in a single layer), where the alloying element is selected from the group consisting of titanium, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, iron, cobalt, rhodium, nickel, copper, silver, zinc, aluminum, and silicon.
  • the coating composition includes a plurality of layers where at least (1 ) one alloying element layer is a layer of iron, and/or (2) one alloying element layer is an alloy of iron and at least one alloying element selected from the group consisting of titanium, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, cobalt, rhodium, nickel, copper, silver, zinc, aluminum, and silicon.
  • the coating composition can be iron and at least one alloying element; where the alloying element is selected from the group consisting of titanium, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, cobalt, rhodium, nickel, copper, silver, zinc, aluminum, and silicon. More preferably, the coating compositions described above include an alloying element selected from titanium, molybdenum, chromium, nickel, aluminum, and silicon; even more preferably the coating compositions include an alloying element selected from molybdenum, chromium and nickel; and still more preferably an alloying element selected from chromium and nickel.
  • the alloying element is selected from the group consisting of titanium, zirconium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, manganese, cobalt, rhodium, nickel, copper, silver, zinc, aluminum, and silicon. More preferably,
  • the coating composition can be formed by treating the substrate with the deposition composition (e.g., at a temperature below an annealing temperature) and thereby depositing an alloying element or alloying element layer onto the substrate.
  • the treatment of the substrate with the deposition composition preferably, includes the chemical vapor deposition of at least one of the alloying element from a volatile deposition agent.
  • the herein described process can, optionally, include annealing the coating composition and the substrate to form a product that can include the surface specification and the core specification.
  • the annealing process can include enclosing the substrate in a deposition chamber; annealing the coating composition and the substrate within the deposition chamber; and then removing the product from the deposition chamber.
  • This example can further include coating the substrate with the coating composition within the deposition chamber, that is, the coating and annealing are completed in a single deposition chamber (e.g., a deposition-annealing furnace).
  • the coating and annealing process can include enclosing the substrate in a deposition chamber; coating the substrate with the coating composition; moving the substrate carrying the coating composition to an annealing furnace; annealing the coating composition and the substrate in the annealing furnace; and then removing the product from the annealing furnace.
  • the steel customization process can include removing the first steel product from the deposition chamber after treating the first substrate with the first deposition composition; positioning the second steel substrate in the deposition chamber; then treating the second steel substrate with the second deposition agent; and then removing the second product from the deposition chamber.
  • the steel customization process can include moving a first coated composition for the deposition chamber to the annealing furnace and positioning the second substrate in the deposition chamber, then annealing the first coated composition while coating the second substrate; and then moving the second substrate to the same or a different annealing furnace.
  • a deposition time e.g., a deposition time
  • a single deposition chamber and single annealing furnace can be operated in tandem.
  • a single deposition chamber be operated with a plurality of annealing furnaces operated in parallel.
  • the steel customization process includes the casting of the substrate and before the substrate cools the coating of the substrate.
  • the process can be substantially free of cooling the substrate to a temperature of less than 50 °C, 100 °C, 150 °C, 200 °C, 250 °C, 300 °C, 350 °C, 400 °C, 450 °C, 500 °C, 550 °C, 600 °C, 650 °C, or 700 °C until after annealing.
  • the substrate is manufactured (e.g., cast and shaped) and then treated with the deposition agent without cooling to a temperature of less than 200 °C, less than 300 °C, less than 400 °C, or less than 500 °C until after annealing. Even more preferably, the substrate is treated with the deposition agent at a temperature of less than about 500 °C, 400 °C, or 300 °C.
  • the steel manufacturing process includes receiving an order for a stainless steel product that includes performance or composition criteria; then providing a carbon steel substrate that is sufficient to carry a stainless steel layer; depositing at least one alloying element selected from nickel and chromium, optionally including iron, onto the carbon steel substrate, at a temperature below an annealing temperature, thereby forming a coating composition that is carried by the carbon steel substrate; then annealing the coating composition and the carbon steel substrate to form a stainless steel product that carries the stainless steel layer and includes a core composition that is carbon steel; and then satisfying the order by providing the stainless steel product that carries the stainless steel layer and that includes the core composition that is carbon steel.
  • the steel manufacturing process can further include providing a deposition layer carried by the product. That is, the process can include treating the substrate with a deposition composition to form the coating composition carried by the substrate, annealing the coating composition and the substrate, and then depositing another coating composition upon the annealed product.
  • the steel manufacturing process can further include providing an overcoating to the (annealed) product.
  • the overcoating can be, for example, a layer of an alloying element (e.g., the same alloying element that is impregnating the sponge-iron layer, or a different alloying element), a plurality of alloying elements (e.g., as an alloy layer or as distinct/individual layers), an oxide (e.g., a silicon oxide, an aluminum oxide, or a transition metal oxide), or a nitride (e.g., a silicon nitride, or a transition metal nitride).
  • an alloying element e.g., the same alloying element that is impregnating the sponge-iron layer, or a different alloying element
  • a plurality of alloying elements e.g., as an alloy layer or as distinct/individual layers
  • an oxide e.g., a silicon oxide, an aluminum oxide, or a transition metal oxide
  • a nitride

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Metallurgy (AREA)
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  • Organic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Physics & Mathematics (AREA)
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  • General Chemical & Material Sciences (AREA)
  • Electrochemistry (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Other Surface Treatments For Metallic Materials (AREA)
  • Chemical Vapour Deposition (AREA)
  • Physical Vapour Deposition (AREA)

Abstract

L'invention concerne un procédé de personnalisation de métal qui fournit un produit métallique d'alliage qui répond à des spécifications prédéfinies de produit, qui sont généralement basées sur l'épaisseur total des matériaux. Le procédé de personnalisation du métal peut être utilisé sur de quelconques substrats commercialement disponibles (par exemple, une barre d'aluminium, une bobine d'aluminium, une barre d'acier, une bobine d'acier et leurs alliages) mais, de préférence, le substrat est constitué d'acier (par exemple l'acier au carbone, l'acier pauvre en carbone ou des alliages d'acier). Le présent procédé peut comprendre la réception d'une spécification de produit qui peut comprendre des critères de performances ou de composition ; la conversion de la spécification de produit en une spécification de surface et en une spécification de noyau ; puis le traitement d'un substrat par une composition de dépôt, par exemple, à une température inférieure à la température de recuit, ce qui permet le dépôt d'au moins un élément d'alliage sur le substrat pour former une composition de revêtement qui est supportée par le substrat ; puis le recuit du substrat revêtu pour obtenir un produit qui réponde à la spécification de produit.
PCT/US2013/030724 2012-05-15 2013-03-13 Personnalisation de l'acier à un stade tardif WO2013172941A1 (fr)

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US10765898B2 (en) 2016-07-07 2020-09-08 Bull Moose Tube Company Steel coated metal structures and methods of fabricating the same

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EP0175632B1 (fr) * 1984-09-13 1989-10-25 The Goodyear Tire & Rubber Company Elément d'acier revêtu d'un alliage de laiton quaternaire et caoutchouc renforcé par celui-ci

Patent Citations (1)

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EP0175632B1 (fr) * 1984-09-13 1989-10-25 The Goodyear Tire & Rubber Company Elément d'acier revêtu d'un alliage de laiton quaternaire et caoutchouc renforcé par celui-ci

Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US10765898B2 (en) 2016-07-07 2020-09-08 Bull Moose Tube Company Steel coated metal structures and methods of fabricating the same

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