WO2021126518A1 - Iron-based high corrosion and wear resistance alloys - Google Patents

Iron-based high corrosion and wear resistance alloys Download PDF

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Publication number
WO2021126518A1
WO2021126518A1 PCT/US2020/062714 US2020062714W WO2021126518A1 WO 2021126518 A1 WO2021126518 A1 WO 2021126518A1 US 2020062714 W US2020062714 W US 2020062714W WO 2021126518 A1 WO2021126518 A1 WO 2021126518A1
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WIPO (PCT)
Prior art keywords
alloy
example embodiments
iron
less
disclosure
Prior art date
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Ceased
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PCT/US2020/062714
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English (en)
French (fr)
Inventor
Cameron Jacob EIBL
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Oerlikon Metco US Inc
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Oerlikon Metco US Inc
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Filing date
Publication date
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Priority to CA3163544A priority Critical patent/CA3163544A1/en
Priority to JP2022533109A priority patent/JP2023507264A/ja
Priority to US17/775,770 priority patent/US20220389549A1/en
Priority to EP20902752.3A priority patent/EP4077742A4/en
Priority to CN202080083745.2A priority patent/CN114787395B/zh
Publication of WO2021126518A1 publication Critical patent/WO2021126518A1/en
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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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
    • C21D8/00—Modifying the physical properties of ferrous metals or ferrous alloys by deformation combined with, or followed by, heat treatment
    • 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
    • C21D6/00—Heat treatment of ferrous alloys
    • C21D6/002—Heat treatment of ferrous alloys containing Cr
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C33/00—Making ferrous alloys
    • C22C33/02—Making ferrous alloys by powder metallurgy
    • C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
    • C22C33/0278—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5%
    • C22C33/0285—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements with at least one alloying element having a minimum content above 5% with Cr, Co, or Ni having a minimum content higher than 5%
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/22—Ferrous alloys, e.g. steel alloys containing chromium with molybdenum or tungsten
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/18—Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/32—Ferrous alloys, e.g. steel alloys containing chromium with boron
    • 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
    • C23C30/00—Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/067—Metallic material containing free particles of non-metal elements, e.g. carbon, silicon, boron, phosphorus or arsenic
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/04—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the coating material
    • C23C4/06—Metallic material
    • C23C4/08—Metallic material containing only metal elements
    • 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
    • C23C4/00—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge
    • C23C4/12—Coating by spraying the coating material in the molten state, e.g. by flame, plasma or electric discharge characterised by the method of spraying
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D65/00—Parts or details
    • F16D65/02—Braking members; Mounting thereof
    • F16D65/12—Discs; Drums for disc brakes
    • F16D65/127—Discs; Drums for disc brakes characterised by properties of the disc surface; Discs lined with friction material
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D66/00—Arrangements for monitoring working conditions, e.g. wear, temperature
    • F16D66/02—Apparatus for indicating wear
    • F16D66/021—Apparatus for indicating wear using electrical detection or indication means
    • F16D66/028—Apparatus for indicating wear using electrical detection or indication means with non-electrical sensors or signal transmission, e.g. magnetic, optical
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D69/00—Friction linings; Attachment thereof; Selection of coacting friction substances or surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F9/00—Making metallic powder or suspensions thereof
    • B22F9/02—Making metallic powder or suspensions thereof using physical processes
    • B22F9/06—Making metallic powder or suspensions thereof using physical processes starting from liquid material
    • B22F9/08—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
    • B22F9/082—Making metallic powder or suspensions thereof using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying atomising using a fluid
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
    • F16D2250/00—Manufacturing; Assembly
    • F16D2250/0038—Surface treatment
    • F16D2250/0046—Coating

Definitions

  • Alloys according to example embodiments are iron-based, and may limit the amount of incorporated cobalt and nickel, thus improving their attractiveness for numerous wear and corrosion applications.
  • an iron-based alloy includes 20 wt% to 50 wt% Cr, 0 wt % to 15 wt % W, 0 wt% to 15 wt% Mo, and 3 wt% to 6 wt% B.
  • the Pitting Resistance Equivalent Number (PREN) which is calculated as Cr + 3.3 * (Mo + 0.5 * W) + 16 * N is greater than 30 at 1300 K under substantially equilibrium solidification conditions.
  • a mole fraction of a hard phase of the alloy is between 40% and 80% at 1300K under substantially equilibrium solidification conditions.
  • FIG. 1 is a diagram illustrating the thermodynamic solidification of an alloy (X4), according an example embodiment.
  • FIG. 3 is an illustration of the microstructure of a splat quenched arc melted ingot of X4, according an example embodiment.
  • FIG. 5 is a diagram illustrating the thermodynamic solidification of an alloy (X9), according an example embodiment
  • intermetallic phases in high Cr, Mo, and/or W stainless steels is a problem with high fractions of intermetallic phases correlated with reduced toughness and/or ductility.
  • this material is intended to have reduced to no cracking after deposition via thermal spray or other process, it is advantageous to reduce the presence of any embrittling phases.
  • the intermetallic phase mole fraction is defined as the sum under equilibrium solidification conditions of all chi, sigma, and laves phases.
  • the surface temperature may reach 800K during extreme braking events, and as a result it is advantageous that intermetallic phases do not precipitate during service.
  • the alloy comprises, in mole percent, less than 20% intermetallic phases. In other example embodiments, at 800K the alloy comprises, in mole percent, less than 15% intermetallic phases. In further example embodiments, at 800K the alloy comprises, in mole percent, less than 10% intermetallic phases. In still further example embodiments, at 800K the alloy comprises, in mole percent, less than 8% intermetallic phases.
  • the formation of hard phases such as borides, carbides, borocarbides, oxides, and nitrides can improve the wear resistance of an alloy. There are practical limits to the fraction of hard phases where excessively high values may lead to the alloy cracking after deposition or in service, especially when exposed to cyclical and rapid changes in temperature. Hard phases in this disclosure can be calculated as the sum of all borides, carbides, borocarbides, oxides, and/or nitrides under equilibrium solidification conditions.
  • alloy X4 illustrated in FIG. 1 there are two hard phases present at 1300K: an M3B2 phase designated by the label 104 and an M2B phase designated by the label 105; the sum of these hard phases is 66.7 mol%.
  • M2B designated by the label 205 there is only one hard phase present, M2B designated by the label 205, so the mole fraction of hard phases at 1300K is 58.8%.
  • M2B designated by the label 505 there is only one hard phase present, M2B designated by the label 505, so the mole fraction of hard phases at 1300K is 49%.
  • Liquidus temperature is defined thermodynamically as the lowest temperature where the alloy is 100% liquid. In alloys X4 and X5, the liquidus temperature is 1925K as designated by the labels 106 and 206. In alloy X9, the liquidus temperature is 1819K.
  • the liquidus temperature of the alloy is less than 2000K. In other example embodiments, the liquidus temperature of the alloy is less than 1975K. In further example embodiments, the liquidus temperature of the alloy is less than 1950K. In still further example embodiments, the liquidus temperature of the alloy is less than 1925K.
  • the liquidus temperature of the alloy is less than 1875K.
  • the PREN of the matrix phase is a strong predictor of corrosion performance of the alloy. As discussed above with respect to Equation (1), PREN is calculated as [Cr + 3.3 * (Mo + 0.5 * W) + 16 * N], where elemental values are in weight percent. Elemental weight percent is measured using energy-dispersive X-ray spectroscopy (EDS) in a scanning electron microscope (SEM)
  • the PREN is calculated from the matrix phase, designated by the label 303, measured via EDS as being equal to 38.3.
  • the PREN of the matrix phase designated by the label 402 is measured as being equal to 48.3. Measured matrix PREN values for all arc melted alloys manufactured are listed in Table 2.
  • the alloys described in this disclosure may be deposited as a coating intended to provide corrosion resistance. Where corrosive media are present, such as high chloride content water, excessive coating porosity may allow corrosive media to penetrate to the substrate. If this penetration occurs, corrosion of the substrate may lead to surface discoloration, reduced overlay performance, and/or disbanding of the coating from the substrate. As a result, it may be advantageous to control the percentage of porosity in a coating deposited by thermal spraying, or by other deposition methods.
  • alloys may be described by their bulk chemistry.
  • the powders comprise in weight percent: 20% to 50% Chromium, 0% to 15% Molybdenum, 0% to 15% Tungsten, 3% to 6% Boron.
  • the powders comprise in weight percent: 25% to 50% Chromium, 0% to 15% Molybdenum, 0% to 15% Tungsten, 3% to 6% Boron.
  • the powders comprise in weight percent: 30% to 45% Chromium, 0% to 15% Molybdenum, 0% to 15% Tungsten, 3% to 6% Boron.
  • the powders comprise in weight percent: 28% to 36% Chromium, 8% to 12% Molybdenum, 2% to 6% Tungsten, 4.8% to 5.6% Boron, balance iron and impurities.
  • the powders comprise in weight percent: 25% to 39% Chromium, 7% to 13% Molybdenum, 2% to 6% Tungsten, 4.6% to 5.8% Boron. It is understood that in the above embodiments, the balance of alloy elements includes iron and impurities.
  • the powders comprise in weight percent: 38% to 46% Chromium, 3% to 6% Molybdenum, 0% to 4% Tungsten, 4.0% to 4.8% Boron, balance iron and impurities.
  • the powders comprise in weight percent: 36% to 48% Chromium, 2% to 8% Molybdenum, 0% to 6% Tungsten, 3.8% to 5.0% Boron. It is understood that in the above embodiments, the balance of alloy elements includes iron and impurities.
  • the powders comprise in weight percent: 36% to 48% Chromium 0% to 4% Tungsten, 3.8% to 4.8% Boron, the balance including iron and impurities.
  • the powders comprise in weight percent: 35% to 45%, 3.4% to 4.2% Boron, In example embodiments, the powders comprise in weight percent less than 1% carbon. In other example embodiments, the powders comprise in weight percent less than 0.5% carbon. In further example embodiments, the powders comprise in weight percent less than 0.25% carbon. In still further example embodiments, the powders comprise in weight percent less than 0.1% carbon.
  • alloys are manufactured into powders.
  • the alloys are manufactured into powders by gas atomization.
  • Table 4 provides measured gas atomized powder chemistries of alloys according to embodiments of this disclosure.
  • alloys described are manufactured into powders by water atomization.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • General Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Plasma & Fusion (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Thermal Sciences (AREA)
  • Powder Metallurgy (AREA)
  • Coating By Spraying Or Casting (AREA)
  • Manufacture Of Metal Powder And Suspensions Thereof (AREA)
  • Heat Treatment Of Articles (AREA)
  • Braking Arrangements (AREA)
PCT/US2020/062714 2019-12-18 2020-12-01 Iron-based high corrosion and wear resistance alloys Ceased WO2021126518A1 (en)

Priority Applications (5)

Application Number Priority Date Filing Date Title
CA3163544A CA3163544A1 (en) 2019-12-18 2020-12-01 Iron-based high corrosion and wear resistance alloys
JP2022533109A JP2023507264A (ja) 2019-12-18 2020-12-01 鉄基高耐食性・耐摩耗性合金
US17/775,770 US20220389549A1 (en) 2019-12-18 2020-12-01 Iron-based high corrosion and wear resistance alloys
EP20902752.3A EP4077742A4 (en) 2019-12-18 2020-12-01 HIGH CORROSION AND WEAR RESISTANCE IRON-BASED ALLOYS
CN202080083745.2A CN114787395B (zh) 2019-12-18 2020-12-01 铁基高耐腐蚀性和耐磨性合金

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201962949761P 2019-12-18 2019-12-18
US62/949,761 2019-12-18

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WO2021126518A1 true WO2021126518A1 (en) 2021-06-24

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PCT/US2020/062714 Ceased WO2021126518A1 (en) 2019-12-18 2020-12-01 Iron-based high corrosion and wear resistance alloys

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US (1) US20220389549A1 (cg-RX-API-DMAC7.html)
EP (1) EP4077742A4 (cg-RX-API-DMAC7.html)
JP (1) JP2023507264A (cg-RX-API-DMAC7.html)
CN (1) CN114787395B (cg-RX-API-DMAC7.html)
CA (1) CA3163544A1 (cg-RX-API-DMAC7.html)
WO (1) WO2021126518A1 (cg-RX-API-DMAC7.html)

Cited By (3)

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WO2023104251A1 (de) 2021-12-10 2023-06-15 HPL Technologies GmbH Grundkörper mit einer beschichtung
WO2024051897A1 (de) 2022-09-11 2024-03-14 HPL Technologies GmbH Grundkörper mit einem beschichtungssystem
DE102024101348A1 (de) 2022-12-23 2024-07-04 HPL Technologies GmbH Grundkörper mit einem Beschichtungssystem

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CN116575023B (zh) * 2023-04-23 2026-03-17 长沙市萨普新材料有限公司 一种原位强化相高温耐磨涂层复合材料及其制备方法
EP4588592A1 (en) 2024-01-16 2025-07-23 Höganäs AB (publ) Solid solution held chromium carbides for thermal spraying and method of making the same

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2023104251A1 (de) 2021-12-10 2023-06-15 HPL Technologies GmbH Grundkörper mit einer beschichtung
WO2024051897A1 (de) 2022-09-11 2024-03-14 HPL Technologies GmbH Grundkörper mit einem beschichtungssystem
DE102024101348A1 (de) 2022-12-23 2024-07-04 HPL Technologies GmbH Grundkörper mit einem Beschichtungssystem

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Publication number Publication date
CN114787395A (zh) 2022-07-22
EP4077742A4 (en) 2023-07-19
CA3163544A1 (en) 2021-06-24
CN114787395B (zh) 2025-02-25
US20220389549A1 (en) 2022-12-08
JP2023507264A (ja) 2023-02-22
EP4077742A1 (en) 2022-10-26

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