Methods for sub-austenite transformation temperature deposition of inorganic particles and articles produced by the same

Patent metadata

Field	Value
Publication number	US-12110597-B2
Application number	US-201917279374-A
Country	US
Kind code	B2
Filing date	Sep 20, 2019
Priority date	Sep 28, 2018
Publication date	Oct 8, 2024
Grant date	Oct 8, 2024

Abstract

Methods of applying an inorganic material to a metal substrate that includes a metallic material having an austenite transformation temperature. The method includes depositing inorganic particles onto a surface of the metal substrate. In some embodiments, methods may include depositing inorganic particles at a deposition temperature that does not cause the metallic material to exceed the austenite transformation temperature. The inorganic particles deposited onto the surface of the metal substrate may form an abrasion-resistant coating on the surface of the metal substrate. The difference between the coefficient of thermal expansion of the metallic material and the coefficient of thermal expansion of the abrasion-resistant coating may be 10×10−6/degrees C. or less.

First claim

What is claimed is:

1. A method of applying an inorganic material to a metal substrate that comprises a metallic material that undergoes transformation to an austenitic phase at an austenite transformation temperature, the method comprising:
depositing inorganic particles onto a surface of the metal substrate at a deposition temperature that does not cause the metallic material to exceed the austenite transformation temperature of the metallic material, and
depositing additional inorganic particles onto the inorganic particles in one or more additional deposition processes to form a multi-layer abrasion-resistant coating comprising a boron-doped titanium carbonitride layer and a titanium carbonitride layer,
wherein a deposition temperature of the one or more additional deposition processes does not cause the metallic material to exceed the austenite transformation temperature of the metallic material.

2. The method of claim 1 , wherein the inorganic particles are deposited by a vapor deposition process.

3. The method of claim 1 , wherein the inorganic particles comprise at least one of: titanium carbonitride, boron, boron-doped titanium carbonitride, aluminum titanium nitride, titanium aluminum nitride, chromium nitride, titanium nitride, and a combination thereof.

4. The method of claim 1 , wherein the inorganic particles deposited onto the surface of the metal substrate are deposited in a first deposition process,
wherein the method further comprises a second deposition process that deposits additional inorganic particles onto the inorganic particles deposited in the first deposition process, and wherein the second deposition process comprises a deposition temperature that does not exceed the austenite transformation temperature of the metallic material of the metal substrate.

5. The method of claim 4 , wherein the additional inorganic particles are different from the inorganic particles deposited in the first deposition process.

6. The method of claim 1 , wherein the multi-layer coating further comprises a titanium nitride layer.

7. The method of claim 1 , wherein an outermost layer of the multi-layer coating comprises boron-doped titanium carbonitride.

8. The method of claim 1 , wherein the deposition temperature is in the range of 600 degrees C. to 860 degrees C.

9. The method of claim 1 , wherein the metallic material is a steel.

10. The method of claim 1 , wherein the metallic material is a martensitic steel.

11. The method of claim 1 , wherein the inorganic particles form an abrasion-resistant coating on the surface of the metal substrate,
wherein the metallic material comprises a steel having a first coefficient of thermal expansion measured at T degrees C. after deposition of the abrasion-resistant coating and the abrasion-resistant coating comprises a second coefficient of thermal expansion measured at T degrees C. after deposition of the abrasion-resistant coating,
wherein T is equal to one degree C. greater than a temperature at which the steel starts to transform to martensite during cooling after deposition of the abrasion-resistant coating, and
wherein the difference between the first coefficient of thermal expansion of the metallic material and the second coefficient of thermal expansion of the abrasion-resistant coating is 10×10 −6 /degrees C. or less.

12. The method of claim 11 , wherein the difference between the first coefficient of thermal expansion of the metallic material and the second coefficient of thermal expansion of the abrasion-resistant coating is in the range of 10×10 −7 /degrees C., to 10×10 −6 /degrees C.

13. The method of claim 11 , wherein the method further comprises depositing additional inorganic particles onto the abrasion-resistant coating in one or more additional deposition processes to form a multi-layer abrasion-resistant coating,
wherein a deposition temperature of the one or more additional depositions processes does not exceed the austenite transformation temperature of the metallic material of the metal substrate,
wherein the multi-layer abrasion-resistant coating comprises a boron-doped titanium carbonitride layer, and
wherein the coefficient of thermal expansion of the multi-layer abrasion-resistant coating is defined by a sum of a fractional coefficient of thermal expansion for each layer of the multi-layer coating, and wherein the fractional coefficient of thermal expansion for each layer is calculated with the following equation:
fCTE=(Tl/Tt)*CTEl,

where:
fCTE=the fractional coefficient of thermal expansion for a respective layer,
Tl=the thickness of a respective layer,
Tt=the total thickness of the multilayer coating, and
CTEl=the coefficient of thermal expansion for a respective layer.

14. The method of claim 1 , wherein the metal substrate comprises an extruder component.

15. A method of applying an inorganic material to a metal substrate that comprises a metallic material that undergoes transformation to an austenitic phase at an austenite transformation temperature, the method comprising:
depositing inorganic particles onto a surface of the metal substrate at a deposition temperature that does not cause the metallic material to exceed the austenite transformation temperature of the metallic material;
further comprising, prior to deposition of inorganic particles, depositing a layer of titanium nitride on the surface of the metal substrate at a first temperature above the austenite transformation temperature of the metallic material of the metal substrate, and
cooling the layer of titanium nitride and the metal substrate to a second temperature below the martensite transformation temperature of the metallic material such that austenite formed in the metallic material during deposition of the layer of titanium nitride is transformed to martensite.

16. The method of claim 15 , wherein the second temperature is in the range of 100 degrees C. to 400 degrees C.

Assignees

• Corning Inc

Inventors

• Brew Thomas William
• Brown Dennis Michael
• Miller Brian James
• Okafor Obiefuna Chukwuemeka

Classifications

• C23C28/042

  including a refractory ceramic layer, e.g. refractory metal oxides, ZrO2, rare earth oxides · CPC title

• C23C16/36

  Carbonitrides · CPC title

• C23C16/0272

  Deposition of sub-layers, e.g. to promote the adhesion of the main coating · CPC title

• B21C25/025

  Selection of materials therefor · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title