High strength and corrosion resistant ferrochrome alloy bulk and article comprising the same

Patent metadata

Field	Value
Publication number	US-2023002868-A1
Application number	US-202117385990-A
Country	US
Kind code	A1
Filing date	Jul 27, 2021
Priority date	Jun 30, 2021
Publication date	Jan 5, 2023
Grant date	—

Abstract

A high strength and corrosion resistant ferrochrome alloy bulk is disclosed, which comprises, in weight percent: 30-68% Cr, 1.5-8% Ni, 1.6-6% C, and the balance Fe and incidental impurities, of which a Fe/Ni ratio is in a range from 5 to 10 and a Cr/C ratio is in a range between 10 and 33. Experimental data reveal that, samples of the high strength and corrosion resistant ferrochrome alloy bulk all possess hardness above HV400 and excellent corrosion resistance due to the high content of Cr. As a result, experimental data have proved that the high-strength and corrosion-resistant ferrochrome alloy bulk of the present invention has a significant potential to replace conventional high-strength stainless steels, so as to be widely applied in various industrial fields, e.g., aviation, transportation, marine facility components, chemical equipment and pipe fittings, engine parts, turbine blades, valves, bearings, building materials, and so on.

First claim

What is claimed is:

1 . A high strength and corrosion resistant ferrochrome alloy bulk, being made by sequentially applying a melting process and a solidification process to a virgin material, and having a hardness greater than HV400; wherein the high strength and corrosion resistant ferrochrome alloy bulk comprises, in weight percent:
30-68% Cr; 1.5-8% Ni; 1.6-6% C; and the balance Fe and incidental impurities; wherein a Fe/Ni ratio is in a range from 5 to 10, and a Cr/C ratio being in a range between 10 and 33.

2 . The high strength and corrosion resistant ferrochrome alloy bulk of claim 1 , being produced by using a manufacturing method selected from a group consisting of: vacuum arc melting process, electric resistance wire heating process, rapid solidification process, mechanical alloying method in combination with spark plasma sintering process, and powder metallurgic method.

3 . The high strength and corrosion resistant ferrochrome alloy bulk of claim 1 , wherein the high strength and corrosion resistant ferrochrome alloy bulk is disposed on a surface of a work piece by using a process selected from a group consisting of casting process, electric-arc welding process, laser welding process, plasma-arc welding process, thermal spraying process, 3D additive manufacturing process, mechanical process, and chemical process.

4 . The high strength and corrosion resistant ferrochrome alloy bulk of claim 1 , being processed to be in an as-cast state, or being in a heat-treated state after being applied with a heat treatment that is selected from a group consisting of precipitation hardening treatment, annealing treatment and homogenization treatment.

5 . An article, being made of a high strength and corrosion resistant ferrochrome alloy bulk having a hardness greater than HV400; wherein the high strength and corrosion resistant ferrochrome alloy bulk comprises, in weight percent:
30-68% Cr; 1.5-8% Ni; 1.6-6% C; and the balance Fe and incidental impurities; wherein a Fe/Ni ratio is in a range from 5 to 10, and a Cr/C ratio being in a range between 10 and 33.

6 . A high strength and corrosion resistant ferrochrome alloy bulk, being made by sequentially applying a melting process and a solidification process to a virgin material, and having a hardness greater than HV400; wherein the high strength and corrosion resistant ferrochrome alloy bulk comprises, in weight percent:
30-68% Cr; 1.5-8% Ni; 1.6-6% C; up to 5% M, wherein M comprises at least one additive element that is selected from a group consisting of B, Al, Si, Sn, Ti, V, Mn, Co, Cu, Zr, Nb, Mo, Ta, and W; and the balance Fe and incidental impurities; wherein a Fe/Ni ratio is in a range from 5 to 10, and a Cr/C ratio being in a range between 10 and 33; and wherein in case of M including Si, a content of Si being smaller or equal to 1.5%.

7 . The high strength and corrosion resistant ferrochrome alloy bulk of claim 6 , being produced by using a manufacturing method selected from a group consisting of: vacuum arc melting process, electric resistance wire heating process, rapid solidification process, mechanical alloying method in combination with spark plasma sintering process, and powder metallurgic method.

8 . The high strength and corrosion resistant ferrochrome alloy bulk of claim 6 , wherein the high strength and corrosion resistant ferrochrome alloy bulk is disposed on a surface of a work piece by using a process selected from a group consisting of casting process, electric-arc welding process, laser welding process, plasma-arc welding process, thermal spraying process, 3D additive manufacturing process, mechanical process, and chemical process.

9 . The high strength and corrosion resistant ferrochrome alloy bulk of claim 6 , being processed to be in an as-cast state, or being in a heat-treated state after being applied with a heat treatment that is selected from a group consisting of precipitation hardening treatment, annealing treatment and homogenization treatment.

10 . An article, being made of a high strength and corrosion resistant ferrochrome alloy bulk having a hardness greater than HV400; wherein the high strength and corrosion resistant ferrochrome alloy bulk comprises, in weight percent:
30-68% Cr; 1.5-8% Ni; 1.6-6% C; up to 5% M, wherein M comprises at least one additive element that is selected from a group consisting of B, Al, Si, Sn, Ti, V, Mn, Co, Cu, Zr, Nb, Mo, Ta, and W; and the balance Fe and incidental impurities; wherein a Fe/Ni ratio is in a range from 5 to 10, and a Cr/C ratio being in a range between 10 and 33; and wherein in case of M including Si, a content of Si being smaller or equal to 1.5%.

Assignees

• Univ Nat Tsing Hua

Inventors

• Yeh Jien-Wei

Classifications

• B22F2998/00

  Supplementary information concerning processes or compositions relating to powder metallurgy · CPC title

• B23K2103/05

  Stainless steel · CPC title

• B23K26/34

  Laser welding for purposes other than joining · CPC title

• C22C38/08 Primary

  containing nickel {(C22C38/105 takes precedence)} · CPC title

• C23C30/00

  Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process (C23C26/00, C23C28/00 take precedence) · CPC title