Free graphite containing powders

Patent metadata

Field	Value
Publication number	US-2023037455-A1
Application number	US-202217957385-A
Country	US
Kind code	A1
Filing date	Sep 30, 2022
Priority date	Oct 17, 2016
Publication date	Feb 9, 2023
Grant date	—

Abstract

An improved atomized powder metal material containing an increased amount of free graphite after heat treatment and/or sintering is provided. The powder metal material is typically a ferrous alloy and includes carbon in an amount of 1.0 wt. % to 6.5 wt. % and silicon in an amount of 0.1 wt. % to 6.0 wt. %, based on the total weight of the powder metal material. The powder metal material can also include various other alloying elements, for example at least one of nickel (Ni), cobalt (Co), copper (Cu), tin (Sn), aluminum (Al), sulfur (S), phosphorous (P), boron (B), nitrogen (N), chromium (Cr), manganese (Mn), molybdenum (Mo), vanadium (V), niobium (Nb), tungsten (W), titanium (Ti), tantalum (Ta) zirconium (Zr), zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba) magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).

First claim

1 . A method of manufacturing a material, comprising the step of:
atomizing an iron-based composition to form a powder metal, the iron-based composition including carbon (C) in an amount of 1.0 wt. % to 2.0 wt. % and silicon (Si) in an amount of 0.1 wt. % to 6.0 wt. %, based on the total weight of the powder metal, the powder metal optionally including at least one of nickel (Ni), cobalt (Co), copper (Cu), tin (Sn), aluminum (Al), sulfur (S), phosphorous (P), boron (B), nitrogen (N), chromium (Cr), manganese (Mn), molybdenum (Mo), vanadium (V), niobium (Nb), tungsten (W), titanium (Ti), tantalum (Ta) zirconium (Zr), zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba) magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).

2 . The method of claim 1 including heat treating the atomized powder metal.

3 . The method of claim 1 including sintering the atomized powder metal.

4 . A method of manufacturing a material, comprising the step of:
atomizing an iron-based composition to form a powder metal, the iron-based composition including carbon (C) in an amount of 2.0 wt. % to 5.0 wt. % and silicon (Si) in an amount of 2.5 wt. % to 6.0 wt. %, based on the total weight of the powder metal, the powder metal optionally including at least one of nickel (Ni), cobalt (Co), copper (Cu), tin (Sn), aluminum (Al), sulfur (S), phosphorous (P), boron (B), nitrogen (N), chromium (Cr), manganese (Mn), molybdenum (Mo), vanadium (V), niobium (Nb), tungsten (W), titanium (Ti), tantalum (Ta) zirconium (Zr), zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba) magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).

5 . The method of claim 4 including heat treating the atomized powder metal.

6 . The method of claim 4 including sintering the atomized powder metal.

7 . A method of manufacturing a material, comprising the step of:
atomizing an iron-based composition to form a powder metal, the iron-based composition including carbon (C) in an amount of 5.0 wt. % to 6.5 wt. % and silicon (Si) in an amount of 0.1 wt. % to 6.0 wt. %, based on the total weight of the powder metal, the powder metal optionally including at least one of nickel (Ni), cobalt (Co), copper (Cu), tin (Sn), aluminum (Al), sulfur (S), phosphorous (P), boron (B), nitrogen (N), chromium (Cr), manganese (Mn), molybdenum (Mo), vanadium (V), niobium (Nb), tungsten (W), titanium (Ti), tantalum (Ta) zirconium (Zr), zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba) magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).

8 . The method of claim 7 including heat treating the atomized powder metal.

9 . The method of claim 7 including sintering the atomized powder metal.

10 . A method of manufacturing a material, comprising the step of:
atomizing an iron-based composition to form a powder metal, the iron-based composition including carbon (C) in an amount of 2.0 wt. % to 5.0 wt. %, silicon (Si) in an amount of 0.1 wt. % to 2.5 wt. %, and at least one of the following: nickel in an amount of 4.0 to 46 wt. %, cobalt in an amount of 0.1 to 46 wt. %, copper in an amount of 3.0 to 40 wt. %, tin an amount of 0.1 to 15 wt. %, aluminum in an amount of 0.1 to 10 wt. %, sulfur in an amount of 0.05 to 2.0 wt. %, phosphorous in an amount of 1.0 to 2.0 wt. %, boron in an amount of 0.20 to 1.0 wt. %, nitrogen in an amount of 0.05 to 1.0 wt. %, chromium in an amount of 2 to 25 wt. %, manganese in an amount of 2 to 25 wt. %, molybdenum in an amount of 4 to 10 wt. %, vanadium (V) in an amount of 0.1 to 10 wt. %, niobium (Nb) in an amount of 0.1 to 10 wt. %, tungsten (W) in an amount of 0.1 to 20 wt. %, titanium (Ti) in an amount of 0.1 to 10 wt. %, tantalum (Ta) in an amount of 0.1 to 10 wt. %, and zirconium (Zr) in an amount of 0.1 to 10 wt. %, based on the total weight of the powder metal, and the powder metal optionally including at least one of zinc (Zn), strontium (Sr), calcium (Ca), barium (Ba), magnesium (Mg), lithium (Li), sodium (Na), and potassium (K).

11 . The method of claim 10 including heat treating the atomized powder metal.

12 . The method of claim 10 including sintering the atomized powder metal.

Assignees

• Fed Mogul Llc
• La Corp De Lecole Polytechnique De Montreal

Inventors

• Boisvert Mathieu
• L'Esperance Gilles
• Beaulieu Philippe
• Christopherson Jr Denis B

Classifications

• B22F1/00

  Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties · CPC title

• C21D6/005

  containing Mn · CPC title

• C21D6/007

  containing Co · CPC title

• C21D6/004

  containing Cr and Ni · CPC title

• C21D6/008

  containing Si · CPC title