EP0007062A1 - Preparation of phosphorus-containing metallic glass-forming alloy melts - Google Patents
Preparation of phosphorus-containing metallic glass-forming alloy melts Download PDFInfo
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- EP0007062A1 EP0007062A1 EP79102260A EP79102260A EP0007062A1 EP 0007062 A1 EP0007062 A1 EP 0007062A1 EP 79102260 A EP79102260 A EP 79102260A EP 79102260 A EP79102260 A EP 79102260A EP 0007062 A1 EP0007062 A1 EP 0007062A1
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- EP
- European Patent Office
- Prior art keywords
- phosphorus
- flux
- alloy
- percent
- weight
- Prior art date
- Legal status (The legal status 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 status listed.)
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- 229910045601 alloy Inorganic materials 0.000 title claims abstract description 56
- 239000000956 alloy Substances 0.000 title claims abstract description 56
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 title claims abstract description 41
- 229910052698 phosphorus Inorganic materials 0.000 title claims abstract description 41
- 239000011574 phosphorus Substances 0.000 title claims abstract description 41
- 239000000155 melt Substances 0.000 title claims abstract description 23
- 238000007496 glass forming Methods 0.000 title claims abstract description 12
- 238000002360 preparation method Methods 0.000 title description 2
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims abstract description 55
- 230000004907 flux Effects 0.000 claims abstract description 47
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims abstract description 46
- JKWMSGQKBLHBQQ-UHFFFAOYSA-N diboron trioxide Chemical compound O=BOB=O JKWMSGQKBLHBQQ-UHFFFAOYSA-N 0.000 claims abstract description 46
- 229910052742 iron Inorganic materials 0.000 claims abstract description 22
- 229910052759 nickel Inorganic materials 0.000 claims abstract description 18
- 239000010941 cobalt Substances 0.000 claims abstract description 14
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 claims abstract description 14
- 229910017052 cobalt Inorganic materials 0.000 claims abstract description 13
- 238000002844 melting Methods 0.000 claims abstract description 13
- 230000008018 melting Effects 0.000 claims abstract description 13
- 229910052723 transition metal Inorganic materials 0.000 claims abstract description 5
- 150000003624 transition metals Chemical class 0.000 claims abstract description 5
- 238000000034 method Methods 0.000 claims description 16
- 239000000203 mixture Substances 0.000 claims description 14
- 230000008569 process Effects 0.000 claims description 14
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 claims description 12
- 229910052796 boron Inorganic materials 0.000 claims description 12
- 229910052751 metal Inorganic materials 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 6
- 229910052752 metalloid Inorganic materials 0.000 claims description 6
- 150000002738 metalloids Chemical class 0.000 claims description 6
- 229910001092 metal group alloy Inorganic materials 0.000 claims description 5
- 229910052799 carbon Inorganic materials 0.000 claims description 4
- 229910000640 Fe alloy Inorganic materials 0.000 claims description 3
- 229910000990 Ni alloy Inorganic materials 0.000 claims description 3
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 2
- 229910052802 copper Inorganic materials 0.000 claims description 2
- 239000010949 copper Substances 0.000 claims description 2
- 229910044991 metal oxide Inorganic materials 0.000 abstract description 9
- 150000004706 metal oxides Chemical class 0.000 abstract description 9
- 238000007670 refining Methods 0.000 abstract description 8
- 230000003647 oxidation Effects 0.000 abstract description 7
- 238000007254 oxidation reaction Methods 0.000 abstract description 7
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N Titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 abstract description 6
- 239000012535 impurity Substances 0.000 abstract description 6
- 238000001704 evaporation Methods 0.000 abstract description 5
- 230000008020 evaporation Effects 0.000 abstract description 4
- 239000004408 titanium dioxide Substances 0.000 abstract description 2
- 229910052810 boron oxide Inorganic materials 0.000 abstract 2
- 238000010309 melting process Methods 0.000 abstract 1
- 229940073644 nickel Drugs 0.000 abstract 1
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 7
- 229910052760 oxygen Inorganic materials 0.000 description 7
- 239000001301 oxygen Substances 0.000 description 7
- 239000007787 solid Substances 0.000 description 7
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 6
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 6
- 238000011109 contamination Methods 0.000 description 6
- 229910052710 silicon Inorganic materials 0.000 description 6
- 239000010703 silicon Substances 0.000 description 6
- 239000010936 titanium Substances 0.000 description 6
- 229910052719 titanium Inorganic materials 0.000 description 6
- 239000002994 raw material Substances 0.000 description 5
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 4
- 229910052786 argon Inorganic materials 0.000 description 4
- 230000008901 benefit Effects 0.000 description 4
- 229910000480 nickel oxide Inorganic materials 0.000 description 4
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 description 4
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 3
- 238000004458 analytical method Methods 0.000 description 3
- QDWJUBJKEHXSMT-UHFFFAOYSA-N boranylidynenickel Chemical compound [Ni]#B QDWJUBJKEHXSMT-UHFFFAOYSA-N 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N iron oxide Inorganic materials [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 2
- 229910000531 Co alloy Inorganic materials 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 229910052791 calcium Inorganic materials 0.000 description 2
- 239000011575 calcium Substances 0.000 description 2
- 239000003153 chemical reaction reagent Substances 0.000 description 2
- 229910002804 graphite Inorganic materials 0.000 description 2
- 239000010439 graphite Substances 0.000 description 2
- 230000006698 induction Effects 0.000 description 2
- 239000004615 ingredient Substances 0.000 description 2
- VAKIVKMUBMZANL-UHFFFAOYSA-N iron phosphide Chemical compound P.[Fe].[Fe].[Fe] VAKIVKMUBMZANL-UHFFFAOYSA-N 0.000 description 2
- 239000000395 magnesium oxide Substances 0.000 description 2
- 239000013618 particulate matter Substances 0.000 description 2
- DLYUQMMRRRQYAE-UHFFFAOYSA-N tetraphosphorus decaoxide Chemical compound O1P(O2)(=O)OP3(=O)OP1(=O)OP2(=O)O3 DLYUQMMRRRQYAE-UHFFFAOYSA-N 0.000 description 2
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229910002455 CoPx Inorganic materials 0.000 description 1
- -1 FeO Chemical compound 0.000 description 1
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 1
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 230000002378 acidificating effect Effects 0.000 description 1
- 230000002411 adverse Effects 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 1
- 229910052790 beryllium Inorganic materials 0.000 description 1
- ATBAMAFKBVZNFJ-UHFFFAOYSA-N beryllium atom Chemical compound [Be] ATBAMAFKBVZNFJ-UHFFFAOYSA-N 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 239000000701 coagulant Substances 0.000 description 1
- 229910000428 cobalt oxide Inorganic materials 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 230000002939 deleterious effect Effects 0.000 description 1
- 235000013766 direct food additive Nutrition 0.000 description 1
- 239000007789 gas Substances 0.000 description 1
- 229910052732 germanium Inorganic materials 0.000 description 1
- GNPVGFCGXDBREM-UHFFFAOYSA-N germanium atom Chemical compound [Ge] GNPVGFCGXDBREM-UHFFFAOYSA-N 0.000 description 1
- 229910052735 hafnium Inorganic materials 0.000 description 1
- VBJZVLUMGGDVMO-UHFFFAOYSA-N hafnium atom Chemical compound [Hf] VBJZVLUMGGDVMO-UHFFFAOYSA-N 0.000 description 1
- 239000001307 helium Substances 0.000 description 1
- 229910052734 helium Inorganic materials 0.000 description 1
- SWQJXJOGLNCZEY-UHFFFAOYSA-N helium atom Chemical compound [He] SWQJXJOGLNCZEY-UHFFFAOYSA-N 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- APFVFJFRJDLVQX-UHFFFAOYSA-N indium atom Chemical compound [In] APFVFJFRJDLVQX-UHFFFAOYSA-N 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- 239000005300 metallic glass Substances 0.000 description 1
- 238000002156 mixing Methods 0.000 description 1
- 229910052750 molybdenum Inorganic materials 0.000 description 1
- 239000011733 molybdenum Substances 0.000 description 1
- 229910017604 nitric acid Inorganic materials 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 230000005855 radiation Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000007711 solidification Methods 0.000 description 1
- 230000008023 solidification Effects 0.000 description 1
- 238000004611 spectroscopical analysis Methods 0.000 description 1
- 238000004528 spin coating Methods 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 229910052718 tin Inorganic materials 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 238000009834 vaporization Methods 0.000 description 1
- 230000008016 vaporization Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 238000007704 wet chemistry method Methods 0.000 description 1
- 229910052726 zirconium Inorganic materials 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B9/00—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals
- C22B9/10—General processes of refining or remelting of metals; Apparatus for electroslag or arc remelting of metals with refining or fluxing agents; Use of materials therefor, e.g. slagging or scorifying agents
Definitions
- Glassy solid structures are obtained from such alloys by processes such as the melt spin process wherein a fine jet of the molten alloy is impinged upon a rapidly moving chill surface for solidification. Orifice diameters in this process are exceedingly small, and orifice pluggage on account of solid impurities contained in the melt can represent serious problems.
- Iron, cobalt or nickel based phosphorus-containing glass-forming alloys which additionally contain boron as a metalloid are particularly prone to contamination with solid particles. In such alloy, these particles were found to be predominantly small particles of Ti0 2 and/or TiB0 3 , both of which have high melt points, and both of which are relatively insoluble in the melt. It was found that titanium is an impurity commonly contained in ferrophosphorus, which is used as a source of phosphorus in making these alloys, although titanium may also be present as contaminant in other raw materials employed in making these alloys.
- the present invention provides refining flux for reducing oxidation of and loss of phosphorus values from phosphorus-containing alloys, especially phosphorus-containing iron, nickel and/or cobalt-based alloys.
- Phosphorus-containing metallic glass-forming alloy melts are covered with a layer of molten boron trioxide flux.
- molten boron trioxide flux protects the melt from oxidation, dissolves oxide particulates and impurities from the molten metal alloy and prevents the evaporation of phosphorus values.
- the flux floating on the alloy melt will not interfere with subsequent casting or spinning operations, and the alloy melt can be replenished directly through the flux layer. Alloys prepared according to the process of the present invention leave minimum residues in the jetting crucible in subsequent melt spin operations.
- Phosphorus-containing iron, nickel and/or cobalt-based alloys are desirably melted under a boron trioxide flux additionally comprising oxides of iron, nickel and/or cobalt.
- the flux layer protects the molten alloy from oxidation, reduces or eliminates contamination of the melt with particulate matter, especially metal oxides, and prevents loss of phosphorus values by vaporization.
- Metallic glass-forming alloys which benefit from protection by boron trioxide flux contain phosphorus as a metalloid component, alone or together with other metalloids, such as boron, carbon and silicon.
- the phosphorus component of such alloys is usually contributed by ingredients having the formulas FeP , NiP x , CoP x , MnP x , wherein x is between abut 0.3 and l.l and preferably between about 0.5 and 1.
- Preferred alloy compositions include alloys utilizing as source of phosphorus FeP wherein x is between about 0.5 and 1.
- Preferred alloy compositions include transition metal alloys containing between about 3 and 25 weight percent phosphorus. These alloys have a phosphorus partial pressure of less than 20 micron, and melting points of between about 900°C and 1200°C.
- Phosphorus-containing alloys based on one or more of iron, nickel and/or cobalt which benefit from melting under the refining boron trioxide flux which additionally contains oxides of iron, nickel and/or cobalt have the general formula M a P b Y c wherein M is a metal selected from one or more of the group consisting of iron, cobalt and nickel; P represents phosphorus; Y represents a metalloid selected from one or both of the group consisting of boron and carbon; and a, b and c are in atomic percent, wherein a is about 70 to 90, b is 0-20, but - desirably at least 1, the sum of b + c is about 10 to 30, the sum of a + b + c being 100.
- M may be replaced by one or more of any transition metal other than iron, cobalt and nickel.
- Suitable replacements include silicon, chromium, vanadium, aluminum, tin, antimony, germanium, indium, beryllium, molybdenum, titanium, manganese, tungsten, zirconium, hafnium and copper, for example.
- the phosphorus content of the alloy will ordinarily be derived from ferrophosphorus, which may be of any suitable phosphorus content, such as commercially available grades containing about 18 and 25 percent by weight phosphorus.
- the boron trioxide flux comprises compositions of the formula B 2 0 3 of about 95 weight percent purity, preferably better than about 98 weight percent purity, the balance being represented by incidental impuritiess or intentional additives which are substantially inert, that is to say, that they do not materially interfere with the intended function of the boron trioxide flux.
- Suitable boron trioxide fluxes have a melting point between about 400°C and 600°C, preferably between about 400° and 500°C, and have a vapor pressure of below about 20 micron.
- the oxide is suitably chosen to correspond to the major metal component of the alloy.
- the oxide component in the flux desirably, but not necessarily, is an oxide of iron.
- Nickel-containing melts desirably are refined under a flux-containing nickel oxide.
- the flux desirably contains from about 20 to 80 percent by weight boron trioxide.
- the metal oxide e.g. iron, cobalt or nickel oxide
- the metal oxide coacts with the boron trioxide to obtain the desired result. It is believed that oxygen from the metal oxide combines with titanium metal contained in the melt as an impurity, perhaps forming Ti0 2 , which is then bound in the molten flux.
- the boron trioxide seems to act as a coagulant for the titanium dioxide as well as for other particulate matter which may be contained in the melt.
- the boron trioxide because of its acidic character, seemingly tends to prevent oxidation of phosphorus, if present, to the five valent oxide state, as might occur due to presence of small amounts of oxygen in the melt. In the five valent state, phosphorus is volatile under refining conditions encountered in making the alloys here under consideration.
- oxides of iron namely FeO, Fe203"and Fe 3 0 4
- FeO being preferred.
- any of the oxides of cobalt, CoO, Co203, as well as Co 3 0 41 may be employed.
- use of oxides of cobalt is not ordinarily preferred.
- Nickel oxide for reasons of availability as well as effectiveness, is the preferred metal oxide.
- Metal oxides of commercial degree of purity are suitable for use.
- the boron trioxide (H 2 0 3 ) similarly may be of any degree commercial purity.
- the boron trioxide is desirably employed in amount of 20 to 80 percent by weight, preferably 30 to 70 percent by weight, most preferably 40 to 60 percent by weight of the flux, the balance being represented by the metal oxide.
- other components which do not materially interfere with the protective and refining functions of the flux may be included in the flux composition for any desired purpose, e.g. melting point reduction, although addition of other components is not ordinarily preferred.
- the flux compositions are employed in amount sufficient to provide a flux layer of between about 1 and 50 millimeter thickness, preferably between abbut 2 and 10 millimeter thickness on top of the molten metal alloy. It is an advantage of these flux compositions that their solubility in the alloys is generally low, so that gross contamination of the alloy with the flux is avoided. Furthermore, minor contamination of the alloy with boron values from the flux is generally not deleterious, that is to say that such contamination would not adversely affect the glass-forming capabilities of the alloy, nor its properties in the solid state.
- the temperature of the alloy melt can be between about 1000°C and 1500°C, and preferably between about 1100°C and 1400°C.
- the temperature of the boron trioxide flux can be between about 900°C and 1400°C.
- the boron trioxide flux should be present at temperatures leading normally to oxidation and/or evaporation of phosphorus values, and in particular the boron trioxide should be present when the alloy is in the molten state.
- the boron trioxide to obtain the full benefit of its function, is desirably added to the cold charge. If it is added after the alloy is melted, considerable amounts of phosphorus can be lost.
- the flux should remain in contact with the surface of the melt at melting temperature for a time period for at least about one minute, desirably of at least about 5 minutes. Contact times of, say, between about 5 minutes and 5 hours, desirably of between about 30 minutes and about 3 hours are eminently suitable.
- the melt may be agitated.
- Suitable melting furnaces include those lined with high temperature ceramic materials. Preferred furnace linings are made from magnesia, zirconia and alumina.
- suitable inert atmospheres may be provided above the flux, including such as those provided by helium or argon. Alternatively, the melting operation may be conducted under vacuum. However, provision of inert atmospheres is not essential. If an inert atmosphere is supplied, argon is preferred.
- Iron, nickel, phosphorus, and boron containing glass-forming alloy compositions were prepared by melting together under vacuum raw materials of the following purity: iron, 99.9 weight percent pure; nickel, 99.9 weight percent pure; nickel boride, 99 weight percent pure having boron content of between about 17 and 19 weight percent; ferrophosphorus (Type I) containing 61.43 weight percent iron and 20.39 weight percent boron; ferrophosphorus (Type II) containing 79 weight percent iron and 21 weight percent phosphorus. To each charge there was added an amount of F e 40N i 40 P 14 B 6 (atomic percent) . metal alloy to provide an initial susceptor for induction heating of the charge.
- Example 3 The cast ingots were subjected to analysis for insolubles, oxygen, silicon, calcium, iron, nickel, phosphorus, and boron.
- the ingot obtained in Example 3 was further subjected to a second melt cycle at 1200°C for 1 hour in vacuum under a flux of B 2 0 3 8
- the remelted alloy was again cast into an ingot and subjected to analysis.
- Table II The results of the analysis are shown in Table II below.
- Iron, nickel, boron and phosphorus were determined by wet chemistry; oxygen was determined by placing pieces of raw alloy in a graphite boat in a Leco oxygen analyzer. This method determines only dissolved oxygen, but not chemically bonded oxygen.
- the procedure for determining insolubles involved dissolving a 2 gram sample of the solid ingot in 100 milliliter of a reagent solution composed of 50 milliliter nitric acid (70% ANO 3 ); 10 milliliter of sulfuric acid (100% H 2 SO 4 ) and 40 milliliter of water. The alloy was refluxed in the reagent solution until dissolved. The resultant solution was filtered through an analytical filter to determine insoluble content as ash residue. Silicon and calcium were determined by taking an aliquot part of the solution, evaporating the solution, mixing the residue with spectrographic grade graphite and determining the traces by emissions spectroscopy.
- This example illustrates production of an alloy containing Fe: 45.9 + 1 percent by weight; Ni: 44.6 + 1 percent by weight; P: 7.85 + 0.32 percent by weight; B: 1.45 + 0.11 percent by weight.
- the raw materials charged are iron, electrolytic fragments, 99.9 percent pure; nickel pellets, 99.9 percent pure; ferrophosphorus, low silicon grade (less than about 0.5 percent silicon); nickel-boron, low aluminum grade (as available, for example, from Shieldalloy Company).
- the furnace Prior to and during the charging operation the furnace is purged with argon gas. The required amounts of iron, nickel and ferrophosphorus are charged to the furnace, and the charge is gradually heated until melting.
- an oxidizing acid flux consisting of about 50 weight percent nickel oxide and about 50 weight percent B 2 0 3 is added to the molten charge in an amount of about 8 Ibs. per 2,500 lb. metal charge to produce about a 1/8 inch thick layer of flux.
- the melt is refined under this flux at a temperature of about 1,180° to 1,200°C for 20 to 30 minutes, taking care to avoid temperatures in excess of 1200°C during the refining operation. Thereafter, the flux is skimmed and the nickel boron is added to the melt. The heat is finished under an argon blanket. Total refining and holding time at the 1,180° to 1,200°C is about 45 to 60 minutes.
- the refined alloy is then cast at about 1,000°C.
- alloy of the above composition prepared using the NiO/B 2 O 3 flux as above described had a titanium content of only 0.04 percent by weight, whereas an alloy obtained under otherwise identical conditions from the same raw materials, but without use of the flux, had a titanium content about 0.16 percent by weight. Furthermore, alloy prepared under conditions of the present invention had significantly lower contamination with other oxidizable elements which tend to form insoluble solid oxides. As a consequence, metal refined in accordance with the present invention, as above described, caused substantially less restriction of a casting nozzle in a subsequent spin casting operation.
Abstract
Description
- Recent advances in the metallurgical arts include development of alloys which, when rapidly quenched from the melt at rates in excess of about 104 to 10 6 "C per second, form glassy (amorphous) solids. Such glass-forming alloys commonly are based on transition metals, usually iron, nickel and/or cobalt, in conjunction with one or more metalloids of phosphorus, boron and carbon. Glass-forming alloys are, for example, described in U.S. Pat. 3,856,513 issued December 24, 1974 to Chen et al.
- Preparation of phosphide based melts of glass-forming alloys under ambient atmosphere leads to oxide inclusions in the glassy metal product. The conventional method of excluding the ambient atmosphere by vacuum melting leads to possible losses of phosphorus values from the melt due to evaporation. Iron phosphide is a basic ingredient in many glass-forming metallic alloy compositions, and in the high purity form required for such purpose, it is quite costly. Inexpensive forms of iron phosphide available are impure and contain phosphorus in form which can evaporate upon heating, and which tends to form volatile phosphorus pentoxide, and which poses a safety hazard and results in changes of the alloy composition. Glassy solid structures are obtained from such alloys by processes such as the melt spin process wherein a fine jet of the molten alloy is impinged upon a rapidly moving chill surface for solidification. Orifice diameters in this process are exceedingly small, and orifice pluggage on account of solid impurities contained in the melt can represent serious problems. Iron, cobalt or nickel based phosphorus-containing glass-forming alloys which additionally contain boron as a metalloid are particularly prone to contamination with solid particles. In such alloy, these particles were found to be predominantly small particles of Ti02 and/or TiB03, both of which have high melt points, and both of which are relatively insoluble in the melt. It was found that titanium is an impurity commonly contained in ferrophosphorus, which is used as a source of phosphorus in making these alloys, although titanium may also be present as contaminant in other raw materials employed in making these alloys.
- The present invention provides refining flux for reducing oxidation of and loss of phosphorus values from phosphorus-containing alloys, especially phosphorus-containing iron, nickel and/or cobalt-based alloys.
- Phosphorus-containing metallic glass-forming alloy melts are covered with a layer of molten boron trioxide flux. Such layer protects the melt from oxidation, dissolves oxide particulates and impurities from the molten metal alloy and prevents the evaporation of phosphorus values. The flux floating on the alloy melt will not interfere with subsequent casting or spinning operations, and the alloy melt can be replenished directly through the flux layer. Alloys prepared according to the process of the present invention leave minimum residues in the jetting crucible in subsequent melt spin operations.
- Phosphorus-containing iron, nickel and/or cobalt-based alloys are desirably melted under a boron trioxide flux additionally comprising oxides of iron, nickel and/or cobalt. The flux layer protects the molten alloy from oxidation, reduces or eliminates contamination of the melt with particulate matter, especially metal oxides, and prevents loss of phosphorus values by vaporization.
- Metallic glass-forming alloys which benefit from protection by boron trioxide flux contain phosphorus as a metalloid component, alone or together with other metalloids, such as boron, carbon and silicon. The phosphorus component of such alloys is usually contributed by ingredients having the formulas FeP , NiPx, CoPx, MnPx, wherein x is between abut 0.3 and l.l and preferably between about 0.5 and 1. Preferred alloy compositions include alloys utilizing as source of phosphorus FeP wherein x is between about 0.5 and 1. Preferred alloy compositions include transition metal alloys containing between about 3 and 25 weight percent phosphorus. These alloys have a phosphorus partial pressure of less than 20 micron, and melting points of between about 900°C and 1200°C.
- Phosphorus-containing alloys based on one or more of iron, nickel and/or cobalt which benefit from melting under the refining boron trioxide flux which additionally contains oxides of iron, nickel and/or cobalt have the general formula MaPbYc wherein M is a metal selected from one or more of the group consisting of iron, cobalt and nickel; P represents phosphorus; Y represents a metalloid selected from one or both of the group consisting of boron and carbon; and a, b and c are in atomic percent, wherein a is about 70 to 90, b is 0-20, but - desirably at least 1, the sum of b + c is about 10 to 30, the sum of a + b + c being 100. In the above formula, up to about 80 percent of M may be replaced by one or more of any transition metal other than iron, cobalt and nickel. Suitable replacements include silicon, chromium, vanadium, aluminum, tin, antimony, germanium, indium, beryllium, molybdenum, titanium, manganese, tungsten, zirconium, hafnium and copper, for example. The phosphorus content of the alloy will ordinarily be derived from ferrophosphorus, which may be of any suitable phosphorus content, such as commercially available grades containing about 18 and 25 percent by weight phosphorus.
- The boron trioxide flux comprises compositions of the formula B203 of about 95 weight percent purity, preferably better than about 98 weight percent purity, the balance being represented by incidental impuritiess or intentional additives which are substantially inert, that is to say, that they do not materially interfere with the intended function of the boron trioxide flux.
- Suitable boron trioxide fluxes have a melting point between about 400°C and 600°C, preferably between about 400° and 500°C, and have a vapor pressure of below about 20 micron.
- In the fluxes of the present invention which additionally contain an oxide of iron, cobalt and/or nickel, the oxide is suitably chosen to correspond to the major metal component of the alloy. For example, if iron is the only or major metal component of the alloy, the oxide component in the flux desirably, but not necessarily, is an oxide of iron. Nickel-containing melts desirably are refined under a flux-containing nickel oxide. The flux desirably contains from about 20 to 80 percent by weight boron trioxide.
- In the melting operation the metal oxide (e.g. iron, cobalt or nickel oxide) coacts with the boron trioxide to obtain the desired result. It is believed that oxygen from the metal oxide combines with titanium metal contained in the melt as an impurity, perhaps forming Ti02, which is then bound in the molten flux. The boron trioxide seems to act as a coagulant for the titanium dioxide as well as for other particulate matter which may be contained in the melt. Moreover, the boron trioxide, because of its acidic character, seemingly tends to prevent oxidation of phosphorus, if present, to the five valent oxide state, as might occur due to presence of small amounts of oxygen in the melt. In the five valent state, phosphorus is volatile under refining conditions encountered in making the alloys here under consideration.
- Of the oxides of iron, namely FeO, Fe203"and Fe304, all are suitable, FeO being preferred. Likewise, any of the oxides of cobalt, CoO, Co203, as well as Co3041 may be employed. However, for reasons of high cost, use of oxides of cobalt is not ordinarily preferred. Nickel oxide, for reasons of availability as well as effectiveness, is the preferred metal oxide. Metal oxides of commercial degree of purity are suitable for use.
- The boron trioxide (H203) similarly may be of any degree commercial purity.
- In the metal oxide containing fluxes, the boron trioxide is desirably employed in amount of 20 to 80 percent by weight, preferably 30 to 70 percent by weight, most preferably 40 to 60 percent by weight of the flux, the balance being represented by the metal oxide. Of course, if desired, other components which do not materially interfere with the protective and refining functions of the flux may be included in the flux composition for any desired purpose, e.g. melting point reduction, although addition of other components is not ordinarily preferred.
- The flux compositions are employed in amount sufficient to provide a flux layer of between about 1 and 50 millimeter thickness, preferably between abbut 2 and 10 millimeter thickness on top of the molten metal alloy. It is an advantage of these flux compositions that their solubility in the alloys is generally low, so that gross contamination of the alloy with the flux is avoided. Furthermore, minor contamination of the alloy with boron values from the flux is generally not deleterious, that is to say that such contamination would not adversely affect the glass-forming capabilities of the alloy, nor its properties in the solid state.
- The temperature of the alloy melt can be between about 1000°C and 1500°C, and preferably between about 1100°C and 1400°C. The temperature of the boron trioxide flux can be between about 900°C and 1400°C.
- To prevent oxidation and loss of phosphorus value from the alloy, the boron trioxide flux should be present at temperatures leading normally to oxidation and/or evaporation of phosphorus values, and in particular the boron trioxide should be present when the alloy is in the molten state. The boron trioxide, to obtain the full benefit of its function, is desirably added to the cold charge. If it is added after the alloy is melted, considerable amounts of phosphorus can be lost.
- To fulfill its refining function, the flux should remain in contact with the surface of the melt at melting temperature for a time period for at least about one minute, desirably of at least about 5 minutes. Contact times of, say, between about 5 minutes and 5 hours, desirably of between about 30 minutes and about 3 hours are eminently suitable. If desired, the melt may be agitated. Suitable melting furnaces include those lined with high temperature ceramic materials. Preferred furnace linings are made from magnesia, zirconia and alumina. If desired, suitable inert atmospheres may be provided above the flux, including such as those provided by helium or argon. Alternatively, the melting operation may be conducted under vacuum. However, provision of inert atmospheres is not essential. If an inert atmosphere is supplied, argon is preferred.
- Iron, nickel, phosphorus, and boron containing glass-forming alloy compositions were prepared by melting together under vacuum raw materials of the following purity: iron, 99.9 weight percent pure; nickel, 99.9 weight percent pure; nickel boride, 99 weight percent pure having boron content of between about 17 and 19 weight percent; ferrophosphorus (Type I) containing 61.43 weight percent iron and 20.39 weight percent boron; ferrophosphorus (Type II) containing 79 weight percent iron and 21 weight percent phosphorus. To each charge there was added an amount of Fe40Ni40P14B6 (atomic percent) . metal alloy to provide an initial susceptor for induction heating of the charge. No Fe40Ni40P1486 was added in case of sample 5 since the ferrophosphorus employed coupled sufficiently with the radiation. The charge was contained in a magnesia crucible covered with boron trioxide and heated by means of induction heating coils. The melt of Examples 1, 2, 4, 5 was maintained under vacuum under a layer of B203 flux at a temperature of 1200°C for one hour, before casting it into ingots. The melt of Example 3 was soaked at 1300°C for 1 hour. The amounts of materials charged are summarized in Table 1 below:
- The cast ingots were subjected to analysis for insolubles, oxygen, silicon, calcium, iron, nickel, phosphorus, and boron.. The ingot obtained in Example 3 was further subjected to a second melt cycle at 1200°C for 1 hour in vacuum under a flux of B2038 The remelted alloy was again cast into an ingot and subjected to analysis. The results of the analysis are shown in Table II below.
- Iron, nickel, boron and phosphorus were determined by wet chemistry; oxygen was determined by placing pieces of raw alloy in a graphite boat in a Leco oxygen analyzer. This method determines only dissolved oxygen, but not chemically bonded oxygen. The procedure for determining insolubles involved dissolving a 2 gram sample of the solid ingot in 100 milliliter of a reagent solution composed of 50 milliliter nitric acid (70% ANO3); 10 milliliter of sulfuric acid (100% H2SO4) and 40 milliliter of water. The alloy was refluxed in the reagent solution until dissolved. The resultant solution was filtered through an analytical filter to determine insoluble content as ash residue. Silicon and calcium were determined by taking an aliquot part of the solution, evaporating the solution, mixing the residue with spectrographic grade graphite and determining the traces by emissions spectroscopy.
- This example illustrates production of an alloy containing Fe: 45.9 + 1 percent by weight; Ni: 44.6 + 1 percent by weight; P: 7.85 + 0.32 percent by weight; B: 1.45 + 0.11 percent by weight. The raw materials charged are iron, electrolytic fragments, 99.9 percent pure; nickel pellets, 99.9 percent pure; ferrophosphorus, low silicon grade (less than about 0.5 percent silicon); nickel-boron, low aluminum grade (as available, for example, from Shieldalloy Company). Prior to and during the charging operation the furnace is purged with argon gas. The required amounts of iron, nickel and ferrophosphorus are charged to the furnace, and the charge is gradually heated until melting. At that point, an oxidizing acid flux consisting of about 50 weight percent nickel oxide and about 50 weight percent B203 is added to the molten charge in an amount of about 8 Ibs. per 2,500 lb. metal charge to produce about a 1/8 inch thick layer of flux. The melt is refined under this flux at a temperature of about 1,180° to 1,200°C for 20 to 30 minutes, taking care to avoid temperatures in excess of 1200°C during the refining operation. Thereafter, the flux is skimmed and the nickel boron is added to the melt. The heat is finished under an argon blanket. Total refining and holding time at the 1,180° to 1,200°C is about 45 to 60 minutes. The refined alloy is then cast at about 1,000°C.
- Using identical raw materials, alloy of the above composition prepared using the NiO/B2O3 flux as above described had a titanium content of only 0.04 percent by weight, whereas an alloy obtained under otherwise identical conditions from the same raw materials, but without use of the flux, had a titanium content about 0.16 percent by weight. Furthermore, alloy prepared under conditions of the present invention had significantly lower contamination with other oxidizable elements which tend to form insoluble solid oxides. As a consequence, metal refined in accordance with the present invention, as above described, caused substantially less restriction of a casting nozzle in a subsequent spin casting operation.
Claims (10)
and wherein the flux comprises oxides of iron, nickel, and/or copper together with boron trioxide.
Applications Claiming Priority (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US925578 | 1978-07-17 | ||
US05/925,579 US4175950A (en) | 1978-07-17 | 1978-07-17 | Preparation of phosphorus containing metallic glass forming alloy melts |
US05/925,578 US4181521A (en) | 1978-07-17 | 1978-07-17 | Preparation of glass-forming alloys under a refining metal oxide/boron trioxide slag |
US925579 | 1986-10-30 |
Publications (2)
Publication Number | Publication Date |
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EP0007062A1 true EP0007062A1 (en) | 1980-01-23 |
EP0007062B1 EP0007062B1 (en) | 1981-10-21 |
Family
ID=27129912
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Application Number | Title | Priority Date | Filing Date |
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EP19790102260 Expired EP0007062B1 (en) | 1978-07-17 | 1979-07-04 | Preparation of phosphorus-containing metallic glass-forming alloy melts |
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EP (1) | EP0007062B1 (en) |
CA (1) | CA1120728A (en) |
DE (1) | DE2961066D1 (en) |
Cited By (1)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0067634A2 (en) * | 1981-06-12 | 1982-12-22 | Allegheny Ludlum Steel Corporation | Method of melting an alloy in an induction furnace |
Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE245197C (en) * | ||||
DE639131C (en) * | 1934-07-02 | 1936-11-28 | Electrochimie D Electrometallu | Process for the production of alloys containing boron |
DE649284C (en) * | 1932-05-15 | 1937-09-23 | Electrochimie D Electrometallu | Slag for the production of low-oxygen steel |
DE678763C (en) * | 1935-02-26 | 1939-07-20 | Heraeus Vacuumschmelze Akt Ges | Process for accelerating metallurgical slag reactions |
DE2246723B1 (en) * | 1972-09-22 | 1973-09-06 | Ver Deutsche Metallwerke Ag | Non ferrous melt surface protection - using a glass compsn |
US3856513A (en) * | 1972-12-26 | 1974-12-24 | Allied Chem | Novel amorphous metals and amorphous metal articles |
-
1979
- 1979-07-04 EP EP19790102260 patent/EP0007062B1/en not_active Expired
- 1979-07-04 DE DE7979102260T patent/DE2961066D1/en not_active Expired
- 1979-07-10 CA CA000331545A patent/CA1120728A/en not_active Expired
Patent Citations (6)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
DE245197C (en) * | ||||
DE649284C (en) * | 1932-05-15 | 1937-09-23 | Electrochimie D Electrometallu | Slag for the production of low-oxygen steel |
DE639131C (en) * | 1934-07-02 | 1936-11-28 | Electrochimie D Electrometallu | Process for the production of alloys containing boron |
DE678763C (en) * | 1935-02-26 | 1939-07-20 | Heraeus Vacuumschmelze Akt Ges | Process for accelerating metallurgical slag reactions |
DE2246723B1 (en) * | 1972-09-22 | 1973-09-06 | Ver Deutsche Metallwerke Ag | Non ferrous melt surface protection - using a glass compsn |
US3856513A (en) * | 1972-12-26 | 1974-12-24 | Allied Chem | Novel amorphous metals and amorphous metal articles |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP0067634A2 (en) * | 1981-06-12 | 1982-12-22 | Allegheny Ludlum Steel Corporation | Method of melting an alloy in an induction furnace |
EP0067634A3 (en) * | 1981-06-12 | 1983-02-16 | Allegheny Ludlum Steel Corporation | Method of melting an alloy in an induction furnace |
Also Published As
Publication number | Publication date |
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DE2961066D1 (en) | 1981-12-24 |
EP0007062B1 (en) | 1981-10-21 |
CA1120728A (en) | 1982-03-30 |
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