WO2016112341A1 - Alliages résistants à l'aluminium en fusion - Google Patents

Alliages résistants à l'aluminium en fusion Download PDF

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Publication number
WO2016112341A1
WO2016112341A1 PCT/US2016/012730 US2016012730W WO2016112341A1 WO 2016112341 A1 WO2016112341 A1 WO 2016112341A1 US 2016012730 W US2016012730 W US 2016012730W WO 2016112341 A1 WO2016112341 A1 WO 2016112341A1
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Prior art keywords
alloy
less
reaction
aluminum
molten aluminum
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PCT/US2016/012730
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English (en)
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Kenneth VECCHIO
James VECCHIO
Justin Lee Cheney
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Scoperta, Inc.
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Publication of WO2016112341A1 publication Critical patent/WO2016112341A1/fr

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    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/10—Cast-iron alloys containing aluminium or silicon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C1/00—Compositions of refractory mould or core materials; Grain structures thereof; Chemical or physical features in the formation or manufacture of moulds
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C3/00—Selection of compositions for coating the surfaces of moulds, cores, or patterns
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/06—Permanent moulds for shaped castings
    • B22C9/061—Materials which make up the mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22C—FOUNDRY MOULDING
    • B22C9/00—Moulds or cores; Moulding processes
    • B22C9/10—Cores; Manufacture or installation of cores
    • B22C9/101—Permanent cores
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D21/00—Casting non-ferrous metals or metallic compounds so far as their metallurgical properties are of importance for the casting procedure; Selection of compositions therefor
    • B22D21/002—Castings of light metals
    • B22D21/007—Castings of light metals with low melting point, e.g. Al 659 degrees C, Mg 650 degrees C
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C16/00—Alloys based on zirconium
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C27/00—Alloys based on rhenium or a refractory metal not mentioned in groups C22C14/00 or C22C16/00
    • C22C27/02—Alloys based on vanadium, niobium, or tantalum
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C37/00—Cast-iron alloys
    • C22C37/06—Cast-iron alloys containing chromium
    • C22C37/08—Cast-iron alloys containing chromium with nickel

Definitions

  • ALLOYS the entirety of which is incorporated herein by reference.
  • This disclosure generally relates to materials and coatings which can be resistant to flowing molten aluminum, and methods for producing the same.
  • Casting components can degrade due to their reaction with molten aluminum during the manufacturing of aluminum parts within the casting component.
  • the reaction rate between the casting component and the molten aluminum thus can govern the lifetime of the components' utility.
  • the reaction rate can be increased and lifetime decreased when the component is subject to contact with flowing aluminum due to the component experiencing more of a reaction with the molten aluminum.
  • H13 steel One conventional material used to create components by the aluminum casting industry due to its relatively high resistance to molten aluminum is H13 steel.
  • H13 steel has the composition of: Fe-bal, C: 0.32-0.40, Cr: 5.13-5.25, Mo: 1.33-1.4, Si: 1, V: 1 , and the steel is air or oil quenched from 1000 °C - 1025°C.
  • the method may comprise coating a component formed from a base material with an alloy, wherein the alloy has a reaction rate to aluminum less than 50% than that of the base material.
  • the alloy can be a Nb-Zr alloy with 30-60 wt. % Zr.
  • the alloy can be a grey cast iron.
  • the alloy can be a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)ioo- x Nb x with x ranging from 10 to 30 wt.%.
  • the alloy can be a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron) 100-x Nb x with x ranging from 0 to 10 wt.%.
  • the alloy can have a reaction rate less than 10% than that of the base material. In some embodiments, the alloy can have a reaction rate less than 5% than that of the base material.
  • an alloy resistant to molten aluminum comprising two or more elements, wherein the alloy has a reaction level of less than 38 atom%, wherein the reaction level is calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K.
  • the reaction level can be 10 atom% or less. In some embodiments, the reaction level can be 5 atom% or less.
  • the alloy can be a Nb-Zr alloy with 30-60 wt. % Zr. In some embodiments, the alloy can be a grey cast iron. In some embodiments, the alloy can be a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)ioo- x Nb x with x ranging from 10 to 30 wt.%. In some embodiments, the alloy can be a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)ioo- x Nb x with x ranging from 0 to 10 wt.%.
  • an alloy resistant to molten aluminum comprising two or more elements, wherein the alloy has a reaction level of less than 40 atom%, wherein the reaction level is calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K.
  • the reaction level can be 10 atom% or less. In some embodiments, the reaction level can be 5 atom% or less.
  • an article of manufacture for use in an aluminum casting process comprising at least a portion of an alloy, wherein the alloy has a reaction rate in molten aluminum of less than or equal to 1 ⁇ 2 the rate of H13 steel.
  • the alloy can be a grey cast iron.
  • the alloy can be pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)ioo- x Nb x with x ranging from 0 to 10 wt.%.
  • the alloy can have a reaction rate less than 10% than that of the base material. In some embodiments, the alloy can have a reaction rate less than 5% than that of the base material.
  • a casting component for casting aluminum wherein the casting component is either clad with or is comprised of a metal alloy composition, the metal alloy composition having a reaction level of about 38 atom % or less, wherein the reaction level is defined as the minimum alloy content of the metal alloy composition in the phase diagram between aluminum and the metal alloy composition where the liquidus curve is at or above 1500 K.
  • the alloy can have a reaction rate in molten aluminum of less than or equal to 1 ⁇ 2 the rate of H13 steel.
  • a % loss of an alloy rod, based on area loss and diameter loss, formed the metal alloy composition can be less than 5% after undergoing a molten aluminum flow rate of 0.2 meters/second.
  • a casting component for casting aluminum wherein the casting component is either clad with or is comprised of a metal alloy composition, the metal alloy composition having a reaction level of about 40 atom % or less, wherein the reaction level is defined as the minimum alloy content of the metal alloy composition in the phase diagram between aluminum and the metal alloy composition where the liquidus curve is at or above 1500 K.
  • a method of casting aluminum comprising providing molten aluminum into contact with a surface of a casting component, wherein the casting component is either clad with or is comprised of a metal alloy composition, the metal alloy composition having a reaction level of about 38 atom % or less, wherein the reaction level is defined as the minimum alloy content of the metal alloy composition in the phase diagram between aluminum and the metal alloy composition where the liquidus curve is at or above 1500 K; and casting the molten aluminum.
  • a method of casting aluminum comprising providing molten aluminum into contact with a surface of a casting component, wherein the casting component is either clad with or is comprised of a metal alloy composition, the metal alloy composition having a reaction level of about 40 atom % or less, wherein the reaction level is defined as the minimum alloy content of the metal alloy composition in the phase diagram between aluminum and the metal alloy composition where the liquidus curve is at or above 1500 K; and casting the molten aluminum.
  • Also disclosed herein are embodiments of a method of protecting a component from molten aluminum reaction the method comprising coating a component formed from a base material with an alloy, wherein the alloy has a reaction level to molten aluminum of less than 38 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K, and wherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.
  • Also disclosed herein are embodiments of a method of protecting a component from molten aluminum reaction the method comprising coating a component formed from a base material with an alloy, wherein the alloy has a reaction level to molten aluminum of less than 40 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K, and wherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.
  • the alloy can be a Nb-Zr alloy with 30-60 wt. % Zr. In some embodiments, the alloy can have a reaction rate to molten aluminum less than 50% than that of the base material. In some embodiments, the alloy can be a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)ioo- x Nb x with x ranging from 10 to 30 wt.%. In some embodiments, the alloy can be a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)ioo- x Nb x with x ranging from 0 to 10 wt.%. In some embodiments, the alloy can have a reaction rate less than 10% than that of the base material. In some embodiments, the alloy can have a reaction rate less than 5% than that of the base material.
  • an alloy resistant to molten aluminum comprising two or more elements, a reaction level of less than 38 atom%, wherein the reaction level is calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K, and a minimum concentration of highly resistant secondary phases of 5 mole %.
  • the reaction level can be 10 atom% or less. In some embodiments, the reaction level can be 5 atom% or less. In some embodiments, the alloy can be a Nb-Zr alloy with 30-60 wt. % Zr.
  • an alloy resistant to molten aluminum comprising two or more elements, a reaction level of less than 40 atom%, wherein the reaction level is calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K, and a minimum concentration of highly resistant secondary phases of 5 mole %.
  • the alloy can be a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron) ioo- x Nb x with x ranging from 10 to 30 wt.%. In some embodiments, the alloy can be a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron) ioo- x Nb x with x ranging from 0 to 10 wt.%. In some embodiments, the alloy can have a minimum concentration of highly resistant secondary phases of 10 mole %. In some embodiments, the alloy can have a minimum concentration of highly resistant secondary phases of 20 mole %.
  • the alloy can comprise Fe and the following in weight percent: Nb: about 10, Si: 0 to about 2, Mn: 0 to about 2, and C: 0 to about 2.5.
  • the alloy can comprise Fe and one of the following in weight percent: Nb: about 10, Si: about 1.6, Mn: about 0.5, C: about 2.5; Nb: about 10, Si: about 1.6, Mn: about 0.5, C: about 2.0; Nb: about 10, Si: about 1.6, Mn: about 0.5, C: about 1.5; or Nb: about 10, Si: about 1.6, Mn: about 0.5, C: about 1.0.
  • the alloy can be a coating on a base substrate. In some embodiments, the alloy can be a casting component for casting molten aluminum. [0028] Also disclosed herein are embodiments of an article of manufacture for use in an aluminum casting process, the article comprising an alloy forming at least a portion of the article, wherein the alloy has a reaction level to molten aluminum of less than 38 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K, and wherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.
  • the alloy can be a grey cast iron. In some embodiments, the alloy can have a reaction rate in molten aluminum of less than or equal to 1 ⁇ 2 the rate of H13 steel. In some embodiments, the alloy can be pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron)ioo- x Nb x with x ranging from 0 to 10 wt.%. In some embodiments, the alloy can have a reaction rate less than 10% than that of the H13 steel. In some embodiments, the alloy can have a reaction rate less than 5% than that of the HI 3 steel.
  • an article of manufacture for use in an aluminum casting process, the article comprising an alloy forming at least a portion of the article, wherein the alloy has a reaction level to molten aluminum of less than 40 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K, and wherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.
  • Also disclosed herein are embodiments of a method of protecting a component from molten aluminum reaction the method comprising coating a component formed from a base material with an alloy, wherein the alloy has a reaction level to molten aluminum of less than 38 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K, and wherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.
  • Also disclosed herein are embodiments of a method of protecting a component from molten aluminum reaction the method comprising coating a component formed from a base material with an alloy, wherein the alloy has a reaction level to molten aluminum of less than 40 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K, and wherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.
  • Figure 1 illustrates a phase diagram of an alloy showing calculation of reaction level according to certain embodiments of the disclosure.
  • Figure 2 illustrates an SEM micrograph showing reaction width measurement according to certain embodiments of the disclosure.
  • Figure 3 illustrates a sample coupon after an aluminum bath exposure showing area loss measurements according to certain embodiments of the disclosure.
  • casting components that can come into contact (either intentionally or unintentionally) with molten aluminum, as well as alloys and articles resistant to deleterious effects of molten aluminum.
  • casting components that can have the resistance to molten aluminum include casting nozzles and casting molds, though other casting components could be used as well.
  • the casting components can be coated with an aluminum-resistant alloy, and thus have a different material substrate underneath the coating, or can be manufactured partially or completely from an aluminum-resistant alloy.
  • a method of protection which can involve the cladding, or coating, of conventional components with a material which can have enhanced resistance to molten aluminum.
  • Cladding can involve the deposition of a layer of a high resistance material, and can be deposited using a variety of techniques including, but not limited to: TIG welding, MIG welding, thermal spray, PTA welding, laser cladding, etc.
  • a successful cladding can protect the component from contact with the molten aluminum, and thus the lifetime of the component can be governed by the reaction rate of the cladding material and not the underlying component.
  • the cladding can increase the lifetime of the component by 10% (or about 10%) or more as compared to the underlying component.
  • the cladding can increase the lifetime of the component by 200% (or about 200%) or more as compared to the underlying component. In some embodiments, the cladding can increase the lifetime of the component by 400% (or about 400%) or more as compared to the underlying component.
  • a method for increasing lifetime is described by which the component itself can be made from an alloy which is highly resistant to molten aluminum.
  • the resistant alloy that is made to use the component itself is compared against a conventional material used to create components by the aluminum casting industry, HI 3 steel.
  • HI 3 steel is Fe-bal, C: 0.32-0.40, Cr: 5.13-5.25, Mo: 1.33-1.4, Si: 1 , V: 1 which is air or oil quenched from 1000 °C - 1025°C.
  • the use of a resistant alloy to fabricate the component can increase the lifetime of component by 10% (or about 10%) or more compared to HI 3 steel. In some embodiments, the use of a resistant alloy to fabricate the component can increase the lifetime by 200% (or about 200%) or more compared to an HI 3 steel component. In some embodiments, the use of a resistant alloy to fabricate the component can increase the lifetime by 400% (or about 400%) or more compared to a H13 steel component.
  • the term alloy can refer to the chemical composition of powder used to form a desired component, the powder itself (such as feedstock), the composition of a metal component formed, for example, by the heating and/or deposition of the powder, and the metal component itself.
  • this disclosure can be fully described by the metal alloy compositions.
  • the alloy compositions can be used to form the cladding layer or used to fabricate the component.
  • Table 1 lists the alloy chemistries evaluated according to the base element and the alloying element composition (in weight percent).
  • grey cast iron is listed as the base element. The particular alloys were chosen based on their reaction level with Al determined from a binary phase diagram between the alloying element and Al.
  • the composition for gray cast iron is the base alloy whereby alloying additions are added. For example, in the case of alloy 25, grey cast iron makes up 90% (or about 90%) of the alloy chemistry and pure Nb makes up the remaining 10% (or about 10%), also commonly written as (grey cast iron)9oNbio.
  • grey cast iron is any iron-based material with 2.5 to 4 wt.% carbon (or about 2.5 to about 4 wt. % carbon).
  • the grey cast iron can contain a graphite phase.
  • Nb-V-Zr-Ti may provide advantageous properties.
  • certain metals can be avoided such as copper, nickel, palladium, hafnium, platinum, iron, chromium, cobalt, and manganese.
  • the alloy can be considered a pseudo alloy with a pseudo binary phase diagram.
  • a pseudo binary phase diagram is a common phrase used by metallurgists to describe a phase diagram where one of the sides is not a pure element.
  • the alloy might be 60Zr-40Nb and a pseudo binary phase diagram can be evaluated where one end of the phase diagram is pure 60Zr-40Nb and the other end is pure Al. This is not a true binary phase diagram because any point on the diagram is really a three element alloy.
  • the alloy can be further modified from Alloy 25 presented in Table 1. Specifically, the carbon level can be reduced to reduce or prevent the potential of the weld overlay to crack.
  • the alloy can comprise the following elemental ranges in weight percent (balance iron):
  • Nb 0 to 10 (or about 0 to about 10)
  • Si 0 to 2 (or about 0 to about 2)
  • Mn 0 to 2 (or about 0 to about 2)
  • the alloy can comprise the following in weight percent:
  • the alloy may contain a non-zero amount of that element.
  • the disclosed alloys can incorporate the above elemental constituents to a total of 100 wt. %.
  • the alloy may include, may be limited to, or may consist essentially of the above named elements.
  • the alloy may include 2% or less of impurities. Impurities may be understood as elements or compositions that may be included in the alloys due to inclusion in the feedstock components, through introduction in the manufacturing process.
  • the Fe content identified in all of the compositions described in the above paragraphs may be the balance of the composition as indicated above, or alternatively, the balance (or remainder) of the composition may comprise Fe and other elements. In some embodiments, the balance may consist essentially of Fe and may include incidental impurities.
  • thermodynamic criteria which can be used to predict the desired performance of the alloy.
  • certain criteria can be used to define the thermodynamic behavior of the alloys.
  • the criteria can be used to define the reaction rate of the alloy with molten aluminum.
  • the criteria are advantageous in order to use computational metallurgy to design the best performing alloys from the billions of potential choices.
  • the first criterion is defined as the reaction level [101] shown in Figure 1.
  • the reaction level is calculated using thermodynamic phase diagrams, such as the Fe-Al phase diagram shown in Figure 1.
  • the Fe-Al phase diagram shows an example of the methodology for determining the reaction level of an individual element with Al.
  • the reaction level is calculated by evaluating the minimum alloy content of the alloy element that is reacting with Al where the liquidus curve is at or above 1500K, which is a relevant temperature at which an aluminum casting component might operate (e.g., this is the conventional temperature used for casting aluminum parts).
  • the reaction level of pure iron would be between 38 atom % (or about 38 atom %) and 40 atom % (or about 40 atom %) as shown at the intersection of the 1500K isotherm with the liquidus line.
  • Decreasing reaction levels can correspond to decreasing reaction rates with molten aluminum and thereby increasing component lifetime.
  • the reaction rate of the alloy with molten aluminum decreases and component lifetime increases. Therefore, an alloy with a low reaction level can be the most resistant to molten aluminum attack.
  • the reaction level of H13 would be similar to the reaction level of Fe.
  • reaction level tells that at 1500K the liquid could have up to 38% dissolved iron in it.
  • a lower reaction level such as 10%, can indicate that the liquid can contain up to 10% dissolved iron. Therefore, a lower reaction level signifies a decreasing ability of the liquid to dissolve the solid component and thereby an increase in the lifetime of the solid.
  • the alloy can have a reaction level of less than 40 atom % (or less than about 40 atom %). In some embodiments, the alloy can have a reaction level of less than 39 atom % (or less than about 39 atom %). In some embodiments, the alloy can have a reaction level of less than 38 atom % (or less than about 38 atom %). In some embodiments, the alloy can have a reaction level of less than 10 atom % (or less than about 10 atom %). In some embodiments, the alloy can have a reaction level of less than 5 atom % (or less than about 5 atom %).
  • the alloy can have a reaction level of 40 atom % (or about 40 atom %) or less. In some embodiments, the alloy can have a reaction level of 39 atom % (or about 39 atom %) or less. In some embodiments, the alloy can have a reaction level of 38 atom % (or about 38 atom %) or less. In some embodiments, the alloy can have a reaction level of 10 atom % (or about 10 atom %) or less. In some embodiments, the alloy can have a reaction level of 5 atom % (or about 5 atom %) or less.
  • the second criterion is the reaction slope at 1500K and is calculated by evaluating the slope of the liquidus curve at 1500K in the alloy/pure aluminum phase diagram. A steeper slope predicts a lower reaction rate and a shallower slope predicts a higher reaction rate. Thus, reaction improvements can be made by increasing the liquidus curve slope at a particular temperature, such as the 1500K discussed in the examples herein.
  • the general principles discussed herein are to shift the liquidus and temperature isotherm point (at whatever desirable temperature that maybe) towards the Al side of the phase diagram (e.g., making the alloy have more limited solubility of the specific alloy metal with Al) while also increasing the slope of the liquidus curve at that particular temperature (e.g., requiring higher and higher temperatures to achieve more metal solubility in molten Al).
  • This can give alloys which are more resistant to the molten aluminum, thus having less reaction, and may be more easily used in liquid aluminum applications.
  • 1500K is a representative number that is based on the conventional melting temperature of aluminum. This temperature value can be adjusted as necessary for a particular configuration, for example different aluminum alloys may achieve solidification at higher or lower melting temperatures. The same application as above can be thus applied to those temperatures as well. Further, the phase diagram disclosed with respect to Fe and Al is just one embodiment, and different phase diagrams having different properties can be used as well.
  • a highly resistant secondary phase can have a measured reaction rate below a certain threshold.
  • the highly resistant secondary phases can have a measured reaction rate of below 0.5 ⁇ /hr (or below about 0.5 ⁇ /hr).
  • the alloy can have a minimum concentration of highly resistant secondary phases. Highly resistant secondary phases are calculated thermodynamically for a given alloy at room temperature and are given in mole fraction. In some embodiments, the alloy can have a minimum of 5 mole % (or about 5 mole %) of highly resistant secondary phases. In some embodiments, the alloy can have a minimum of 10 mole % (or about 10 mole %) of highly resistant secondary phases. In some embodiments, the alloy can have a minimum of 20 mole % (or about 20 mole %) of highly resistant secondary phases.
  • the alloy can be fully described by a set of performance criteria used to measure the resistance to molten aluminum attack. Through extensive experimentation, two test methods were developed in order to characterize molten aluminum resistivity.
  • the first method involved submerging the alloy in a molten aluminum bath at 750°C temperature for 48 hours.
  • HI 3 steel a common alloy used in the aluminum casting industry, was tested in this way.
  • the reaction width is used as a metric to characterize the reaction rate of the alloy. As shown in Figure 2, the reaction width [201] is defined as the distance by which the alloy shows reaction with the molten aluminum.
  • the micrograph shows three distinct regions, 1) unreacted HI 3 steel
  • reaction region which of which is used to calculate the reaction width [203]
  • aluminum rich region [204].
  • One skilled in the art can easily distinguish all three regions using energy dispersive spectroscopy.
  • reaction rate of the material can then be calculated based on the reaction width measurement and the testing time. Reaction rate measurements are shown in Table 2 for a selection of experimental alloys. As shown, the majority of experimental alloys tested do not show an improvement in reaction rate, thus demonstrating the difficulty in designing such an alloy. Also shown is the improvement factor over H13 steel, which is a useful metric to define the molten aluminum resistance of the alloy.
  • the alloy can show a molten aluminum resistance which is 2 times or better (or about 2 times or more better) than a base material, such as H13 steel. In some embodiments, the alloy can show a molten aluminum resistance which is 10 times or better (or about 10 times or more better) than H13 steel. In some embodiments, the alloy can show a molten aluminum resistance which is 40 times or better (or about 40 times or more better) than HI 3 steel.
  • the alloy can have a reaction rate to molten aluminum that is less than 50% (or less than about 50%) than the reaction rate of the base material it is coated on, such as H13 steel.
  • the alloy can have a reaction rate that is less than 10% (or less than about 10%) than the reaction rate of the base material it is coated on.
  • the alloy can have a reaction rate that is less than 5% (or less than about 5%) than the reaction rate of the base material it is coated on.
  • a second method was devised in order to characterize the resistance of the alloy in the presence of flowing molten aluminum.
  • a 0.25" diameter alloy rod was manufactured and spun in a bath of molten aluminum at a 470 rotational speed. These testing conditions resulted in a flow rate of 0.2 meters/second on the surface of the alloy coupon.
  • the performance of the experimental alloys in this test is shown in Table 3.
  • the diameter and area loss of the specimen is measured according to Figure 3.
  • the original diameter of the sample [302] and the diameter of the un-reacted area of the sample after exposure [301] are used to calculate the % loss of each experimental alloy composition. It can be advantageous to have a % loss less than that of HI 3.
  • Conditional language such as “can,” “could,” “might,” or “may,” unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain embodiments include or do not include, certain features, elements, and/or steps. Thus, such conditional language is not generally intended to imply that features, elements, and/or steps are in any way required for one or more embodiments.
  • the above recited ranges can be specific ranges, and not within a particular % of the value. For example, within less than or equal to 10 wt./vol. % of, within less than or equal to 5 wt./vol. % of, within less than or equal to 1 wt./vol. % of, within less than or equal to 0.1 wt./vol. % of, and within less than or equal to 0.01 wt./vol. % of the stated amount.

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Abstract

Des modes de réalisation de l'invention concernent des procédés de protection d'un matériau d'une réaction à partir d'aluminium en fusion. Dans certains modes de réalisation, un revêtement peut être appliqué sur un substrat qui a une vitesse de réaction considérablement inférieure avec l'aluminium en fusion, ce qui permet d'empêcher les dommages ou les modifications chimiques survenant sur le substrat. L'alliage de revêtement peut être formé à partir de fonte en combinaison avec du niobium dans certains modes de réalisation.
PCT/US2016/012730 2015-01-09 2016-01-08 Alliages résistants à l'aluminium en fusion WO2016112341A1 (fr)

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