U.S. patent application number 15/966424 was filed with the patent office on 2018-11-08 for low cobalt hard facing alloy.
This patent application is currently assigned to ROLLS-ROYCE plc. The applicant listed for this patent is ROLLS-ROYCE plc. Invention is credited to David A. STEWART.
Application Number | 20180320258 15/966424 |
Document ID | / |
Family ID | 59011037 |
Filed Date | 2018-11-08 |
United States Patent
Application |
20180320258 |
Kind Code |
A1 |
STEWART; David A. |
November 8, 2018 |
LOW COBALT HARD FACING ALLOY
Abstract
A stainless steel alloy comprising essentially 19 to 22 percent
by weight chromium, 8.5 to 10.5 percent by weight nickel, 4.5 to
5.75 percent by weight silicon, 0.8 to 2.2 percent by weight
carbon, 0.0 to 0.2 percent by weight nitrogen, 0.2 to 1.2 percent
by weight cobalt, 3.0 to 7.0 percent by weight manganese, 0.0 to
9.0 percent by weight niobium, 0.005 to 0.6 percent by weight
titanium, 0.3 to 6.0 percent by weight molybdenum, and the balance
iron plus impurities.
Inventors: |
STEWART; David A.; (Derby,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
ROLLS-ROYCE plc |
London |
|
GB |
|
|
Assignee: |
ROLLS-ROYCE plc
London
GB
|
Family ID: |
59011037 |
Appl. No.: |
15/966424 |
Filed: |
April 30, 2018 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22F 2301/35 20130101;
C22C 38/44 20130101; C22C 38/48 20130101; C23C 24/00 20130101; C22C
38/002 20130101; B22F 7/08 20130101; C22C 38/50 20130101; C23C
30/00 20130101; B22F 3/15 20130101; B22F 7/04 20130101; C22C 38/001
20130101; C22C 38/34 20130101; C22C 38/52 20130101; C22C 38/58
20130101; C22C 33/0285 20130101 |
International
Class: |
C22C 38/58 20060101
C22C038/58; C22C 38/52 20060101 C22C038/52; C22C 38/50 20060101
C22C038/50; C22C 38/48 20060101 C22C038/48; C22C 38/44 20060101
C22C038/44; C22C 38/34 20060101 C22C038/34; C22C 38/00 20060101
C22C038/00; B22F 3/15 20060101 B22F003/15; B22F 7/08 20060101
B22F007/08 |
Foreign Application Data
Date |
Code |
Application Number |
May 3, 2017 |
GB |
1707019.4 |
Claims
1. An alloy comprising essentially of 19 to 22 percent by weight
chromium, 8.5 to 10.5 percent by weight nickel, 4.5 to 5.75 percent
by weight silicon, 1.7 to 2.2 percent by weight carbon, 0.0 to 0.2
percent by weight nitrogen, 0.2 to 1.2 percent by weight cobalt,
3.0 to 7.0 percent by weight manganese, 0.0 to 9.0 percent by
weight niobium, 0.005 to 0.6 percent by weight titanium, 0.3 to 6.0
percent by weight molybdenum, and the balance iron plus
impurities.
2. An alloy according to claim 1 wherein the impurities consist of
0 to 0.03 percent by weight phosphor, 0 to 0.03 percent by weight
sulphur.
3. An alloy according to claim 1 wherein the alloy comprises 4.0 to
6.0 percent by weight molybdenum.
4. An alloy according to claim 1 comprising essentially of 19 to 22
percent by weight chromium, 8.5 to 10.5 percent by weight nickel,
4.5 to 5.25 percent by weight silicon, 1.8 to 2.2 percent by weight
carbon, 0.0 to 0.2 percent by weight nitrogen, 0.2 to 0.4 percent
by weight cobalt, 3.0 to 7.0 percent by weight manganese, 6.5 to
8.0 percent by weight niobium, 0.005 to 0.05 percent by weight
titanium, 0.3 to 0.5 percent by weight molybdenum, and the balance
iron plus impurities.
5. An alloy according to claim 1 comprising essentially of 19 to 22
percent by weight chromium, 8.5 to 10.5 percent by weight nickel,
5.25 to 5.75 percent by weight silicon, 1.7 to 2.0 percent by
weight carbon, 0.0 to 0.2 percent by weight nitrogen, 0.2 to 0.4
percent by weight cobalt, 3.0 to 7.0 percent by weight manganese,
8.0 to 9.0 percent by weight niobium, 0.3 to 0.5 percent by weight
titanium, 0.3 to 0.5 percent by weight molybdenum, and the balance
iron plus impurities.
6. A method of forming an alloy comprising the step of providing an
alloy in powder form, the alloy comprising essentially of 19 to 22
percent by weight chromium, 8.5 to 10.5 percent by weight nickel,
4.5 to 5.75 percent by weight silicon, 1.7 to 2.2 percent by weight
carbon, 0.0 to 0.2 percent by weight nitrogen, 0.2 to 1.2 percent
by weight cobalt, 3.0 to 7.0 percent by weight manganese, 0.0 to
9.0 percent by weight niobium, 0.005 to 0.6 percent by weight
titanium, 0.3 to 6.0 percent by weight molybdenum, and the balance
iron plus impurities; and heating and isostatically pressing the
powder.
7. An article having a coating comprising an alloy comprising
essentially of 19 to 22 percent by weight chromium, 8.5 to 10.5
percent by weight nickel, 4.5 to 5.75 percent by weight silicon,
1.7 to 2.2 percent by weight carbon, 0.0 to 0.2 percent by weight
nitrogen, 0.2 to 1.2 percent by weight cobalt, 3.0 to 7.0 percent
by weight manganese, 0.0 to 9.0 percent by weight niobium, 0.005 to
0.6 percent by weight titanium, 0.3 to 6.0 percent by weight
molybdenum, and the balance iron plus impurities.
8. An article having a coating according to claim 7, comprising
essentially of 19 to 22 percent by weight chromium, 8.5 to 10.5
percent by weight nickel, 4.5 to 5.25 percent by weight silicon,
1.8 to 2.2 percent by weight carbon, 0.0 to 0.2 percent by weight
nitrogen, 0.2 to 0.4 percent by weight cobalt, 3.0 to 7.0 percent
by weight manganese, 6.5 to 8.0 percent by weight niobium, 0.005 to
0.05 percent by weight titanium, 0.3 to 0.5 percent by weight
molybdenum, and the balance iron plus impurities.
9. An article having a coating according to claim 7, comprising
essentially of 19 to 22 percent by weight chromium, 8.5 to 10.5
percent by weight nickel, 5.25 to 5.75 percent by weight silicon,
1.7 to 2.0 percent by weight carbon, 0.0 to 0.2 percent by weight
nitrogen, 0.2 to 0.4 percent by weight cobalt, 3.0 to 7.0 percent
by weight manganese, 8.0 to 9.0 percent by weight niobium, 0.3 to
0.5 percent by weight titanium, 0.3 to 0.5 percent by weight
molybdenum, and the balance iron plus impurities.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This disclosure claims the benefit of UK Patent Application
No. GB 1707019.4, filed on 3 May 2017, which is hereby incorporated
herein in its entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to steel alloys and
particularly a chromium nickel silicon stainless steel alloy with
low cobalt that may be suited for use in nuclear reactors,
particularly in the components used in the steam generating plant
of nuclear reactors.
BACKGROUND OF THE INVENTION
[0003] Traditionally, cobalt-based alloys, including Stellite.TM.
alloys, have been used for wear-based applications including, for
example, in nuclear power applications. The alloys may be used to
both form components or to provide hard-facing where harder or
tougher material is applied to a base metal or substrate.
[0004] It is common for hard-facing to be applied to a new part
during production to increase its wear resistance. Alternatively,
hard-facing may be used to restore a worn surface. Extensive work
in research has resulted in the development of a wide range of
alloys and manufacturing procedures dependent on the properties
and/or characteristics of the required application.
[0005] Within the nuclear industry the presence of cobalt within an
alloy gives rise to the potential for the cobalt to activate within
a neutron flux to result in the radioisotope cobalt-60 which has a
long half-life. This makes the use of cobalt undesirable for alloys
used in this industry. The cobalt may be released as the alloy
wears through various processes, one of which is galling that is
caused by adhesion between sliding surfaces caused by a combination
of friction and adhesion between the surfaces, followed by slipping
and tearing of crystal structure beneath the surface. This will
generally leave some material stuck or even friction welded to the
adjacent surface, whereas the galled material may appear gouged
with balled-up or torn lumps of material stuck to its surface.
[0006] Replacements for Stellite have been developed by the
industry with low or nil cobalt quantities. Exemplary alloys are
detailed in the table below:
TABLE-US-00001 Alloy Cr C Nb Nb + Va Ni Si Fe Co Ti GB2167088 15-25
1-3 5-15 5-15 2.7-5.6 Bal Nil Nil T5183 19-22 1.8-2.2 6.5-8.0
8.5-10.5 4.5-5.25 Bal 0.2 Trace US5660939 19-22 1.7-2.0 8.0-9.0
8.5-10.5 5.25-5.75 Bal 0.2 0.3-0.7
[0007] In GB2167088 niobium is provided, but always with the
presence of vanadium, which prevents the chromium from combining
with the carbon and weakening the matrix. The vanadium also acts as
a grain refiner within the wholly austenitic alloy that helps the
keep the size of the grains within the alloy within an acceptable
range.
[0008] The alloys of U.S. Pat. No. 5,660,939 modified the alloy of
T5183 by the deliberate addition of titanium and by increasing the
amounts of niobium and silicon. The controlled additions of
titanium, niobium and silicon alter the structure of the steel to
provide a duplex auszenitic/ferritic microstructure which undergoes
secondary hardening due to the formation of an iron silicon
intermetallic phase.
[0009] Further hardening is achievable by hot isostatic pressing
(HIPPING) of the stainless steel alloy when in powder form where
secondary hardening occurs within the ferritic phase of the duplex
microstructure.
[0010] The niobium provides a preferential carbide former over
chromium, enabling high chromium levels to be maintained within the
matrix so as to give good corrosion performance. Low cobalt based
alloys, or cobalt alloy replacements, typically comprise
significant quantities of carbide forming elements which can form
alloys with hardness values in excess of 500 Hv. As with
traditional Stellite alloys, the high levels of hardness observed
can make machining difficult, resulting in poor mechanical
properties for, for example, ductility, fracture toughness, impact
resistance and workability. Additionally, the cost of using such
alloys is high due to the need for special treatments and/or
precision casting or other near net shape manufacturing methods to
limit further machining.
[0011] Accordingly, it would therefore be advantageous to provide
an alloy without the aforementioned disadvantages.
SUMMARY OF THE INVENTION
[0012] The present invention accordingly provides, in a first
aspect, an alloy comprising essentially of 19 to 22 percent by
weight chromium, 8.5 to 10.5 percent by weight nickel, 4.5 to 5.75
percent by weight silicon, 1.7 to 2.2 percent by weight carbon, 0.2
to 1.2 percent by weight cobalt, 3.0 to 7.0 percent by weight
manganese, 0.0 to 9.0 percent by weight niobium, 0.0 to 0.2 wt %
nitrogen, 0.005 to 0.6 percent by weight titanium, 0.3 to 6.0
percent by weight molybdenum, and the balance iron plus
impurities.
[0013] The impurities may consist of 0 to 0.03 percent by weight
phosphor, 0 to 0.03 percent by weight sulphur.
[0014] The alloy may comprises 0.1 to 0.5 percent by weight
molybdenum.
[0015] The alloy may comprises 4.0 to 6.0 percent by weight
molybdenum.
[0016] The alloy may comprise essentially of 19 to 22 percent by
weight chromium, 8.5 to 10.5 percent by weight nickel, 4.5 to 5.25
percent by weight silicon, 1.8 to 2.2 percent by weight carbon, 0.2
to 0.4 percent by weight cobalt, 3.0 to 7.0 percent by weight
manganese, 6.5 to 8.0 percent by weight niobium, 0.0 to 0.2 wt %
nitrogen, 0.005 to 0.05 percent by weight titanium, 0.3 to 0.5
percent by weight molybdenum, and the balance iron plus
impurities.
[0017] The alloy may comprise essentially of 19 to 22 percent by
weight chromium, 8.5 to 10.5 percent by weight nickel, 5.25 to 5.75
percent by weight silicon, 1.7 to 2.0 percent by weight carbon, 0.2
to 0.4 percent by weight cobalt, 3.0 to 7.0 percent by weight
manganese, 8.0 to 9.0 percent by weight niobium, 0.3 to 0.5 percent
by weight titanium, 0.3 to 0.5 percent by weight molybdenum, and
the balance iron plus impurities.
[0018] The alloy may be in powder form which is consolidated in a
hot isostatic press.
[0019] The alloy may be applied to an article to provide a coating
on the article. The coating may be hard faced or welded onto the
article.
[0020] The alloy may be used in a steam generating plant. The steam
may be generated through a nuclear reaction.
[0021] A preferred embodiment of the present invention will now be
described, by way of example only.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The improved alloys described here have been developed
having 19 to 22 percent by weight chromium, 8.5 to 10.5 percent by
weight nickel, 4.5 to 5.75 percent by weight silicon, 0.25 to 2.2
percent by weight carbon, 0.2 to 1.2 percent by weight cobalt, 3.0
to 7.0 percent by weight manganese, 0.0 to 9.0 percent by weight
niobium, 0.0 to 0.2 wt % nitrogen, 0.005 to 0.6 percent by weight
titanium, 0.3 to 6.0 percent by weight molybdenum, and the balance
iron plus impurities.
[0023] The impurities may be up to 0.2 wt % cobalt, up to 0.3 wt %
molybdenum, up to 0.03 wt % phosphor, up to 0.03 wt % sulphur.
[0024] The new alloy has an acceptable galling resistance as
carbides will be formed, and the matrix continues to have a duplex
austenitic/ferritic microstructure which undergoes secondary
hardening due to the formation of an iron silicon intermetallic
phase. The added nitrogen may further improve the galling
resistance of the austenite phase.
[0025] Although carbides continue to be formed the alloy has a
resultant lover overall carbide caused, in part, by the weight
percentage content of niobium and carbon that give an alloy with an
acceptable hardness but greater ductility and toughness. This
improvement in ductility opens up the range of range of
applications where consideration to shock events has to be
considered as well as the overall wear resistance requirement.
[0026] The manganese increases the hardenability of the alloy and,
in conjunction with the carbide formation, further increases the
galling resistance of the alloy. The silicon helps the alloy retain
a duplex microstructure.
* * * * *