1.7 Percent Or More Carbon Containing (e.g., Cast Iron) Patents (Class 148/321)
  • Publication number: 20110017364
    Abstract: A component for wind turbines includes cast austempered ductile iron containing about 3.0 to about 3.8 weight percent carbon, about 1.9 to about 2.8 weight percent silicon, up to about 0.3 weight percent manganese, up to about 0.8 weight percent copper, up to about 2.0 weight percent nickel, up to about 0.3 weight percent molybdenum, about 0.03 to about 0.06 weight percent magnesium, less than about 0.05 weight percent chromium, less than about 0.02 weight percent vanadium, and less than about 0.01 weight percent sulfur. The component is preferably a drive shaft or gearbox component having a mass of more than about 3 tons. A method of manufacturing the component is also provided.
    Type: Application
    Filed: July 23, 2009
    Publication date: January 27, 2011
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Junyoung Park, Gregory Keith Bouse, Jason Robert Parolini, Sujith Sathian
  • Patent number: 7846381
    Abstract: Disclosed are methods of making ferritic ductile iron castings (60-40-18) with high toughness (6 ft.lb minimum Charpy V at ?20 F and 10 ft.lb minimum Charpy V at +72 F), without adding Nickel and without annealing.
    Type: Grant
    Filed: January 29, 2008
    Date of Patent: December 7, 2010
    Assignee: Aarrowcast, Inc.
    Inventor: Cesar Augusto Rezende Braga
  • Patent number: 7843104
    Abstract: A stator component whose composition and processing enable the component to axially compress magnetic sheets of a stator and also inhibit joule heating of the component to the extent that the need for a separate flux shield can be eliminated. The component is formed of a ductile iron alloy containing, by weight, about 3.25 to about 3.40% carbon, about 3.70 to about 3.80% silicon, about 4.50 to about 4.70% nickel, up to about 0.20% manganese, up to about 0.06% magnesium, less than 0.02% phosphorus, less than 0.02% sulfur, with the balance being iron and incidental impurities. Following heat treatment, the component exhibits properties that inhibit joule heating of the component by eddy currents induced by alternating magnetic fields of the stator.
    Type: Grant
    Filed: January 23, 2008
    Date of Patent: November 30, 2010
    Assignee: General Electric Company
    Inventor: Subrahmanyam Thangirala
  • Patent number: 7833362
    Abstract: A method by which high temperature properties of a ductile iron alloy, including creep and LCF properties, can be increased for pressure-containing components that are subject to creep and low cycle fatigue. The method comprises modifying the ductile iron alloy to contain 0.4 to 0.8 weight percent molybdenum. A casting of the modified ductile iron alloy is produced and then annealed at a temperature of at least 725° C. for not less than five hours to eliminate carbides and/or stabilize pearlite in the casting. The annealed casting of the modified ductile iron alloy exhibits improved creep resistance and low cycle fatigue properties in comparison to an identical casting of a ductile iron alloy that does not contain molybdenum.
    Type: Grant
    Filed: September 22, 2008
    Date of Patent: November 16, 2010
    Assignee: General Electric Company
    Inventors: Mark Roger Brown, Thomas Robbins Tipton, Liming Xu
  • Patent number: 7824605
    Abstract: An as-cast carbidic ductile iron is provided, having a pearlitic matrix with 5-50% by volume carbides and high wear resistance properties. The as-cast carbidic ductile iron is produced without an austempering heat treatment step. The as-cast carbidic ductile iron preferably includes a carbide stabilizing element and a spheroidizing agent.
    Type: Grant
    Filed: December 15, 2006
    Date of Patent: November 2, 2010
    Assignee: Dexter Foundry, Inc.
    Inventors: Jeffrey Paul Lemke, Robert Edward Eppich
  • Patent number: 7794650
    Abstract: A graphite-containing, heat-resistant cast iron for exhaust equipment members used at temperatures exceeding 800° C., comprising 3.5-5.6% of Si and 1.2-15% of W on a weight basis, and having intermediate layers, in which W and Si are concentrated, in the boundaries of graphite particles and a matrix. An exhaust equipment member formed by this heat-resistant cast iron has an AC1 transformation point is 840° C. or higher when measured from 30° C. at a temperature-elevating speed of 3° C./minute, and a thermal cracking life of 780 cycles or more in a thermal fatigue test, in which heating and cooling are conducted under the conditions of an upper-limit temperature of 840° C., a temperature amplitude of 690° C. and a constraint ratio of 0.25.
    Type: Grant
    Filed: November 9, 2004
    Date of Patent: September 14, 2010
    Assignee: Hitachi Metals, Ltd.
    Inventors: Yoshio Igarashi, Seiichi Endo, Masahiro Miyake, Tsunehiro Kawata
  • Patent number: 7754142
    Abstract: A high-carbon austenitic iron-base alloy with good corrosion and wear resistance, particularly useful for valve seat insert applications when corrosion resistance is required, comprises about 1.8-3.5 wt % carbon, about 12-24 wt % chromium, about 0.5-4 wt % silicon, about 12-25 wt % nickel, about 2-12 wt % molybdenum and tungsten combined, about 0.05-4 wt % niobium and vanadium combined, about 0-1 wt % titanium, about 0.01-0.2 wt % aluminum, about 0.05-3 wt % copper, and less than 1.5 wt % manganese, with the balance being iron and a small amount of impurities.
    Type: Grant
    Filed: April 13, 2007
    Date of Patent: July 13, 2010
    Assignee: Winsert, Inc.
    Inventor: Xuecheng Liang
  • Publication number: 20100154942
    Abstract: An aspect of the present disclosure relates to an alloy composition, which may include 52 atomic percent to 68 atomic percent iron, 13 to 21 atomic percent nickel, 2 to 12 atomic percent cobalt, 10 to 19 atomic percent boron, optionally 1 to 5 atomic percent carbon, and optionally 0.3 to 16 atomic percent silicon. The alloy may include 5 to 95% by volume of one or more spinodal microconstituents, wherein the microconstituents exhibit a length scale less than 50 nm in a glass matrix.
    Type: Application
    Filed: October 16, 2009
    Publication date: June 24, 2010
    Applicant: THE NANOSTEEL COMPANY, INC.
    Inventors: Daniel James BRANAGAN, Jeffrey E. SHIELD, Alla V. SERGUEEVA
  • Publication number: 20100043927
    Abstract: An alloy composition of FeaBbSicPxCyCuz. Parameters meet the following conditions: 79?a?86 atomic %; 5?b?13 atomic %; 0?c?8 atomic %; 1?x?8 atomic %; 0?y?5 atomic %, 0.4?z?1.4 atomic %; and 0.08?z/x?0.8. Or, parameters meet the following conditions: 81?a?86 atomic %; 6?b?10 atomic %; 2?c?8 atomic %; 2?x?5 atomic %; 0?y?4 atomic %; 0.4?z?1.4 atomic %, and 0.08?z/x?0.8.
    Type: Application
    Filed: August 20, 2009
    Publication date: February 25, 2010
    Inventor: Akihiro MAKINO
  • Publication number: 20090320971
    Abstract: A method for manufacturing mechanical components made of spheroidal cast iron, comprising the following steps: -providing a casting of a mechanical component made of cast iron having a structure which is at least partially ferritic and has a carbon content ranging from 2.5% to 4.0% and a silicon content ranging from 2.0% to 3.5%; -bringing the cast iron casting having an at least partially ferritic structure to a temperature for partial austenitizing which is higher than the lower limit austenitizing temperature (Ac1) and lower than the upper limit austenitizing temperature (Ac3) for a time required to obtain an at least partially austenitic structure; -performing a thermal treatment for isothermal hardening at a temperature ranging from 250° C. to 400° C. in order to obtain a matrix which has at least partially a pearlitic-ferritic or perferritic structure.
    Type: Application
    Filed: June 18, 2007
    Publication date: December 31, 2009
    Applicant: ZANARDI FONDERIE S.P.A.
    Inventors: Maurizio BRONZATO, Zeljko ILIBASIC, Franco ZANARDI
  • Patent number: 7628870
    Abstract: A valve guide of alloyed gray cast iron comprising from about 3 to about 3.5 wt. % carbon, about 0.2 wt. % phosphorous maximum, from about 0.35 to about 0.75 wt. % molybdenum, from about 1.8 to about 3 wt. % silicon, from about 0.6 to about 1 wt. % manganese, from about 0.8 to about 1.5 wt. % chromium, balance essentially iron, is heat treated by austenitizing, quenching, and tempering, to obtain a Rockwell C hardness from about 35 to about 45. The microstructure comprises at least about 3% intercellular carbide in a matrix of tempered martensite. Such valve guide exhibits improved wear resistance during use in an internal combustion engine.
    Type: Grant
    Filed: February 8, 2005
    Date of Patent: December 8, 2009
    Assignee: Helio Precision Products, Inc.
    Inventors: C. Bruce Blackwell, Howard M. Livingston
  • Patent number: 7618499
    Abstract: An Fe-base in-situ composite alloy, castable into 3-dimensional bulk objects, where the alloy includes a matrix having one or both of a nano-crystalline phase and an amorphous phase, and a face-centered cubic crystalline phase. The alloy has an Fe content more than 60 atomic percent.
    Type: Grant
    Filed: October 1, 2004
    Date of Patent: November 17, 2009
    Inventors: William L. Johnson, Choongyun Paul Kim
  • Patent number: 7615123
    Abstract: A powder metallurgy cold-work tool steel article of hot isostatic compacted nitrogen atomized, prealloyed powder. The alloy of the article includes the addition of niobium, which combined with the use of gas atomization, results in a fine carbide size distribution. This in turn results in improved bend fracture strength and impact toughness. In addition, as a result of isostatic compaction of nitrogen gas atomized prealloyed powder a fine distribution of carbides results to obtain a microstructure that achieves both improved toughness and wear resistance.
    Type: Grant
    Filed: September 29, 2006
    Date of Patent: November 10, 2009
    Assignee: Crucible Materials Corporation
    Inventors: Alojz Kajinic, Andrzej L. Wojcieszynski
  • Publication number: 20090257903
    Abstract: The present invention relates to a high speed steel with a chemical composition that comprises, in % by weight: 0.6-2.1 C 3-5 Cr 4-14 Mo max 5 W max 15 Co 0.5-4 V, balance Fe and impurities from the manufacturing of the material, which steel is powder metallurgically manufactured and has a content of Si in the range of 0.7<Si?2.
    Type: Application
    Filed: September 7, 2006
    Publication date: October 15, 2009
    Inventor: Stefan Sundin
  • Patent number: 7497915
    Abstract: A machinable austempered cast iron article has improved strength, machinability, fatigue performance, and resistance to environmental cracking. A method of making the machinable austempered cast iron article includes austenitizing an iron composition having a substantially pearlitic microstructure in an intercritical temperature range of between 1380° F. and 1500° F. This produces a ferritic plus austenitic microstructure. The ferritic plus austenitic microstructure is quenched into an austempering temperature range of between 575° F. and 750° F. within 3 minutes to prevent formation of pearlite. The ferritic plus austenitic microstructure is then austempered in the austempering temperature range of between 575° F. and 750° F. to produce a microstructure of a continuous matrix of equiaxed ferrite with islands of austenite. Finally, the microstructure of the continuous matrix of equiaxed ferrite with islands of austenite is cooled to ambient temperature to produce the machinable austempered cast iron article.
    Type: Grant
    Filed: March 14, 2006
    Date of Patent: March 3, 2009
    Assignee: Intermet Corporation
    Inventors: Alan Peter Druschitz, David Carroll Fitzgerald
  • Publication number: 20080308193
    Abstract: A graphite-containing, heat-resistant cast iron for exhaust equipment members used at temperatures exceeding 800° C., comprising 3.5-5.6% of Si and 1.2-15% of W on a weight basis, and having intermediate layers, in which W and Si are concentrated, in the boundaries of graphite particles and a matrix. An exhaust equipment member formed by this heat-resistant cast iron has an AC transformation point is 840° C. or higher when measured from 30° C. at a temperature-elevating speed of 3° C./minute, and a thermal cracking life of 780 cycles or more in a thermal fatigue test, in which heating and cooling are conducted under the conditions of an upper-limit temperature of 840° C., a temperature amplitude of 690° C. and a constraint ratio of 0.25.
    Type: Application
    Filed: November 9, 2004
    Publication date: December 18, 2008
    Inventors: Yoshio Igarashi, Seiichi Endo, Masahiro Miyake, Tsunehiro Kawata
  • Patent number: 7419554
    Abstract: A grey cast iron alloy for producing cylinder block and/or cylinder head castings including iron, carbon, silicon, manganese, phosphorus, sulphur, tin, copper, chromium, molybdenum and nitrogen. The nitrogen content of the alloy is in the range of 0.0095-0.016 percent.
    Type: Grant
    Filed: September 19, 2005
    Date of Patent: September 2, 2008
    Assignee: Volvo Lastvagnar AB
    Inventors: Kent Eriksson, Tony Liu, Berndt Gyllensten, Johan Oberg
  • Publication number: 20080202652
    Abstract: A ferrous seal sliding part excellent in heat crack resistance, seizure resistance and abrasion resistance is provided. The ferrous seal sliding part has a seal sliding surface, wherein the seal sliding surface has a quench hardened layer having a structure in which a martensite parent phase forms a solid solution with carbon of 0.15 to 0.6 wt % and contains cementite dispersed therein in a content of 3 to 50% by volume.
    Type: Application
    Filed: January 10, 2008
    Publication date: August 28, 2008
    Inventors: Takemori Takayama, Chikara Nakao
  • Publication number: 20080145264
    Abstract: Low carbon carburizing (surface hardening) and higher carbon through hardening steels primarily containing molybdenum, vanadium and nickel and, to a lesser amount, chromium used for rolling contact bearings, gears and other similar applications where high hardness at elevated temperatures is required. The alloy steel includes, in % by weight: 0.05% to 1.25% C; up to 1.25% Cr; 0.40% to 4% Mn; up to 4.0% Mo; up to 2.0% V; 1.0% to 3.0% Ni; 4% to 8% (Mo+V+Ni+Cr); less than 0.20% Si; and balance Fe plus incidental additions and impurities. The method for providing a steel having improved hardness at elevated temperatures includes the steps of: (a) providing an alloy including, in % by weight: less than 1.25% Cr, 0.4% to 4% Mn, up to 4% Mo, up to 2% V, 1 to 3% Ni, 4% to 8% (Mo+V+Ni+Cr), less than 0.2% Si, a C content selected from one of 0.05% to 0.40% C defining a carburizing steel or greater than 0.40% to 1.
    Type: Application
    Filed: December 19, 2006
    Publication date: June 19, 2008
    Applicant: The Timken Company
    Inventors: Dennis W. Hetzner, George M. Waid
  • Publication number: 20080078475
    Abstract: A powder metallurgy cold-work tool steel article of hot isostatic compacted nitrogen atomized, prealloyed powder. The alloy of the article includes the addition of niobium, which combined with the use of gas atomization, results in a fine carbide size distribution. This in turn results in improved bend fracture strength and impact toughness. In addition, as a result of isostatic compaction of nitrogen gas atomized prealloyed powder a fine distribution of carbides results to obtain a microstructure that achieves both improved toughness and wear resistance.
    Type: Application
    Filed: September 29, 2006
    Publication date: April 3, 2008
    Inventors: Alojz Kajinic, Andrzej L. Wojcieszynski
  • Patent number: 7163594
    Abstract: A gray iron alloy having a composition comprising about 4.10% to about 4.25% carbon equivalent, about 3.5% to about 3.65% carbon, about 0.4% to about 0.9% manganese, about 1.5% to about 1.9% silicon, less than about 0.12% phosphorous, less than about 0.17% sulfur, about 0.6% to about 0.8% molybdenum and about 0.3% to about 0.6% copper, and where said carbon is predominantly present as free carbon having a Type A flake graphite microstructure. The alloy is particularly useful in the manufacture of brake drums and other articles requiring a combination of high tensile strength and good thermal conductivity.
    Type: Grant
    Filed: October 10, 2003
    Date of Patent: January 16, 2007
    Assignee: Gunite Corporation
    Inventors: Laxmi C. Tandon, Reginal A. Pete, Omar J. Fakhoury
  • Patent number: 7163593
    Abstract: An iron-based alloy comprises 1.5 to 2.5 wt % of C, 0.25 to 4.75 wt % of Ni, and W and V in quantities surrounded by the line L as shown in FIG. 1 of the attached drawings with a balance of Fe and inevitable impurities. The iron-based alloy is obtained by a first heat treatment for applying a solid solution treatment by rapidly cooling the iron-based alloy from a temperature of an austenite forming temperature or more to consequently obtain a mixed matrix comprising a base matrix of martensite and remaining austenite phases and a non-molten carbide, and a second heat treatment for cooling the iron-based alloy after precipitating an MC type carbide within an eutectoid transformation temperature range to consequently precipitate a low carbon content austenite phase.
    Type: Grant
    Filed: April 19, 2002
    Date of Patent: January 16, 2007
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Takeshi Sugawara, Noriyuki Yamada, Makoto Asami
  • Patent number: 7156929
    Abstract: The invention proposes a cast iron alloy for cast iron products which are highly thermally stable, the alloy containing, as nonferrous constituents, at least the elements C, Si, Mo, Al and, as admixtures, Ni, Mg and/or S, and the C content being less than 2.9% by weight. The alloy is used, for example, to produce exhaust manifolds or turbocharger casings.
    Type: Grant
    Filed: July 14, 2003
    Date of Patent: January 2, 2007
    Assignee: Georg Fischer Fahrzeugtechnik AG
    Inventor: Werner Menk
  • Patent number: 7083685
    Abstract: A gray cast iron member includes 2.2–2.8 weight % C, 2.3–3.5 weight % Si, 0.2–0.8 weight % Mn, up to 0.1 weight % P, up to 0.15 weight % S, 0.6–1.4 weight % Cu, up to 0.5 weight % Mo, up to 0.3 weight % Cr, and the balance substantially Fe, Si/C being 0.95 or more, (Si/C)/Cu being up to 1.5. Preferably, it further includes at least one of Ni, Sn, V, Sb and N each in an amount of up to 0.3 weight %.
    Type: Grant
    Filed: July 15, 2005
    Date of Patent: August 1, 2006
    Assignees: Hino Motors, Ltd., Kasuya Seiko Kabushiki Kaisha
    Inventors: Noriaki Katori, Shouichi Ishii
  • Patent number: 7081172
    Abstract: A nodular graphite cast iron is provided, having a pearlite matrix, with high strength and high toughness. The nodular graphite cast iron consists essentially of, by weight %: from 3.0 to 4.6% of carbon; from 1.6 to 2.5% of silicon; from 0.2 to 0.6% of manganese; from 0.02 to 0.05% of magnesium; from 0.0004 to 0.090% of zirconium; at least one of tin and copper such that ? ranges from 0.01 to 0.06% where ? indicates a tin conversion amount defined by a summation of a weight % of the tin and 0.1× a weight % of the copper; and the balance of iron and inevitable foreign matters.
    Type: Grant
    Filed: October 14, 2003
    Date of Patent: July 25, 2006
    Assignee: Aisin Seiki Kabushiki Kaisha
    Inventors: Yasuhiro Enya, Francois Coderre, Yoshikazu Ibayashi, Masaru Matukura
  • Patent number: 7081151
    Abstract: It is possible to generate a desirable form (soft, pliable) of sulfide inclusions in magnesium-treated case irons. Thermodynamically, MnS and MoS2 are not stable in the presence of magnesium. However, by adding magnesium to a cast iron melt containing manganese sulfide/molybdenium sulfide as late as possible, and preferably when the molten cast iron has been dispensed into the mould, such sulfide inclusions may be preserved in magnesium-treated cast iron. Alternatively, said cast iron can also be formed by adding said sulfides directly to the iron after the magnesium reaction has taken place and an in situ equillibrium has been established between magnesium, oxygen and sulfur. Another option is to begin with a sulfur content in excess of the stoichiometric amount required to combine with the added magnesium, thus ensuring an amount of left-over sulfur to promote the formation of the desired sulfide inclusion.
    Type: Grant
    Filed: December 15, 2000
    Date of Patent: July 25, 2006
    Assignee: SinterCast AB
    Inventors: Wolfgang Troschel, Ralf Toller
  • Patent number: 7081150
    Abstract: An additive for increasing the toughness of thin-wall iron castings is provided. The additive includes amounts of a non-ferrous metal oxide and a metal sulfide in which the non-ferrous metal has an affinity for oxygen less than that of iron, and the metal has an affinity for sulfur less than that of magnesium. The metals contained in the oxides and sulfides are also not alkali, alkali earth or rare earth metals to reduce the incidence of defect formation in the castings. The metal oxide and metal sulfide, when added to a cast iron melt react with magnesium added to the melt as a spheroidizing graphite element to form nucleation sites having a core of magnesium oxide surrounded by magnesium sulfide. These nucleation sites allow for increased nucleation of graphite, whether in vermicular or spheroidal form, such that the cross-section of the thin-wall iron casting is more uniform, thereby decreasing the amount of carbide formed in the casting and increasing the toughness of the casting.
    Type: Grant
    Filed: November 7, 2002
    Date of Patent: July 25, 2006
    Inventors: Carl R. Loper, Jr., Simon N. Lekakh
  • Patent number: 6939414
    Abstract: A nodular cast iron alloy for cast iron products having a high modulus of elasticity comprising the chemical constituents C, Si, Cu, Ni and/or Mo, Mn, Mg and S, wherein the alloy is composed in per cent by weight of: C<2.96%, Si 3.8 to 4.3%, Cu 0.5 to 1.0%, Ni and/or Mo 0 to 4%, the molybdenum content being at most 1.0%, Mn 0.1 to 0.8%, Mg 0.03 to 0.07% and S at most 0.015%, the mixture proportions of C and Si being very close to the eutectic.
    Type: Grant
    Filed: December 7, 2002
    Date of Patent: September 6, 2005
    Assignee: Georg Fischer Fahrzeugtechnik AG
    Inventor: Werner Menk
  • Patent number: 6916444
    Abstract: This invention related to a novel iron base alloy using residual austenite to improve wear resistance for valve seat insert material for internal combustion engines. The residual austenite is stable even after heat treatment and liquid nitrogen chilling. The alloy comprises of 2.0-4.0 wt % carbon, 1.0-3.0 wt % silicon, 0-4.0 wt % manganese, 3.0-9.0 wt % chromium, 5.0-15.0 wt % molybdenum, 3.0-15.0 wt % nickel, 0-6.0 wt % vanadium, 0-4.0 wt % niobium, 0-6.0 wt % cobalt, and the balance being iron with impurities.
    Type: Grant
    Filed: February 12, 2002
    Date of Patent: July 12, 2005
    Assignee: Alloy Technology Solutions, Inc.
    Inventor: Xuecheng Liang
  • Patent number: 6908589
    Abstract: The purpose of the present invention is to provide high manganese cast iron containing spheroidal vanadium carbide and method for making which is nonmagnetic as well as superior mechanical properties such as wear-resistance and toughness, and further does not require a water toughing heat treatment which has been needed when nonmagnetic high manganese steel (high manganese cast steel) is obtained by crystallized spheroidal vanadium in austenite matrix, and the high manganese cast iron containing spheroidal vanadium carbide is comprised of C 1.5˜4.0 weight %, V 6˜15 weight %, Si 0.2˜4.0 weight %, Mn 10˜18 weight %, Mg 0.01˜0.1 weight %, remaining iron (Fe) and inevitable impurities, spheroidal vanadium carbide is crystallized within a structure.
    Type: Grant
    Filed: June 13, 2003
    Date of Patent: June 21, 2005
    Assignees: Osaka Prefecture, Kabushiki Kaisha Sankyogokin Chuzoasho, Okamoto Co., Ltd.
    Inventors: Tadashi Kitudo, Mamoru Takemura, Mituaki Matumuro, Hideto Matumoto, Takao Horie, Kazumichi Shimizu
  • Patent number: 6866726
    Abstract: A non-austemper-treated spheroidal graphite cast iron obtainable without being subjected to an austemper treatment. The non-austemper-treated spheroidal graphite cast iron has a tensile strength of 650-850 MPa and an elongation of 7.0-14.5%. In the non-austemper-treated spheroidal graphite cast iron, V-notch material has a fatigue limit of 290 MPa or more. The non-austemper-treated spheroidal graphite cast iron has well-balanced mechanical properties both in tensile strength and elongation and improved tensile strength and elongation than conventional one.
    Type: Grant
    Filed: June 7, 2000
    Date of Patent: March 15, 2005
    Assignee: Asahi Tec Corporation
    Inventors: Katsumi Suzuki, Noriyuki Nakajima, Yoshio Ohba, Takahiro Ono
  • Patent number: 6863744
    Abstract: An iron based alloy material for a thixocasting process and a method for casting the material which extends the service life of dies by inhibiting solidification contraction, and in which casting defects such as size variations and cracks can be inhibited. The material comprises 1.6 wt %?C?2.5 wt % and 3.0 wt %<Si?5.5 wt %, and a carbon equivalent (the value of CE) defined as “C(wt %)+?Si(wt %)” of 2.9 to 3.5. This material is made to be in a half-melted state with 35 to 50 wt % of a solid phase to be cast under a pressure load.
    Type: Grant
    Filed: September 6, 2002
    Date of Patent: March 8, 2005
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Masayuki Tsuchiya, Hiroaki Ueno
  • Patent number: 6861029
    Abstract: A modified nodular cast iron alloy contains positive additions of boron and silicon in a content of greater than 2.4% by wt.
    Type: Grant
    Filed: June 20, 2002
    Date of Patent: March 1, 2005
    Assignee: Georg Fischer Fahrzeugtechnik AG
    Inventors: Werner Menk, Dirk Lindemann, Dirk Richarz
  • Patent number: 6837945
    Abstract: The invention concerns a steel article, which consists of an alloy having a chemical composition, which contains in weight-%: 1.2 to 2.5 C; 0.8 to 2.0 Si, which partly can be replaced by aluminium, which may exist in an amount of max 1.0%; 0.1 to 1.5 Mn; 0.5 to 1.5 Cr; 1.2 to 5.0 (V+Nb/2), however max 1.0 Nb; balance iron and impurities in normal amounts, and having a microstructure which contains 4 to 12 volume-% of MC-carbides. The steel article can be used for manufacturing of cold-work tools, particularly pilger rolls for cold rolling of tubes. The invention also relates to a method of manufacturing the article.
    Type: Grant
    Filed: April 28, 2000
    Date of Patent: January 4, 2005
    Assignee: Uddeholm Tooling Aktiebolag
    Inventors: Odd Sandberg, Bo Rydell
  • Publication number: 20040173290
    Abstract: The novel methods, apparatus and reworked rotary braking surface product, for example those exhibited on interior cylindrical braking surfaces of a cast iron brake drum, serve to replace manufacturing defects exhibiting residual tensile stresses and outwardly directed tool marks with smooth compressed braking surfaces in a final manufacturing stage. The plastically deformed surface shape with reduced roughness and surface irregularities furthermore presents improved braking strength above the yield point and approaching the ultimate material strength of the base drum material. An ultrasonic transducer drives individual freely moving impact elements of a set at frequencies up to 55 kHz into the braking surface to effect plastic deformation at surface and sub-surface layers.
    Type: Application
    Filed: March 11, 2004
    Publication date: September 9, 2004
    Applicant: UIT, L.L.C. Company
    Inventor: Efim S. Statnikov
  • Patent number: 6746550
    Abstract: A process for producing a compacted graphite iron (CGI) article, comprising the steps of: (a) providing a CGI base iron having a composition comprising, in weight percentages, about 3.2 to 3.8 total C, 2.8 to 4.0 Si and the balance at least Fe and incidental impurities; (b) treating, controlling and casting the alloy in a manner known per se; (c) allowing the cast component to cool in the mould to a temperature of at least 775° C.; (d) cleaning the casting in a manner known per se and machining the casting to produce a finished article.
    Type: Grant
    Filed: January 3, 2001
    Date of Patent: June 8, 2004
    Assignee: SinterCast AB
    Inventor: Bertil Isak Hollinger
  • Publication number: 20040079450
    Abstract: A nodular graphite cast iron is provided, having a pearlite matrix, with high strength and high toughness. The nodular graphite cast iron consists essentially of, by weight %: from 3.0 to 4.6% of carbon; from 1.6 to 2.5% of silicon; from 0.2 to 0.6% of manganese; from 0.02 to 0.05% of magnesium; from 0.0004 to 0.090% of zirconium; at least one of tin and copper such that &agr; ranges from 0.01 to 0.06% where a indicates a tin conversion amount defined by a summation of a weight % of the tin and 0.1× a weight % of the copper; and the balance of iron and inevitable foreign matters.
    Type: Application
    Filed: October 14, 2003
    Publication date: April 29, 2004
    Applicant: AISIN SEIKI KABUSHIKI KAISHA
    Inventors: Yasuhiro Enya, Francois Coderre, Yoshikazu Ibayashi, Masaru Matukura
  • Patent number: 6723182
    Abstract: A cobalt-free martensitic steel exhibiting good response to hardening and resistance to softening at high temperatures, the steel containing sub-micron and nano-structural precipitates and intermetallic compounds of silicon, nickel, aluminum, copper and manganese.
    Type: Grant
    Filed: November 14, 2002
    Date of Patent: April 20, 2004
    Inventor: Arthur J. Bahmiller
  • Patent number: 6723180
    Abstract: A gray cast iron alloy for a friction element of a friction clutch, which may be brought into frictional contact with a clutch disk by a friction surface of the friction element, contains: 3.0-3.4 percent by weight C, 1.8-2.3 percent by weight Si, 0.4-0.8 percent by weight Mn, 0.0-0.35 percent by weight P, 0.0-0.125 percent by weight S, 0.4-0.6 percent by weight Mo, with the remainder comprising iron and production-related impurities and/or additives.
    Type: Grant
    Filed: December 20, 2001
    Date of Patent: April 20, 2004
    Assignee: Mannesmann Sachs AG
    Inventors: Achim Link, Jürgen Kleifges
  • Publication number: 20040050457
    Abstract: There is provided a surface treated product that moves relatively in a fluid, wherein a surface of the surface treated product has continuous dimples, each dimple having a diameter of 10 to 2500 &mgr;m and a depth of 50 &mgr;m or less. The surface treated product significantly reduces resistance of a fluid to an object in the fluid, and significantly improves a flow state of the fluid.
    Type: Application
    Filed: June 26, 2003
    Publication date: March 18, 2004
    Applicant: Asahi Tec Corporation
    Inventors: Shiro Kawashima, Hiromi Akahori, Matuo Suzuki, Hidekatu Hirahara, Aturo Yamamoto, Katuya Kawamori
  • Patent number: 6699335
    Abstract: Machine part is constituted with steel with the carbon content of 0.2% or more and reduced with the hydrogen content after hardening by a heat treatment to 0.04 ppm or less. Further, hardness after hardening by the heat treatment is made to Hv 450 or more. Since such a machine part is excellent in the super long life fatigue characteristics, it can be used suitably as a bearing ring or a rolling element of a rolling bearing.
    Type: Grant
    Filed: August 14, 2002
    Date of Patent: March 2, 2004
    Assignees: NSK Ltd.
    Inventors: Yukitaka Murakami, Yasuo Murakami
  • Patent number: 6616777
    Abstract: A thixocast Fe-based alloy material is provided, from which a cast product having mechanical properties uniform over the whole thereof can be produced. The Fe-based alloy material comprises 1.8% by weight≦C≦2.5% by weight, 1.0% by weight≦Si≦3.0% by weight, 0.1% by weight≦Mn≦1.5% by weight, 0.5% by weight≦Ni≦3.0% by weight, and as the balance, iron (Fe) including inevitable impurities. The eutectic crystal amount Ec is in a range of 10% by weight<Ec<50% by weight.
    Type: Grant
    Filed: March 10, 2000
    Date of Patent: September 9, 2003
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Masayuki Tsuchiya, Hiroaki Ueno
  • Patent number: 6613274
    Abstract: The invention provides a cast iron alloy comprising 3.0-3.8% carbon, 06-25% silicon, 0.2-0.65% manganese, 0.01-0.1% tin, <0.025% sulfur, 0.001-0.020% magnesium, 0.1-1.2% copper, 0.04-0.2% chromium, and balance up to 100% of iron and incidental impurities. The matrix structure is a continously variable ferrite/pearlite mixture and the content of carbides is less than 1%. The graphite shape of the alloy is 1 50% flake graphite, 50-99% compacted graphite and at most 10% spheroidal graphite. Such an alloy is easier to machine and less prone to shrinkage than an ordinary compacted graphite cast iron.
    Type: Grant
    Filed: May 22, 2002
    Date of Patent: September 2, 2003
    Assignee: Sintercast AB
    Inventor: Steve Dawson
  • Publication number: 20030102056
    Abstract: It is possible to generate a desirable form (soft, pliable) of sulfide inclusions in magnesium-treated case irons. Thermodynamically, MnS and MoS2 are not stable in the presence of magnesium. However, by adding magnesium to a cast iron melt containing manganese sulfide/molybdenium sulfide as late as possible, and preferably when the molten cast iron has been dispensed into the mould, such sulfide inclusions may be preserved in magnesium-treated cast iron. Alternatively, said cast iron can also be formed by adding said sulfides directly to the iron after the magnesium reaction has taken place and an in situ equillibrium has been established between magnesium, oxygen and sulfur. Another option is to begin with a sulfur content in excess of the stoichiometric amount required to combine with the added magnesium, thus ensuring an amount of left-over sulfur to promote the formation of the desired sulfide inclusion.
    Type: Application
    Filed: October 15, 2002
    Publication date: June 5, 2003
    Inventors: Wolfgang Troschel, Ralf Toller
  • Patent number: 6572712
    Abstract: A compacted graphite iron brake component for use in a braking system having a final composition of: 3.0 to about 4.0 percent carbon; 2.15 to about 2.60 percent silicon; 0.40 to about 0.90 manganese; and the balance iron. The brake component having a frictionally engageable portion with a microstructure of compacted graphite disposed in a pearlitic matrix.
    Type: Grant
    Filed: December 14, 2000
    Date of Patent: June 3, 2003
    Assignees: Waupaca Foundry, Inc., Webb Wheel Products, Inc.
    Inventors: William L. Powell, Paul D. Levering
  • Publication number: 20030070732
    Abstract: The present invention is directed to an iron, aluminum, chromium, carbon alloy and a method of producing the same, wherein the alloy has g good room temperature ductility, excellent high temperature oxidation resistance and ductility. The alloy includes about 10 to 70 at. % iron, about 10 to 45 at. % aluminum, about 1 to 70 at. % chromium and about 0.9 to 15 at. % carbon. The invention is also directed to a material comprising a body-centered-cubic solid solution of this alloy, and a method for strengthening this material by the precipitation of body-centered-cubic particles within the solid solution, wherein the particles have substantially the same lattice parameters as the underlying solid solution. The ease of processing and excellent mechanical properties exhibited by the alloy, especially at high temperatures, allows it to be used in high temperature structural applications, such as a turbocharger component.
    Type: Application
    Filed: September 26, 2002
    Publication date: April 17, 2003
    Inventor: Hui Lin
  • Publication number: 20030066577
    Abstract: A free-cutting tool steel is provided containing Fe and C in an amount of 0.1 to 2.5 wt %, Ti and or Zr where WTi+0.52WZr constitutes 0.03 to 3.5 wt %, and WTi represents Ti content and WZr represents Zr content, at least any one of S, Se and Te where WS+0.4WSe+0.25WTe constitutes 0.01 to 1.0 wt %, and (WTi+0.52WZr)/(WS+0.4WSe+0.25WTe) constitutes 1 to 4, and WS represents S content, WSe represents Se content and WTe represents Te content; and dispersed therein a texture thereof from 0.1 to 10% in terms of area ratio in a section of a machinability improving compound phase of a metallic element component of Ti and/or Zr as major components, and a binding component for the metallic element component containing C and any one of S, Se and Te.
    Type: Application
    Filed: February 28, 2002
    Publication date: April 10, 2003
    Applicant: Kiyohito Ishida, Dokuritsu Gyousei Houjin Sangyo Gijutsu Sougo, Kenkyusho, Katsunari Oikawa
    Inventors: Kiyohito Ishida, Katsunari Oikawa, Toshimitsu Fujii, Yukinori Matsuda, Kozo Ozaki, Seiji Kurata, Takayuki Shimizu
  • Publication number: 20030051776
    Abstract: A nodular graphite cast iron is provided, having a pearlite matrix, with high strength and high toughness. The nodular graphite cast iron consists essentially of, by weight %,: from 3.0 to 4.6% of carbon; from 1.6 to 2.5% of silicon; from 0.2 to 0.6% of manganese; from 0.02 to 0.05% of magnesium; from 0.0004 to 0.090% of zirconium; at least one of tin and copper such that &agr; ranges from 0.01 to 0.06% where &agr; indicates a tin conversion amount defined by a summation of a weight % of the tin and 0.1×a weight % of the copper; and the balance of iron and inevitable foreign matters.
    Type: Application
    Filed: March 13, 2002
    Publication date: March 20, 2003
    Applicant: AISIN SEIKI KABUSHIKI KAISHA
    Inventors: Yasuhiro Enya, Francois Coderre, Yoshikazu Ibayashi, Masaru Matukura
  • Patent number: 6527877
    Abstract: An alloy having two constituents: a crystal structure of orderly solid iron-based solution; a non-metallic phase at least partially soluble in iron including particles which are uniformly dispersed in the volume of the first phase and are of suitable size. In a preferred embodiment, the alloy contains iron with dissolved and bonded carbon as the first phase, which forms the crystal structure, and material partially soluble in iron, for example structurally free molecular carbon, is taken as the second non-metallic phase. The alloy preferably contains the components at the following ratios, % by mass: carbon in a dissolved and in a bonded state: 0.01-1.00; free carbon: 0.01-2.24; iron: balance. The ratio of free carbon to that of carbon in a dissolved and in a bonded state ranges from 0.01 to 20. The alloy Is preferably produced by melting out low carbon semi-product, overheating the semi-product above a liquidus temperature, for example by 20-70° C.
    Type: Grant
    Filed: April 22, 1999
    Date of Patent: March 4, 2003
    Assignee: Limited Liability Company “SKM”
    Inventor: Genrikh Alexeevich Dorofeev
  • Patent number: 6527878
    Abstract: A thixocast casting material is formed of an Fe—C—Si based alloy in which an angle endothermic section due to the melting of a eutectic crystal exists in a latent heat distribution curve and has a eutectic crystal amount Ec in a range of 10% by weight<Ec<50% by weight. This composition comprises 1.8% by weight≦C≦2.5% by weight of carbon, 1.4% by weight≦Si≦3% by weight if silicon and a balance of Fe including inevitable impurities.
    Type: Grant
    Filed: September 25, 2000
    Date of Patent: March 4, 2003
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Takeshi Sugawara, Haruo Shiina, Masayuki Tsuchiya, Kazuo Kikawa, Isamu Takagi