1.7 Percent Or More Carbon Containing (e.g., Cast Iron) Patents (Class 148/321)
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Publication number: 20110017364Abstract: 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: ApplicationFiled: July 23, 2009Publication date: January 27, 2011Applicant: GENERAL ELECTRIC COMPANYInventors: Junyoung Park, Gregory Keith Bouse, Jason Robert Parolini, Sujith Sathian
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Patent number: 7846381Abstract: 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: GrantFiled: January 29, 2008Date of Patent: December 7, 2010Assignee: Aarrowcast, Inc.Inventor: Cesar Augusto Rezende Braga
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Patent number: 7843104Abstract: 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: GrantFiled: January 23, 2008Date of Patent: November 30, 2010Assignee: General Electric CompanyInventor: Subrahmanyam Thangirala
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Patent number: 7833362Abstract: 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: GrantFiled: September 22, 2008Date of Patent: November 16, 2010Assignee: General Electric CompanyInventors: Mark Roger Brown, Thomas Robbins Tipton, Liming Xu
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Patent number: 7824605Abstract: 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: GrantFiled: December 15, 2006Date of Patent: November 2, 2010Assignee: Dexter Foundry, Inc.Inventors: Jeffrey Paul Lemke, Robert Edward Eppich
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Patent number: 7794650Abstract: 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: GrantFiled: November 9, 2004Date of Patent: September 14, 2010Assignee: Hitachi Metals, Ltd.Inventors: Yoshio Igarashi, Seiichi Endo, Masahiro Miyake, Tsunehiro Kawata
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Patent number: 7754142Abstract: 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: GrantFiled: April 13, 2007Date of Patent: July 13, 2010Assignee: Winsert, Inc.Inventor: Xuecheng Liang
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Publication number: 20100154942Abstract: 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: ApplicationFiled: October 16, 2009Publication date: June 24, 2010Applicant: THE NANOSTEEL COMPANY, INC.Inventors: Daniel James BRANAGAN, Jeffrey E. SHIELD, Alla V. SERGUEEVA
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Publication number: 20100043927Abstract: 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: ApplicationFiled: August 20, 2009Publication date: February 25, 2010Inventor: Akihiro MAKINO
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Publication number: 20090320971Abstract: 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: ApplicationFiled: June 18, 2007Publication date: December 31, 2009Applicant: ZANARDI FONDERIE S.P.A.Inventors: Maurizio BRONZATO, Zeljko ILIBASIC, Franco ZANARDI
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Patent number: 7628870Abstract: 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: GrantFiled: February 8, 2005Date of Patent: December 8, 2009Assignee: Helio Precision Products, Inc.Inventors: C. Bruce Blackwell, Howard M. Livingston
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Patent number: 7618499Abstract: 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: GrantFiled: October 1, 2004Date of Patent: November 17, 2009Inventors: William L. Johnson, Choongyun Paul Kim
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Patent number: 7615123Abstract: 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: GrantFiled: September 29, 2006Date of Patent: November 10, 2009Assignee: Crucible Materials CorporationInventors: Alojz Kajinic, Andrzej L. Wojcieszynski
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Publication number: 20090257903Abstract: 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: ApplicationFiled: September 7, 2006Publication date: October 15, 2009Inventor: Stefan Sundin
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Patent number: 7497915Abstract: 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: GrantFiled: March 14, 2006Date of Patent: March 3, 2009Assignee: Intermet CorporationInventors: Alan Peter Druschitz, David Carroll Fitzgerald
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Publication number: 20080308193Abstract: 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: ApplicationFiled: November 9, 2004Publication date: December 18, 2008Inventors: Yoshio Igarashi, Seiichi Endo, Masahiro Miyake, Tsunehiro Kawata
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Patent number: 7419554Abstract: 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: GrantFiled: September 19, 2005Date of Patent: September 2, 2008Assignee: Volvo Lastvagnar ABInventors: Kent Eriksson, Tony Liu, Berndt Gyllensten, Johan Oberg
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Publication number: 20080202652Abstract: 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: ApplicationFiled: January 10, 2008Publication date: August 28, 2008Inventors: Takemori Takayama, Chikara Nakao
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Publication number: 20080145264Abstract: 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: ApplicationFiled: December 19, 2006Publication date: June 19, 2008Applicant: The Timken CompanyInventors: Dennis W. Hetzner, George M. Waid
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Publication number: 20080078475Abstract: 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: ApplicationFiled: September 29, 2006Publication date: April 3, 2008Inventors: Alojz Kajinic, Andrzej L. Wojcieszynski
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Patent number: 7163594Abstract: 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: GrantFiled: October 10, 2003Date of Patent: January 16, 2007Assignee: Gunite CorporationInventors: Laxmi C. Tandon, Reginal A. Pete, Omar J. Fakhoury
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Patent number: 7163593Abstract: 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: GrantFiled: April 19, 2002Date of Patent: January 16, 2007Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Takeshi Sugawara, Noriyuki Yamada, Makoto Asami
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Patent number: 7156929Abstract: 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: GrantFiled: July 14, 2003Date of Patent: January 2, 2007Assignee: Georg Fischer Fahrzeugtechnik AGInventor: Werner Menk
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Patent number: 7083685Abstract: 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: GrantFiled: July 15, 2005Date of Patent: August 1, 2006Assignees: Hino Motors, Ltd., Kasuya Seiko Kabushiki KaishaInventors: Noriaki Katori, Shouichi Ishii
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Patent number: 7081172Abstract: 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: GrantFiled: October 14, 2003Date of Patent: July 25, 2006Assignee: Aisin Seiki Kabushiki KaishaInventors: Yasuhiro Enya, Francois Coderre, Yoshikazu Ibayashi, Masaru Matukura
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Patent number: 7081151Abstract: 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: GrantFiled: December 15, 2000Date of Patent: July 25, 2006Assignee: SinterCast ABInventors: Wolfgang Troschel, Ralf Toller
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Patent number: 7081150Abstract: 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: GrantFiled: November 7, 2002Date of Patent: July 25, 2006Inventors: Carl R. Loper, Jr., Simon N. Lekakh
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Patent number: 6939414Abstract: 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: GrantFiled: December 7, 2002Date of Patent: September 6, 2005Assignee: Georg Fischer Fahrzeugtechnik AGInventor: Werner Menk
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Patent number: 6916444Abstract: 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: GrantFiled: February 12, 2002Date of Patent: July 12, 2005Assignee: Alloy Technology Solutions, Inc.Inventor: Xuecheng Liang
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Patent number: 6908589Abstract: 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: GrantFiled: June 13, 2003Date of Patent: June 21, 2005Assignees: Osaka Prefecture, Kabushiki Kaisha Sankyogokin Chuzoasho, Okamoto Co., Ltd.Inventors: Tadashi Kitudo, Mamoru Takemura, Mituaki Matumuro, Hideto Matumoto, Takao Horie, Kazumichi Shimizu
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Patent number: 6866726Abstract: 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: GrantFiled: June 7, 2000Date of Patent: March 15, 2005Assignee: Asahi Tec CorporationInventors: Katsumi Suzuki, Noriyuki Nakajima, Yoshio Ohba, Takahiro Ono
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Patent number: 6863744Abstract: 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: GrantFiled: September 6, 2002Date of Patent: March 8, 2005Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Masayuki Tsuchiya, Hiroaki Ueno
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Patent number: 6861029Abstract: A modified nodular cast iron alloy contains positive additions of boron and silicon in a content of greater than 2.4% by wt.Type: GrantFiled: June 20, 2002Date of Patent: March 1, 2005Assignee: Georg Fischer Fahrzeugtechnik AGInventors: Werner Menk, Dirk Lindemann, Dirk Richarz
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Patent number: 6837945Abstract: 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: GrantFiled: April 28, 2000Date of Patent: January 4, 2005Assignee: Uddeholm Tooling AktiebolagInventors: Odd Sandberg, Bo Rydell
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Publication number: 20040173290Abstract: 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: ApplicationFiled: March 11, 2004Publication date: September 9, 2004Applicant: UIT, L.L.C. CompanyInventor: Efim S. Statnikov
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Patent number: 6746550Abstract: 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: GrantFiled: January 3, 2001Date of Patent: June 8, 2004Assignee: SinterCast ABInventor: Bertil Isak Hollinger
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Publication number: 20040079450Abstract: 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: ApplicationFiled: October 14, 2003Publication date: April 29, 2004Applicant: AISIN SEIKI KABUSHIKI KAISHAInventors: Yasuhiro Enya, Francois Coderre, Yoshikazu Ibayashi, Masaru Matukura
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Patent number: 6723182Abstract: 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: GrantFiled: November 14, 2002Date of Patent: April 20, 2004Inventor: Arthur J. Bahmiller
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Patent number: 6723180Abstract: 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: GrantFiled: December 20, 2001Date of Patent: April 20, 2004Assignee: Mannesmann Sachs AGInventors: Achim Link, Jürgen Kleifges
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Publication number: 20040050457Abstract: 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: ApplicationFiled: June 26, 2003Publication date: March 18, 2004Applicant: Asahi Tec CorporationInventors: Shiro Kawashima, Hiromi Akahori, Matuo Suzuki, Hidekatu Hirahara, Aturo Yamamoto, Katuya Kawamori
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Patent number: 6699335Abstract: 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: GrantFiled: August 14, 2002Date of Patent: March 2, 2004Assignees: NSK Ltd.Inventors: Yukitaka Murakami, Yasuo Murakami
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Patent number: 6616777Abstract: 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: GrantFiled: March 10, 2000Date of Patent: September 9, 2003Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Masayuki Tsuchiya, Hiroaki Ueno
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Patent number: 6613274Abstract: 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: GrantFiled: May 22, 2002Date of Patent: September 2, 2003Assignee: Sintercast ABInventor: Steve Dawson
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Publication number: 20030102056Abstract: 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: ApplicationFiled: October 15, 2002Publication date: June 5, 2003Inventors: Wolfgang Troschel, Ralf Toller
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Patent number: 6572712Abstract: 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: GrantFiled: December 14, 2000Date of Patent: June 3, 2003Assignees: Waupaca Foundry, Inc., Webb Wheel Products, Inc.Inventors: William L. Powell, Paul D. Levering
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Publication number: 20030070732Abstract: 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: ApplicationFiled: September 26, 2002Publication date: April 17, 2003Inventor: Hui Lin
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Publication number: 20030066577Abstract: 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: ApplicationFiled: February 28, 2002Publication date: April 10, 2003Applicant: Kiyohito Ishida, Dokuritsu Gyousei Houjin Sangyo Gijutsu Sougo, Kenkyusho, Katsunari OikawaInventors: Kiyohito Ishida, Katsunari Oikawa, Toshimitsu Fujii, Yukinori Matsuda, Kozo Ozaki, Seiji Kurata, Takayuki Shimizu
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Publication number: 20030051776Abstract: 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: ApplicationFiled: March 13, 2002Publication date: March 20, 2003Applicant: AISIN SEIKI KABUSHIKI KAISHAInventors: Yasuhiro Enya, Francois Coderre, Yoshikazu Ibayashi, Masaru Matukura
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Patent number: 6527877Abstract: 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: GrantFiled: April 22, 1999Date of Patent: March 4, 2003Assignee: Limited Liability Company “SKM”Inventor: Genrikh Alexeevich Dorofeev
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Patent number: 6527878Abstract: 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: GrantFiled: September 25, 2000Date of Patent: March 4, 2003Assignee: Honda Giken Kogyo Kabushiki KaishaInventors: Takeshi Sugawara, Haruo Shiina, Masayuki Tsuchiya, Kazuo Kikawa, Isamu Takagi