Containing At Least 1.5 Percent Carbon Patents (Class 148/543)
  • Patent number: 11466349
    Abstract: A spheroidal graphite cast iron having an excellent impact strength at low temperature and a method for producing the same are provided. The present disclosure relates to the spheroidal graphite cast iron comprising: C: 3.5 mass % to 4.2 mass %; Si: 2.0 mass % to 2.8 mass %; Mn: 0.2 mass % to 0.4 mass %; Cu: 0.1 mass % to 0.7 mass %; Mg: 0.02 mass % to 0.06 mass %; Cr: 0.01 mass % to 0.15 mass %; and the balance: Fe and inevitable impurities, wherein Mn+Cr+Cu is 0.431 mass % to 1.090 mass %, a graphite nodule count is 230/mm2 or less, and a pearlite fraction is 30% to 85%.
    Type: Grant
    Filed: December 27, 2018
    Date of Patent: October 11, 2022
    Assignees: TOYOTA JIDOSHA KABUSHIKI KAISHA, AISIN TAKAOKA CO., LTD.
    Inventors: Takumi Hijii, Yoshimasa Ureshino, Hitoshi Sakuma, Gou Nakamura, Zhong-zhi Zhang
  • Patent number: 8999085
    Abstract: A high-ductility, high-strength and high Mn steel strip used for steel strips of automobiles requiring superior formability and high strength, a plated steel strip produced by using the same, and a manufacturing method thereof are disclosed. The high Mn steel strip comprises, by weight %, 0.2˜1.5% of C, 10˜25% of Mn, 0.01˜3.0% of Al, 0.005˜2.0% of Si, 0.03% or less of P, 0.03% or less of S, 0.040% or less of N, and the balance of Fe and other unavoidable impurities. The high-ductility, high-strength and high Mn steel strip, and the plated steel strip produced by using the same have superior surface properties and plating characteristics.
    Type: Grant
    Filed: December 22, 2006
    Date of Patent: April 7, 2015
    Assignee: Posco
    Inventors: Seong-Ju Kim, Kwang-Geun Chin, Hyun-Gyu Hwang, Sung-Kyu Kim, Il-Ryoung Sohn, Young-Kook Lee, Oh-Yeon Lee
  • Publication number: 20150028724
    Abstract: A product, such as one or more thin sheets, each containing a single or near-single crystalline inclusion-containing magnetic microstructure, is provided. In one embodiment, the inclusion-containing magnetic microstructure is a Galfenol-carbide microstructure. Various methods and devices, as well as compositions, are also described.
    Type: Application
    Filed: January 31, 2013
    Publication date: January 29, 2015
    Inventors: Eric Summers, Rob Meloy
  • Patent number: 8940110
    Abstract: An iron-based corrosion resistant and wear resistant alloy includes (in weight percentage) carbon from about 1.6 to 3%, silicon from about 0.8 to 2.1%, manganese up to 1.0%, chromium from about 12.0 to 15.0%, molybdenum from about 2.0 to 4.0%, nickel from about 0.2 to 0.8%, copper up to 4.0%, boron up to 0.5%, and the balance including iron and incidental impurities. The alloy is suitable for use in elevated temperature applications such as in valve seat inserts for combustion engines.
    Type: Grant
    Filed: September 15, 2012
    Date of Patent: January 27, 2015
    Assignee: L. E. Jones Company
    Inventors: Cong Yue Qiao, David M. Doll
  • Publication number: 20140352851
    Abstract: A spheroidal graphite cast iron having (a) a composition comprising by mass 3.4-4% of C, 1.9-2.8% of Si, 0.02-0.06% of Mg, 0.2-1% of Mn, 0.2-2% of Cu, 0-0.1% of Sn, 0.85-3% of (Mn+Cu+10×Sn), 0.05% or less of P, and 0.02% or less of S, the balance being Fe and inevitable impurities, and (b) a duplex matrix structure comprising by area 2-40% of fine ferrite phases and 60-98% of fine pearlite phases, the maximum length of the ferrite phases being 300 ?m or less, and (c) the pearlite phases being formed around graphite particles dispersed in the duplex matrix structure.
    Type: Application
    Filed: December 28, 2012
    Publication date: December 4, 2014
    Applicant: HITACHI METALS, LTD.
    Inventors: Lin Wang, Masahide Kawabata, Kentaro Fukumoto
  • Patent number: 8882941
    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: Grant
    Filed: October 16, 2009
    Date of Patent: November 11, 2014
    Assignee: The NanoSteel Company, Inc.
    Inventors: Daniel James Branagan, Jeffrey E. Shield, Alla V. Sergueeva
  • Publication number: 20140255243
    Abstract: A spline hub for a clutch and a manufacturing method thereof are provided. The spline hub may include C: 3.4˜3.9%, Si: 2.1˜2.5%, Mn: 0.2˜0.7%, P: 0.01% or less, S: 0.009˜0.02%, Cu: 0.2˜0.4%, and Mg: 0.04˜0.07% by weight ratio, with the remainder including iron (Fe), as well as other impurities. The material forming the spline hub may have a structure in which spheroidal graphite is precipitated in an austenite matrix structure.
    Type: Application
    Filed: March 7, 2014
    Publication date: September 11, 2014
    Inventor: Jaebong PARK
  • Patent number: 8771589
    Abstract: A spheriodal cast alloy for producing cast iron products with great mechanical strength, high-wear resistance and a high degree of ductility. The alloy comprises the following as non-iron components: between 2.5 and 2.8 wt. % C, between 2.4 and 3.4 wt. % Si, between 0.02 and 0.08 wt. % P, between 0.02 and 0.06 wt. % Mg, between 0.01 and 0.05 wt. % Cr, between 0.002 and 0.02 wt. % Al, between 0.0005 and 0.015 wt. % S, between 0.0002 and 0.002 wt. % B and conventional impurities. The alloy contains between 3.0 and 3.7 wt. % C, between 2.6 and 3.4 wt. % Si, between 0.02 and 0.05 wt. % P, between 0.025 and 0.045 wt. % Mg, between 0.01 and 0.03 wt. % Cr, between 0.003 and 0.017 wt. % Al, between 0.0005 and 0.012 wt. % S and between 0.0004 and 0.002 wt. % B. The alloy is used for example to produce chassis parts or brake discs in the automobile industry.
    Type: Grant
    Filed: November 14, 2005
    Date of Patent: July 8, 2014
    Assignee: Georg Fischer GmbH
    Inventors: Werner Menk, Rolf Rietzscher, Andreas Hecker, Torsten Rieck
  • Publication number: 20140048185
    Abstract: The invention relates to a method of heat treating a cast iron having graphite particles, in particular a cast iron having graphite nodules with a substantially spherical geometry. The method comprises the step of subjecting the cast iron to a first austenitizing temperature, in order to obtain a cast iron having an austenite matrix with a substantially homogeneous carbon content. Subsequently, at least part of the cast iron is subjected to at least a second, different austenitizing temperature in order to change, in at least part of the cast iron, the carbon concentration in a part of the matrix surrounding the (spherical) geometry of the graphite particles. The method yields improved controllability on strength properties characteristics for cast irons including malleable irons, in particular for ductile iron.
    Type: Application
    Filed: March 13, 2012
    Publication date: February 20, 2014
    Applicant: TDI VALUE WEB B.V.
    Inventors: Pieter Cornelis Van Eldijk, Abraham van Eldijk
  • Patent number: 8636948
    Abstract: The present invention provides iron-based infiltration methods for manufacturing powder metallurgy components, compositions prepared from those methods, and methods of designing those infiltration methods. Iron-based infiltration methods table include the steps of providing an iron-based infiltrant composed of a near eutectic liquidus composition of a first iron based alloy system and an iron-based base compact composed of a near eutectic solidus powder composition of a second iron based alloy system. The base compact is placed in contact with the infiltrant and heated to a process temperature above the melting point of the infiltrant to form a liquid component of the infiltrant. Lastly, the base compact is infiltrated with the liquid component of the infiltrant. During infiltration, the liquid component of the infiltrant flows into the pores of the base compact.
    Type: Grant
    Filed: December 3, 2004
    Date of Patent: January 28, 2014
    Assignee: Hoeganaes Corporation
    Inventors: Frederick J. Semel, Kalathur S. Narasimhan
  • Publication number: 20140007991
    Abstract: A family of iron-based, phosphor-containing bulk metallic glasses having excellent processibitity and toughness, methods for forming such alloys, and processes for manufacturing articles therefrom are provided. The inventive iron-based alloy is based on the observation that by very tightly controlling the composition of the metalloid moiety of the Fe-based, P-containing bulk metallic glass alloys it is possible to obtain highly processable alloys with surprisingly low shear modulus and high toughness.
    Type: Application
    Filed: September 10, 2013
    Publication date: January 9, 2014
    Applicant: California Institute of Technology
    Inventors: Marios D. Demetriou, William L. Johnson
  • Publication number: 20130195709
    Abstract: A metal base alloy and methods for producing the alloy. The metal base alloy product includes the formula Mebase Ta Sib Crc Mnj Ve Cf, wherein—Mebase is a metal base selected from the group having Fe, Co and Ni, in an amount ranging from about 45-75 w %. The metal base alloy product contains a substantially homogenous dispersion of separate precipitated carbide particles in an amount ranging from 10-65 percentages by volume and the precipitate carbide particles have an average diameter of 0.01-5 micrometers.
    Type: Application
    Filed: June 23, 2011
    Publication date: August 1, 2013
    Applicant: SUPERIOR METALS SWEDEN AB
    Inventors: Sathees Ranganathan, Sohrab Solaimanzadeh-Azar, Hasse Fredriksson, Advenit Makaya
  • Patent number: 8486329
    Abstract: A process for the production of a semi-solidified iron alloy slurry having a crystallized solid phase and a residual liquid phase, wherein a material having a hypoeutectic cast iron composition is used, and an additive agent having a boiling point that is lower than at least a crystallization initiation temperature of primary crystals of the material is added to a melt of the material when the melt temperature is within a specific temperature range of not lower than the crystallization initiation temperature of the primary crystals and not greater than a temperature that is 50° C. higher than the crystallization initiation temperature, to thereby simultaneously conduct the stirring of the melt by the boiling of the additive agent and the cooling of the melt to a temperature falling within a semi-solidification temperature range thereof.
    Type: Grant
    Filed: March 12, 2009
    Date of Patent: July 16, 2013
    Assignee: Kogi Corporation
    Inventors: Syuichi Shikai, Yasushi Fujinaga, Minoru Sasaki, Toshio Ohkado, Susumu Nishikawa
  • Publication number: 20130146185
    Abstract: Provided is an iron-based amorphous alloy and a method of manufacturing the same. More particularly, provided is an high carbon iron-based amorphous alloy expressed by a general formula Fe?C?Si?BxPyCrz, wherein ?, ?, ?, x, y and z are atomic % of iron (Fe), carbon (C), silicon (Si), boron (B), phosphorus (P), and chrome (Cr) respectively, wherein a is expressed by ?=100?(?+?+x+y+z) atomic %, ? is expressed by 13.5 atomic %???17.8 atomic %, ? is expressed by 0.30 atomic %???1.50 atomic %, x is expressed by 0.1 atomic %?x?4.0 atomic %, y is expressed by 0.8 atomic %?y?7.7 atomic %, and z is expressed by 0.1 atomic %?z?3.0 atomic %.
    Type: Application
    Filed: June 27, 2011
    Publication date: June 13, 2013
    Applicant: POSCO
    Inventors: Sang-Won Kim, Gab-Sik Byun, Young-Geun Son, Eon-Byeong Park, Sang-Hoon Yoon, Sang-Wook Ha, Oh-Joon Kwon, Seung-Dueg Choi, Seong Hoon Yi
  • Publication number: 20130122325
    Abstract: A nodular graphite cast iron, a method for fabricating a vane for a rotary compressor using nodular graphite cast iron, and a vane for a rotary compressor using the same are provided. The nodular graphite cast iron includes 3.4 wt % to 3.9 wt % of carbon (C), 2.0 wt % to 3.0 wt % of silicon (Si), 0.3 wt % to 1.0 wt % of manganese (Mn), 0.1 wt % to 1.0 wt % of chromium (Cr), 0.04 wt % to 0.15 wt % of titanium (Ti), less than 0.08 w% of phosphorus (P), less than 0.025 wt % of sulphur (S), 0.03 wt % to 0.05 wt % of magnesium (Mg), 0.02 wt % to 0.04 wt % of rare earth resource, iron (Fe) and impurities as the remnants, and includes a bainite matrix structure, nodular graphite, and 15 vol % to 35 vol % of carbide.
    Type: Application
    Filed: November 13, 2012
    Publication date: May 16, 2013
    Applicant: LG Electronics Inc.
    Inventor: LG Electronics Inc.
  • Patent number: 8257514
    Abstract: A ferrous seal sliding part excellent in heat crack resistance, seizing resistance and abrasion resistance is provided. The ferrous seal sliding part having a seal sliding surface, wherein the seal sliding surface has a martensite parent phase which forms a solid solution with carbon of 0.15 to 0.6 wt % and contains a first dispersion material of at least either cementite of 5 to 70% by volume or MC-type carbide of 0.1 to 10% by volume and a second dispersion material of at least either graphite of 1 to 15% by volume or Cu alloy phase of 1 to 20% by volume dispersed therein, with a total content of the first dispersion material and the second dispersion material being 5 to 70% by volume.
    Type: Grant
    Filed: March 4, 2005
    Date of Patent: September 4, 2012
    Assignee: Komatsu Ltd.
    Inventors: Takemori Takayama, Koji Yamada, Shigeo Otsuka
  • Patent number: 8187529
    Abstract: A wear resistant, high chromium white iron, in an unheat-treated condition has a microstructure substantially comprising austenite and M7C3 carbides. The white iron contains at least one martensite promoter and at least one austenite stabilizer which are present at respective levels to achieve a balance between their effects whereby the white iron has a microstructure characterized by at least one of: i) being substantially free of martensite at interfaces between the austenite and M7C3 carbides; and ii) having a relatively low level of interconnectivity between carbide particles; such that the white iron is substantially crack-free. The white iron may be as-cast or comprise weld deposited hardfacing.
    Type: Grant
    Filed: October 27, 2004
    Date of Patent: May 29, 2012
    Assignee: Global Tough Alloys Pty Ltd.
    Inventor: Graham Leonard Fraser Powell
  • Patent number: 8156651
    Abstract: A method for producing an outer layer for a roll having a structure having MC carbide dispersed at an area ratio of 20-60%, comprising the steps of (1) centrifugally casting a melt having a composition comprising, by mass, 2.2-6.0% of C, 0.1-3.5% of Si, 0.1-3.5% of Mn, and 8-22% of V, the balance being Fe and inevitable impurity elements, to produce a cylindrical body comprising an inner layer having concentration MC carbide, an MC-carbide-poor outer layer, and a concentration gradient layer between the inner layer and the outer layer, in which the area ratio of MC carbide changes, and (2) cutting the cylindrical body to a depth at which the area ratio of MC carbide is 20% or more.
    Type: Grant
    Filed: September 13, 2005
    Date of Patent: April 17, 2012
    Assignee: Hitachi Metals, Ltd.
    Inventors: Kiyoshi Furushima, Shunji Matsumoto, Ryota Honda, Kiyoshi Hayashi, Takashi Honda, Masatsugu Uchida
  • Publication number: 20100322813
    Abstract: A cast article of a ductile iron wherein the ductile iron includes carbon from about 2.8 to 3.7 w/o, silicon from about 3.0 to 3.5 w/o, molybdenum from 0.8 to 1.5 w/o, magnesium from about 0.025 to 0.60 w/o, sulfur less than 0.01 w/o and nickel from about 0.0 to 1.3 w/o, the remaining content being iron is provided. The cast article is suitable for a gas turbine casing. A method of manufacturing a cast article is also provided.
    Type: Application
    Filed: June 23, 2009
    Publication date: December 23, 2010
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Gregory Keith Bouse, Joseph Jay Jackson, Jason Robert Parolini, Thangirala Subrahmanyam
  • 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
  • Publication number: 20100300148
    Abstract: A family of iron-based, phosphor-containing bulk metallic glasses having excellent processibility and toughness, methods for forming such alloys, and processes for manufacturing articles therefrom are provided. The inventive iron-based alloy is based on the observation that by very tightly controlling the composition of the metalloid moiety of the Fe-based, P-containing bulk metallic glass alloys it is possible to obtain highly processable alloys with surprisingly low shear modulus and high toughness.
    Type: Application
    Filed: May 19, 2010
    Publication date: December 2, 2010
    Applicant: California Institute of Technology
    Inventors: Marios D. Demetriou, William L. Johnson
  • 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: 20090195115
    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: Application
    Filed: January 23, 2008
    Publication date: August 6, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventor: Subrahmanyam Thangirala
  • Patent number: 7563333
    Abstract: The invention concerns an article of a steel which is characterized in that it consists of an alloy which contains in weight-%: 1.2-2.0 C, 0.1-1.5 Si, 0.1-2.0 Mn, max. 0.2 N, max. 0.25 S, 4-8 Cr, 0.5-3.5 (Mo+W/2), 5-8 V, max. 1.0 Nb, balance essentially only iron and unavoidable impurities, and that the steel has a micro-structure obtainable by a manufacturing of the steel which comprises spray forming of an ingot, the micro-structure of which contains 8-15 vol-% carbides of essentially only MC-type where M substantially consists of vanadium, of which carbides at least 80 vol-% have a substantially rounded shape and a size in the longest extension of the carbides amounting to 1-20 ?m.
    Type: Grant
    Filed: May 26, 2006
    Date of Patent: July 21, 2009
    Assignee: Uddeholm Tooling Aktiebolag
    Inventors: Odd Sandberg, Lennart Jönson
  • Patent number: 7534314
    Abstract: A density reducing high carbon containing or UHC-steel and particular a superplastic steel, which besides iron and impurities conventionally accompanying steel, contains the following alloy components in wt. %: 0.8 to 2.5% C 3.5 to 15% Al 0.5 to 4% Cr 0.01 to 4% Si up to 4% Ni, Mn, Mo, Nb, Ta, V, and/or W, wherein the steel includes as additional alloy components 0.1 to 0.85 Sn, and 0 to 3% Ti, Be and/or Ga.
    Type: Grant
    Filed: June 13, 2006
    Date of Patent: May 19, 2009
    Assignee: Daimler AG
    Inventors: Georg Frommeyer, Arndt Gerick, Tilmann Haug, Wolfgang Kleinekathöfer
  • Publication number: 20090007995
    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: Application
    Filed: September 22, 2008
    Publication date: January 8, 2009
    Applicant: GENERAL ELECTRIC COMPANY
    Inventors: Mark Roger Brown, Thomas Robbins Tipton, Liming Xu
  • Publication number: 20080092995
    Abstract: Disclosed are a ferritic heat-resistant cast iron comprising 5.0˜7.0 weight % of Silicon (Si) to improve oxidation resistance of the cast iron and a method for preparing the same.
    Type: Application
    Filed: December 6, 2006
    Publication date: April 24, 2008
    Applicant: Hyundai Motor Company
    Inventor: Ho Chul Shin
  • Patent number: 7160398
    Abstract: A melt of an alloy, represented (Fe1-mTm)100-x-y-zQxRyMz, where T is Co and/or Ni, Q is B and/or C, R is at least one rare-earth element, M is selected from Al, Si, Ti, V, Cr, Mn, Cu, Zn, Ga, Zr, Nb, Mo, Ag, Hf, Ta, W, Pt, Au and Pb; 10 at %?x?35 at %; 2 at %?y?10 at %; 0 at %?z?10 at %; and 0?m?0.5, is prepared. Next, the melt is brought into contact with, and rapidly cooled and solidified by, the surface of a rotating chill roller. The melt is teemed onto a guide member, of which the guide surface defines a tilt angle with a horizontal plane, runs down on the guide surface, and then is fed through at least one tubular hole onto a contact area on the surface of the chill roller.
    Type: Grant
    Filed: June 27, 2003
    Date of Patent: January 9, 2007
    Assignee: Neomax Co., Ltd.
    Inventor: Hirokazu Kanekiyo
  • Patent number: 7070666
    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: September 4, 2003
    Date of Patent: July 4, 2006
    Assignee: INTERMET Corporation
    Inventors: Alan Peter Druschitz, David Carroll Fitzgerald
  • Publication number: 20040244881
    Abstract: A nitrogen trapping agent is added by a metering hopper to raw materials, which are melted and poured into a mold cavity of a metal mold device (18). The molten metal is then cooled and solidified into a casting (B). Before the molten metal is fully cooled and solidified, free nitrogen present in the molten metal is quickly trapped by the nitrogen trapping agent, producing a nitride. Then, a chilled structure generated in the surface layer of the casting (B) is decomposed by heating the casting (B). Finally, the heated casting (B) is machined into a camshaft (A) which is a cast iron member as a final product.
    Type: Application
    Filed: March 9, 2004
    Publication date: December 9, 2004
    Inventors: Takao Watanabe, Toshiaki Onuma, Yoshimi Ueda, Takeshi Sasaki
  • Patent number: 6764560
    Abstract: The present invention provides cast high-carbon steel having high strength and plasticity and a method for its formation. In the method, forming during cooling from the melting point through temperature control results in a structure having small size cementite grains supported in a plastic matrix. Alloys other than high-carbon steel, including nickel, titanium, zirconium, and aluminum, can also be produced by the process.
    Type: Grant
    Filed: October 24, 2000
    Date of Patent: July 20, 2004
    Inventor: Mikhail A. Mogilevsky
  • Publication number: 20040134571
    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: Application
    Filed: March 31, 2003
    Publication date: July 15, 2004
    Inventors: William L. Powell, Paul D. Levering
  • 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: 20040071584
    Abstract: A spheroidal cast iron, particularly for piston rings for pistons of engines, with a particular alloyed chemical composition and subjected to a heat treatment known as austempering, which comprises an austenitization treatment followed by an isothermal hardening treatment, has mechanical characteristics that are comparable with those of the steel currently used to produce piston rings, while maintening the best tribological and self-lubrification characteristics of spheroidal cast irons, and a process suitable to obtain said spheroidal cast iron.
    Type: Application
    Filed: July 24, 2003
    Publication date: April 15, 2004
    Applicant: ERRE-VIS S.p.A.
    Inventors: Alberto Molinari, Dimitri Anguillesi
  • Patent number: 6702905
    Abstract: An iron-based corrosion resistant and wear resistant alloy. The alloy can comprise (in weight percent) 0.005-0.5% boron, 1.2-1.8% carbon, 0.7-1.5% vanadium, 7-11% chromium, 1-3.5% niobium, 6-11% molybdenum, and the balance including iron and incidental impurities. Alternatively, the Nb content can be replaced or combined with Ti, Zr, Hf and/or Ta such that 1%<(Ti+Zr+Nb+Hf+Ta)≦3.5. The alloy has improved hot hardness and high temperature compressive strength and is suitable for use in elevated temperature applications such as in diesel valve seat inserts.
    Type: Grant
    Filed: January 29, 2003
    Date of Patent: March 9, 2004
    Assignee: L. E. Jones Company
    Inventors: Cong Yue Qiao, Todd Trudeau
  • Publication number: 20040025980
    Abstract: A method for producing high-purity spheroidal graphite cast iron. The method comprises at least the steps of pretreating the melt in a closed converter and adding an inocculant when casting it into the mold. The solubility of the substances formed during the pretreatment and during the addition of the inocculant an be adjusted. The nucleation in the melt and the solidification in the mold can be brought into conformity by coordinating the pretreatment and the addition of inocculant.
    Type: Application
    Filed: July 18, 2003
    Publication date: February 12, 2004
    Inventors: Karl Keller, Roland Siclari, Thomas Margaria
  • Patent number: 6544359
    Abstract: The invention relates to a method of producing objects of cast iron containing compacted (vermicular) graphite crystals, by preparing a cast iron melt having substantially a carbon content at the desired final level and a silicon content below the desired final value, so that the equilibrium temperature (TE) for the reaction between carbon and SiO2 falls near 1400° C., and adjusting the temperature of the melt (TM) to a value between the equilibrium temperature (TE) and the “boiling temperature” (TB), to allow absorption of oxygen by the melt to a level exceeding the desired level at the time the melt is poured into a mold, adding the required amount of silicon, and thereafter reducing the oxygen content by addition of magnesium or magnesium containing material, preferably a FeSiMg-alloy to an oxygen level of 10 to 20 ppm oxygen in liquid solution, and forming particles of magnesium silicates as well as cast objects obtained by the method.
    Type: Grant
    Filed: September 26, 2000
    Date of Patent: April 8, 2003
    Assignee: CGI-Promotion AB
    Inventor: Lennart Bäckerud
  • Patent number: 6537395
    Abstract: Processes for producing gray cast iron and the resulting gray cast iron exhibiting consistently good surface finish with prolonged tool life during finish machining with cubic boron nitride and silicon nitride cutting tools at high cutting speeds and low feed rates are provided comprising (1) adding microalloying elements with strong affinity for nitrogen to a gray iron melt; (2) adding microalloying elements with strong affinity for carbon to said melt; and (3) adding microalloying elements with strong affinity for oxygen to said melt, to form a chemically stable, high melting or refractory oxide protective layer at the cutting edge of the tool during metal cutting, thereby suppressing chemical wear.
    Type: Grant
    Filed: July 20, 2001
    Date of Patent: March 25, 2003
    Inventor: Sundaresa V. Subramanian
  • 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
  • Patent number: 6332938
    Abstract: The present invention produces an Fe-based member having a high Young's modulus and a high toughness. In producing an Fe-based member, a first step and a second step are sequentially carried out. At the first step, an Fe-based material comprising 1.5% by weight≦C≦2.5% by weight 1.4% by weight≦Si≦3.5% by weight 0.9% by weight≦Mn≦1.7% by weight 0.5% by weight≦Ni≦1.5% by weight, and the balance of Fe including inevitable impurities is subjected to a thermal treatment at a heating temperature set in a range of TS<T1<TL and under a quenching condition, wherein TS represents a solidus temperature of the Fe-based material, and TL represents a liquidus temperature.
    Type: Grant
    Filed: August 13, 1999
    Date of Patent: December 25, 2001
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventor: Takeshi Sugawara
  • Patent number: 6199618
    Abstract: In order to produce castings from cast iron with foliated graphite, the carbon content of the cast iron can be set at between approximately 3 and 4% by controlling the melting process of the type and/or operation of the melting furnace. The molten mass is then cast in a sand-casting or lost-form method. During conventional cooling, the known mechanical properties of the cooled cast are set. In order to improve these mechanical properties in terms of hardness and strength, the casting is released from its mold at a temperature ranging from 1,100° C. to 800° C. and is immediately subjected to a cooling treatment by being blasted with an air flow in order to cool it to below 723° C. in a given amount of time. The casting, in selected regions, is cooled to below 723° C. by specific intermittent bursts of air in a relatively short amount of time in order to produce a harder structure. The cooling treatment is stopped when the temperature at the eutectoid line of the iron-carbon diagram is reached.
    Type: Grant
    Filed: February 9, 1999
    Date of Patent: March 13, 2001
    Inventors: Michael Fenne, Oswald Holtz
  • Patent number: 6136101
    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 .ltoreq.C.ltoreq.2.5% by weight of carbon, 1.4% by weight .ltoreq.Si.ltoreq.3% by weight of silicon and a balance of Fe including inevitable impurities.
    Type: Grant
    Filed: November 9, 1998
    Date of Patent: October 24, 2000
    Assignee: Honda Giken Kogyo Kabushiki Kaisha
    Inventors: Takeshi Sugawara, Haruo Shiina, Masayuki Tsuchiya, Kazuo Kikawa, Isamu Takagi
  • Patent number: 6110305
    Abstract: A method is proposed for the production of high-strength low-expansion cast iron enabled to acquire improved strength, hardness, and cutting workability while retaining the property of low expansion intact. The product is a low-expansion cast iron having a high nickel content and exhibiting a coefficient of thermal expansion of not more than 8.times.10.sup.-6 /.degree. C. at temperatures in the range of from room temperature to 100.degree. C. By causing a carbide to be finely precipitated in an area ratio in the range of from 0.3% to 20% in the metal structure of the cast iron and lowering the C content in the cast iron, there is produced a high-strength low-expansion cast iron. The deposition of the carbide mentioned above is accomplished by incorporating in the material for cast iron at least one element selected from the group consisting of the transition metal elements of IVa, Va, and VIa Groups in the Periodic Table of the Elements.
    Type: Grant
    Filed: June 14, 1995
    Date of Patent: August 29, 2000
    Assignee: Kabushiki Kaisha Toshiba
    Inventors: Takanobu Nishimura, Motoo Suzuki, Hisato Kamohara
  • Patent number: 6033791
    Abstract: A wear resistant, high-impact iron alloy member (20,22) suitable for use in an impact rock crusher and a method of making the same. The invention provides a white iron alloy member (20,22) having at least one wear surface (24) with carbide granules encapsulated in a matrix (28) of white iron and contained in a selected region adjacent the wear surface (24) of the member (20,22). The iron alloy member is made by a method of casting comprising the steps of: placing a molding insert (35,40) in a mold (60) at a selected location adjacent the wear surface (24); positioning a quantity of carbide granules (29), most preferably tungsten carbide granules 29, in the molding insert (35,40) before pouring; and pouring molten white iron alloy into the mold (60) to form the casting.
    Type: Grant
    Filed: April 4, 1997
    Date of Patent: March 7, 2000
    Assignee: Smith and Stout Research and Development, Inc.
    Inventors: Jerry I. Smith, Anthony E. Stout
  • Patent number: 5976277
    Abstract: A high speed tool steel and a manufacturing method therefor are disclosed, in which carbides are formed in the matrix in a uniform manner, thereby obtaining a high toughness and a high abrasion resistance. The high speed tool steel according to the present invention includes a basic composition of W.sub.a Mo.sub.b Cr.sub.c Co.sub.d V.sub.x C.sub.y Fe.sub.z where the subscripts meet in weight %: 5.0%.ltoreq.a.ltoreq.7.0%, 4.0%.ltoreq.b.ltoreq.6.0%, 3.0%.ltoreq.c.ltoreq.5.0%, 6.5%.ltoreq.d.ltoreq.9.5%, 2.2%.ltoreq.x.ltoreq.8.3%, 1.1%.ltoreq.y.ltoreq.2.18%, and 66.52%.ltoreq.z.ltoreq.73.7%. The final structure has carbides uniformly distributed within a martensite matrix, which are mainly MC and M.sub.6 C carbides. The method includes the steps of melting the above-defined alloy composition, gas spraying the melted alloy to form a bulk material, heat treating the bulk material to decompose the M.sub.2 C carbides to stabilize M.sub.6 C carbides and hot working the heat treated bulk material to a desired shape.
    Type: Grant
    Filed: May 8, 1997
    Date of Patent: November 2, 1999
    Assignees: Pohang Iron & Steel Co., Ltd., Research Institute of Industrial Science & Technology
    Inventors: Woo Jin Park, Eon Sik Lee, Sang Ho Ahn
  • Patent number: 5738737
    Abstract: In a process for making superplastic steel powder or flakes, molten steel is rapidly solidified to form a solidified material comprising substantially single-phase austenitic steel powder or flakes having a grain size of no greater than about 2 .mu.m. The powder or flakes are heated at a temperature of 300.degree. C. to 600.degree. C. to produce superplastic steel comprising a mixture of ferrite steel and at least one metal carbide, the ferrite steel having a randomly oriented structure and having a grain size of no greater than about 2 .mu.m, the at least one metal carbide having a grain size no greater than about 0.5 .mu.m. The steel powder or flake is then recovered for further processing. A consolidated superplastic steel can be formed from the powder or flake by hot pressing the powder or flake at a temperature of between about 650.degree. C. and about 950.degree. C. and at a pressure of about 10 MPa to about 100 MPa for a time sufficient to form a fully dense consolidate.
    Type: Grant
    Filed: November 5, 1991
    Date of Patent: April 14, 1998
    Assignee: The United States of America as represented by the Secretary of the Navy
    Inventor: Jack D. Ayers
  • Patent number: 5720830
    Abstract: A method of making an engineering ferrous metal comprising the steps of adding to liquid engineering ferrous metal solid alloy carbide particles and thereafter permitting the ferrous metal to solidify. The alloy carbide particles are coated with iron or an iron alloy to allow wetting to occur between the powder and the liquid ferrous metal and the particles have a density which matches that of the ferrous metal to provide a uniform distribution of the carbide particles in the ferrous metal. A roll may be made having at least a shell made of metal by such a method by centrifugal casting or electroslag remelting.
    Type: Grant
    Filed: October 21, 1996
    Date of Patent: February 24, 1998
    Assignee: Sheffield Forgemasters Limited
    Inventors: David Wragg, Paul Herbert Hewitt, Jack Nutting
  • Patent number: 5580401
    Abstract: A system for making a gray cast iron scrolls using a high performance inoculant.
    Type: Grant
    Filed: March 14, 1995
    Date of Patent: December 3, 1996
    Assignee: Copeland Corporation
    Inventor: Warren G. Williamson
  • Patent number: 5571347
    Abstract: Disclosed is an improved aluminum base alloy comprising an improved aluminum base alloy comprising 0.2 to 2 wt. % Si, 0.3 to 1.7 wt. % Mg, 0 to 1.2 wt. % Cu, 0 to 1.1 wt. % Mn, 0.01 to 0.4 wt. % Cr, and at least one of the elements selected from the group consisting of 0.01 to 0.3 wt. % V, 0.001 to 0.1 wt. % Be and 0.01 to 0.1 wt. % Sr, the remainder comprising aluminum, incidental elements and impurities. Also disclosed are methods of casting and thermomechanical processing of the alloy.
    Type: Grant
    Filed: September 12, 1994
    Date of Patent: November 5, 1996
    Assignee: Northwest Aluminum Company
    Inventor: S. Craig Bergsma
  • Patent number: 5346561
    Abstract: The spheroidal graphite cast iron member having a surface layer portion mostly composed of a ferrite phase and having a thickness of at least 1 mm, and an inner portion composed of a pearlite phase and a ferrite phase, the surface layer portion having a ferritization ratio of 70% or more which is larger than that of the inner portion by at least about 15% is produced by (a) pouring a spheroidal graphite cast melt into a casting mold; (b) removing the casting mold by shake-out after the completion of solidification of the melt, while substantially the entire portion of the resulting cast iron product is still at a temperature of its A.sub.1 transformation point or higher; (c) when the temperature difference between the surface layer portion and the inner portion has become 40.degree.-60.degree. C., introducing the cast iron product into a uniform-temperature furnace kept at 750.degree.-900.degree. C.
    Type: Grant
    Filed: February 25, 1993
    Date of Patent: September 13, 1994
    Assignee: Hitachi Metals, Ltd.
    Inventors: Fumio Obata, Hisashi Yasuda, Hideaki Nagayoshi, Kiyoshi Suehara, Kouhei Imanishi, Toshiki Yoshida