Disclosed herein are duplex stainless steel alloys comprising 40 wt %-60 wt % ferrite and 60 wt %-40 wt % austenite and methods of formation thereof, the alloys including or consisting essentially of
from 10 wt % to 20 wt % chromium (Cr);
from 6 wt % to 13 wt % molybdenum (Mo);
from 0.5 wt % to 6.5 wt % nickel (Ni);
from 2.25 wt % to 12 wt % manganese (Mn);
from 0.05 wt % to 5 wt % copper (Cu);
from 0.05 wt % to 0.4 wt % nitrogen (N);
from 0.05 wt % to 0.35 wt % carbon (C);
from 0.01 wt % to 3.5 wt % cobalt (Co);
less than 2 wt % silicon (Si);
less than 2 wt % tungsten (W); and
iron (Fe) balance.
The duplex stainless steel alloy may include cast or wrought steel, or it may be in powder form.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C21D 8/00 - Modifying the physical properties by deformation combined with, or followed by, heat treatment
Disclosed herein are duplex stainless steel alloys comprising 40 wt% – 60 wt% ferrite and 60 wt% – 40 wt% austenite and methods of formation thereof, the alloys including or consisting essentially of from 10 wt% to 20 wt% chromium (Cr); from 6 wt% to 13 wt% molybdenum (Mo); from 0.5 wt% to 6.5 wt% nickel (Ni); from 2.25 wt% to 12 wt% manganese (Mn); from 0.05 wt% to 5 wt% copper (Cu); from 0.05 wt% to 0.4 wt% nitrogen (N); from 0.05 wt% to 0.35 wt% carbon (C); from 0.01 wt% to 3.5 wt% cobalt (Co); less than 2 wt% silicon (Si); less than 2 wt% tungsten (W); and iron (Fe) balance. The duplex stainless steel alloy may include cast or wrought steel, or it may be in powder form.
A method for fabricating an article includes forming a billet consisting essentially of a stainless steel composition of
manganese 2.00 wt. %-24.00 wt. %
chromium 19.00 wt. %-30 wt. %
molybdenum 0.50 wt. %-4.0 wt. %
nitrogen 0.25 wt. %-1.10 wt. %
carbon ≤1 wt. %
phosphorus ≤0.03 wt. %
sulfur ≤1 wt. %
nickel <22 wt. %
cobalt <0.10 wt. %
silicon ≤1 wt. %
niobium ≤0.80 wt. %
oxygen ≤1 wt. %
copper ≤0.25 wt. %
balance iron.
The billet is annealed and cold worked to form an article. Without annealing of the article, the article is subsequently case hardened at a single case hardening temperature to form a surface layer on a top surface thereof. Articles formed with the indicated stainless steel composition with case hardened surface layers are also provided.
A method for fabricating an article includes forming a billet consisting essentially of a stainless steel composition of manganese 2.00 wt.% – 24.00 wt.% chromium 19.00 wt.% – 30 wt.% molybdenum 0.50 wt.% – 4.0 wt.% nitrogen 0.25 wt.% – 1.10 wt.% carbon ≤0.08 wt.% phosphorus ≤0.03 wt.% sulfur ≤0.01 wt.% nickel <22 wt.% cobalt <0.10 wt.% silicon ≤0.75 wt.% niobium ≤0.80 wt.% copper ≤0.25 wt.% balance iron. The billet is annealed and cold worked to form article. Without annealing of the article, the article is subsequently case hardened at a single temperature to form a surface layer on a top surface thereof. Articles formed with the indicated stainless steel composition with case hardened surface layers are also provided.
Closed-loop metal powder management methods for additive manufacturing. Virgin metal powder is provided in a closed powder container comprising at least one sensor, tracker, or optical device. The metal powder is transferred to an additive manufacturing system, a portion of a metal powder layer is consolidated, and excess metal powder is transferred from the additive manufacturing system to the powder container, a second powder container, or an internal powder container. Virgin metal powder or a second metal powder are added to the excess metal powder, a quality of the mixed powder is validated, the process is repeated at least once, and powder physical transfer data associated with at least one of the steps is collected and stored in a data repository. Powder material parameters may be measured and assessed, and may be also be stored in the data repository.
Closed-loop metal powder management methods for additive manufacturing. Virgin metal powder is provided in a closed powder container comprising at least one sensor, tracker, or optical device. The metal powder is transferred to an additive manufacturing system, a portion of a metal powder layer is consolidated, and excess metal powder is transferred from the additive manufacturing system to the powder container, a second powder container, or an internal powder container. Virgin metal powder or a second metal powder are added to the excess metal powder, a quality of the mixed powder is validated, the process is repeated at least once, and powder physical transfer data associated with at least one of the steps is collected and stored in a data repository. Powder material parameters may be measured and assessed, and may be also be stored in the data repository.
Closed-loop metal powder management methods for additive manufacturing. Virgin metal powder is provided in a closed powder container comprising at least one sensor, tracker, or optical device. The metal powder is transferred to an additive manufacturing system, a portion of a metal powder layer is consolidated, and excess metal powder is transferred from the additive manufacturing system to the powder container, a second powder container, or an internal powder container. Virgin metal powder or a second metal powder are added to the excess metal powder, a quality of the mixed powder is validated, the process is repeated at least once, and powder physical transfer data associated with at least one of the steps is collected and stored in a data repository. Powder material parameters may be measured and assessed, and may be also be stored in the data repository.
A method for producing an additively manufactured, graded composite transition joint (AM-GCTJ) (300) includes preparing a grating or lattice pattern (101) from a first alloy A (100); the grating or lattice pattern (101) includes pores (110) in the grating or lattice patterns (101). The grating pattern is built from a first end to a second end being denser on the first end than on second end, and gradually reduces density by increasing the pore size and/or reducing density of the grating or lattice pattern; adding a second alloy B (200) powder to the second end of grating or lattice pattern. The second alloy B (200) powder is filled towards the first end. A composite is formed of first alloy A (100) and second alloy B (200) powder in the AM-GCTJ (300). The composite is subjected to hot isotropic pressing (HIP) to densify the composite. The second alloy B (200) is graduated from the first end to the second end of AM-GCTJ (300).
B22F 5/10 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of articles with cavities or holes, not otherwise provided for in the preceding subgroups
B22F 7/00 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting
B22F 7/06 - Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting of composite workpieces or articles from parts, e.g. to form tipped tools
B23K 35/02 - Rods, electrodes, materials, or media, for use in soldering, welding, or cutting characterised by mechanical features, e.g. shape
B23K 35/30 - Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
B22F 10/28 - Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
C22C 33/02 - Making ferrous alloys by powder metallurgy
B22F 10/38 - Process control to achieve specific product aspects, e.g. surface smoothness, density, porosity or hollow structures
9.
STRONG, TOUGH, AND HARD STAINLESS STEEL AND ARTICLE MADE THEREFROM
An iron-base, fine-grained, martensitic stainless steel alloy is disclosed. The alloy is essentially free of delta ferrite and provides very high hardness and good corrosion resistance. The alloy consists essentially of the following composition in weight percent. The balance of the alloy is iron and the usual impurities. A composite article of manufacture is also disclosed that includes a case portion formed of the foregoing alloy.
A precipitation hardenable, martensitic stainless steel is disclosed. The alloy has the following broad composition in weight percent. Ni 10.5-12.5 Co 1.0-6.0 Mo 1.0-4.0 Ti 1.5-2.0 Cr 8.5-11.5 Al Up to 0.5 Mn 1.0 max. Si 0.75 max. B 0.01 max. The balance of the alloy is iron and the usual impurities found in commercial grades of precipitation hardenable martensitic stainless steels as known to those skilled in the state of the art in melting practice for such steels. A method of making parts from the alloy and an article of manufacture made from the alloy are also described.
A powder including a plurality of particulates, each particulate including a soft magnetic metallic core coated with a continuous dielectric coating having a thickness selected from a range of 100 nanometers to 100 micrometers. The particulates have a mean particle size selected from a range of 100 nanometers to 250 micrometers. Methods for forming the powder are disclosed. A soft magnetic composite component includes a soft magnetic material in a dielectric matrix, wherein (i) the soft magnetic material comprises a plurality of particulates comprising metallic cores, (ii) each metallic core is coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores are electrically isolated from each other, and (iv) the dielectric coatings of adjacent metallic cores are consolidated together. Methods for formation of the soft magnetic component by additive manufacturing and hot isostatic pressing are disclosed.
B22F 1/02 - Special treatment of metallic powder, e.g. to facilitate working, to improve properties; Metallic powders per se, e.g. mixtures of particles of different composition comprising coating of the powder
B33Y 70/00 - Materials specially adapted for additive manufacturing
B33Y 80/00 - Products made by additive manufacturing
C03C 10/00 - Devitrified glass ceramics, i.e. glass ceramics having a crystalline phase dispersed in a glassy phase and constituting at least 50% by weight of the total composition
H01F 1/24 - Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder pressed, sintered, or bound together the particles being insulated
12.
SOFT MAGNETIC COMPOSITE MATERIALS AND METHODS AND POWDERS FOR PRODUCING THE SAME
A powder including a plurality of particulates, each particulate including a soft magnetic metallic core coated with a continuous dielectric coating having a thickness selected from a range of 100 nanometers to 100 micrometers. The particulates have a mean particle size selected from a range of 100 nanometers to 250 micrometers. Methods for forming the powder are disclosed. A soft magnetic composite component includes a soft magnetic material in a dielectric matrix, wherein (i) the soft magnetic material comprises a plurality of particulates comprising metallic cores, (ii) each metallic core is coated by a continuous dielectric coating covering >90% of a surface area of the metallic core, (iii) the metallic cores are electrically isolated from each other, and (iv) the dielectric coatings of adjacent metallic cores are consolidated together. Methods for formation of the soft magnetic component by additive manufacturing and hot isostatic pressing are disclosed.
H01F 1/147 - Alloys characterised by their composition
H01F 41/02 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils or magnets
A bonded soft magnet object comprising bonded soft magnetic particles of an iron-containing alloy having a soft magnet characteristic, wherein the bonded soft magnetic particles have a particle size of at least 200 nm and up to 100 microns. Also described herein is a method for producing the bonded soft magnet by indirect additive manufacturing (IAM), such as by: (i) producing a soft magnet preform by bonding soft magnetic particles with an organic binder, wherein the magnetic particles have an iron-containing alloy composition with a soft magnet characteristic, and wherein the particles of the soft magnet material have a particle size of at least 200 nm and up to 100 microns; (ii) subjecting the preform to an elevated temperature sufficient to remove the organic binder to produce a binder-free preform; and (iii) sintering the binder-free preform at a further elevated temperature to produce the bonded soft magnet.
H01F 41/02 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils or magnets
H01F 1/147 - Alloys characterised by their composition
H01F 1/33 - Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metallic particles having oxide skin
C22C 38/02 - Ferrous alloys, e.g. steel alloys containing silicon
B29C 64/165 - Processes of additive manufacturing using a combination of solid and fluid materials, e.g. a powder selectively bound by a liquid binder, catalyst, inhibitor or energy absorber
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
B22F 1/00 - Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
A bonded soft magnet object comprising bonded soft magnetic particles of an iron-containing alloy having a soft magnet characteristic, wherein the bonded soft magnetic particles have a particle size of at least 200 nm and up to 100 microns. Also described herein is a method for producing the bonded soft magnet by indirect additive manufacturing (IAM), such as by: (i) producing a soft magnet preform by bonding soft magnetic particles with an organic binder, wherein the magnetic particles have an iron-containing alloy composition with a soft magnet characteristic, and wherein the particles of the soft magnet material have a particle size of at least 200 nm and up to 100 microns; (ii) subjecting the preform to an elevated temperature sufficient to remove the organic binder to produce a binder-free preform; and (iii) sintering the binder-free preform at a further elevated temperature to produce the bonded soft magnet.
B28B 1/00 - Producing shaped articles from the material
B29C 67/00 - Shaping techniques not covered by groups , or
B22F 3/00 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor
15.
DOUBLE-SHOULDERED CONNECTION FOR DRILLING TUBULARS WITH LARGE INSIDE DIAMETER
A threaded connection for drilling tubulars includes a tubular box section having a sidewall. The box section has a tapered box portion of an inner surface of the sidewall between a first end and a second end. The tapered box portion has internal threads, a first torque shoulder on a first side of the tapered box portion, and a second shoulder on a second side of the tapered box portion. A threaded collar having internal collar threads is positioned between the second end and the second shoulder. A threaded insert having a tubular body with an inner surface and an outer surface having external insert threads is configured for threadably connecting to the internal collar threads. A direction of the internal threads of the tapered box portion is opposite to a direction of the internal collar threads and the external insert threads.
A pressure generating device for use in downhole drilling operations includes a rotating valve portion having a first body with at least one first flow channel, and a stationary valve portion having a second body with at least one second flow channels and at least one bypass channel. A flow restrictor is positioned within the at least one bypass channel for adjusting a total flow area of the at least one bypass channel. During rotation of the rotating valve portion relative to the stationary valve portion, a total flow area of a passage defined by the first flow channel(s), the second flow channel(s), and the at least one bypass channel varies according to a uniform closure pattern to provide uniform pressure pulses within a single revolution of the rotating valve portion. A method of generating uniform pressure pulses in downhole drilling operations is also disclosed.
E21B 21/10 - Valves arrangements in drilling-fluid circulation systems
E21B 7/18 - Drilling by liquid or gas jets, with or without entrained pellets
E21B 7/24 - Drilling using vibrating or oscillating means, e.g. out-of-balance masses
E21B 21/08 - Controlling or monitoring pressure or flow of drilling fluid, e.g. automatic filling of boreholes, automatic control of bottom pressure
E21B 21/12 - Methods or apparatus for flushing boreholes, e.g. by use of exhaust air from motor using drilling pipes with plural fluid passages, e.g. closed circulation systems
E21B 34/06 - Valve arrangements for boreholes or wells in wells
E21B 41/00 - Equipment or details not covered by groups
17.
NI-BASED SUPERALLOY POWDER FOR ADDITIVE MANUFACTURING AND AN ARTICLE MADE THEREFROM
A nickel base superalloy powder for additive manufacturing applications is disclosed. The alloy powder has the following broad weight percent composition: C 0-0.1 Mn 0.5 max. Si 0-0.03 Cr 4-16 Fe 0-1.5 Mo 0-6 W 0-8 Co 0-15 Ti 0-2 A1 0.5-5.5 Nb 0-6 Ta 7.5-14.5 Hf 0-2.0 Zr 0-0.1 Re 0-6 Ru 0-3 B 0-0.03 The balance of the alloy is at least 50% nickel and the usual impurities. An article of manufacture made from the alloy is also disclosed.
C22C 19/05 - Alloys based on nickel or cobalt based on nickel with chromium
C22F 1/10 - Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
B23K 35/30 - Selection of soldering or welding materials proper with the principal constituent melting at less than 1550°C
18.
A METHOD OF MAKING A MULTI-MATERIAL SEGMENTED STATOR FOR A ROTATING ELECTRIC MACHINE AND A STATOR MADE BY SAID METHOD
A method of making a stator for a rotating electrical machine in which a tooth segment from a high saturation induction material and a yoke segment from a silicon steel material. The tooth segment is bond to yoke segment, thereby producing a stator with at least two magnetic saturations.
H02K 1/02 - DYNAMO-ELECTRIC MACHINES - Details of the magnetic circuit characterised by the magnetic material
H02K 15/02 - Methods or apparatus specially adapted for manufacturing, assembling, maintaining or repairing of dynamo-electric machines of stator or rotor bodies
A magnetic iron alloy and process of making the same. The alloy includes iron, approximately 2 wt. % to approximately 8 wt. % cobalt, approximately 0.05 wt. % to approximately 5 wt. % manganese, and approximately 0.05 wt. % to approximately 5 wt. % silicon. The alloy may also include up to approximately 0.3 wt. % chromium, up to approximately 2 wt. % vanadium, up to approximately 1 wt. % nickel, up to approximately 0.05 wt. % niobium, and up to approximately 0.02 wt. % carbon.
This disclosure relates to a new alloy and methods of making same. The new alloy is an enhanced strength Ti-6A1-4V Grade 23+ titanium alloy having the following composition by weight percent: Aluminum ¨ 6.0 wt% to 6.5 wt%; Vanadium ¨ 4.0 wt% to 4.5 wt%: iron ¨ 0.15 wt% to 0.25 wt%; Oxygen ¨ 0.00 wt% to 0.10 wt%; Nitrogen ¨ 0.01 wt% to 0.03 wt%; Carbon ¨ 0.04 wt% to 0.08 wt%; Hydrogen ¨ 0.0000 to 0.0125 wt%; Other Elements, each ¨ 0.0 wt% to 0.1 wt%; Other Elements, total 0.0 wt% to 0.4 wt%; and Titanium ¨ Balance.
This disclosure relates to a new alloy and methods of making same. The new alloy is an enhanced strength Ti-6A1-4V Grade 23+ titanium alloy having the following composition by weight percent: Aluminum - 6.0 wt% to 6.5 wt%; Vanadium - 4.0 wt% to 4.5 wt%; Iron - 0.15 wt% to 0.25 wt%; Oxygen - 0.00 wt% to 0.10 wt%; Nitrogen - 0.01 wt% to 0.03 wt%; Carbon - 0.04 wt% to 0.08 wt%; Hydrogen - 0.0000 wt% to 0.0125 wt%; Other Elements, each - 0.0 wt% to 0.1 wt%; Other Elements, total - 0.0 wt% to 0.4 wt%; and Titanium - Balance.
A soft magnetic alloy having a good combination of formability and magnetic properties is disclosed. The alloy has the formula Fe100-a-b-c-d-e-fSiaMbLcM'dM"eRf wherein M is Cr and/or Mo; L is Co and/or Ni; M' is one or more of Al, Mn, Cu, Ge, Ga; M" is one or more of Ti, V, Hf, Nb, W; and R is one or more of B, Zr, Mg, P, Ce. The elements Si, M, L, M', M", and R have the following ranges in weight percent: Si 4-7 M 0.1-7 L 0.1-10 M' up to 7 M" up to 7 R up to 1 The balance of the alloy is iron and usual impurities. A thin-gauge article made from the alloy and a method of making the thin-gauge article are also disclosed.
A multi-principal element, corrosion resistant alloy is disclosed. The alloy has the following composition in weight percent: Co about 13 to about 28 Ni about 13 to about 28 Fe+Mn about 13 to about 28 Cr about 13 to about 37 Mo about 8 to about 28 N about 0.10 to about 1.00. The alloy also includes the usual impurities found in corrosion resistant alloys intended for the same or similar use. In addition, one or both of W and V may be substituted for some or all of the Mo. The alloy provides a solid solution that is substantially all FCC phase, but may include minor amounts of secondary phases that do not adversely affect the corrosion resistance and mechanical properties provided by the alloy.
An Fe-base, soft magnetic alloy is disclosed. The alloy has the general formula Fe100-a-b-c-d-x-y MaM'bM"cM"'d Px Mny where M is Co and/or Ni, M' is one or more of Zr, Nb, Cr, Mo, Hf, Sc, Ti, V, W, and Ta, M" is one or more of B, C, Si, and Al, and M'" is selected from the group consisting of Cu, Pt, Ir, Zn, Au, and Ag. The subscripts a, b, c, d, x, and y represent the atomic proportions of the elements and have the following atomic percent ranges: 0 ≤ a ≤ 10, 0 ≤ b ≤ 7, 5 ≤ c ≤ 20, 0 ≤ d ≤ 5, 0.1 ≤ x ≤ 15, and 0.1 ≤ y ≤ 5. The balance of the alloy is iron and usual impurities. Alloy powder, a magnetic article made therefrom, and an amorphous metal article made from the alloy are also disclosed.
C22C 45/02 - Amorphous alloys with iron as the major constituent
H01F 1/20 - Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of particles, e.g. powder
H01F 1/147 - Alloys characterised by their composition
A method and apparatus for producing titanium metal powder from a melt. The apparatus includes an atomization chamber having an inner wall that is coated with or formed entirely of a titanium alloy that is the same as the titanium metal powder to prevent contamination of titanium metal powder therein. The inner surfaces of some or all components of the apparatus in a flow path following the atomization chamber may also be coated with or formed entirely of the titanium alloy or CP-Ti.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C22C 1/04 - Making non-ferrous alloys by powder metallurgy
27.
REDUCING ORDERED GROWTH IN SOFT-MAGNETIC FE-CO ALLOYS
A process for making an article of manufacture from elongated strip of a soft-magnetic Fe-Co alloy is disclosed. The process includes a prefabrication annealing step in which the elongated strip is annealed before it is fabricated into parts. The prefabrication annealing step is carried out at a temperature that is greater than the ordering temperature of the alloy. The process further includes the step of cooling the alloy from the annealing temperature at a rate that is selected to cause substantial transformation of the disordered phase of the soft- magnetic Fe-Co alloy to an ordered phase thereof. An article of manufacture made by using the process is also disclosed.
C21D 8/04 - Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips to produce plates or strips for deep-drawing
C21D 8/12 - Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of articles with special electromagnetic properties
C22C 38/10 - Ferrous alloys, e.g. steel alloys containing cobalt
C22C 38/12 - Ferrous alloys, e.g. steel alloys containing tungsten, tantalum, molybdenum, vanadium or niobium
H01F 1/147 - Alloys characterised by their composition
H01F 1/16 - Magnets or magnetic bodies characterised by the magnetic materials therefor; Selection of materials for their magnetic properties of inorganic materials characterised by their coercivity of soft-magnetic materials metals or alloys in the form of sheets
H01F 3/02 - Cores, yokes or armatures made from sheets
H01F 41/02 - Apparatus or processes specially adapted for manufacturing or assembling magnets, inductances or transformers; Apparatus or processes specially adapted for manufacturing materials characterised by their magnetic properties for manufacturing cores, coils or magnets
28.
HIGH TEMPERATURE, DAMAGE TOLERANT SUPERALLOY, AN ARTICLE OF MANUFACTURE MADE FROM THE ALLOY, AND PROCESS FOR MAKING THE ALLOY
A nickel-base alloy is disclosed that has the following weight percent composition. C about 0.005 to about 0.06 Cr about 13 to about 17 Fe about 4 to about 20 Mo about 3 to about 9 W up to about 8 Co up to about 12 Al about 1 to about 3 Ti about 0.6 to about 3 Nb up to about 5.5 B about 0.001 to about 0.012 Mg about 0.0010 to about 0.0020 Zr about 0.01 to about 0.08 Si up to about 0.7 P up to about 0.05 and the balance is nickel, usual impurities, and minor amounts of other elements as residuals from alloying additions during melting,. The alloy provides a combination of high strength, good creep resistance, and good resistance to crack growth. A method of heat treating a nickel base superalloy to improve the tensile ductility of the alloy is also disclosed. An article of manufacture made from the nickel base superalloy described herein is also disclosed.
A Ti-6A1 -4V titanium powder alloy composition having enhanced strength resulting from the addition of one or more of the following elements without requiring an increase in oxygen content: Aluminum Iron Nitrogen Carbon The composition may also be used for Ti-6A1-4V titanium alloy starting bar stock.
The United States Of America, as represented by the Secretary Of The Navy (USA)
Inventor
Sinfield, Matthew
Farren, Jeffrey
Wong, Richard
Martin, William J.
Smith, Richard H.
Para, Shane
Heilmann, James E.
Novotny, Paul M.
Ray, Patrick C.
Deantonio, Dan
Stravinskas, Joe
Abstract
An exemplary welding consumable according to the invention is provided and includes up to about 0.13 wt % carbon, about 0.3 wt % to about 1.4 wt % manganese, about 7.25 wt % to about 11.5 wt % nickel, about 0.6 wt % to about 1.2 wt % molybdenum, about 0.2 wt % to about 0.7 wt % silicon, up to about 0.3 wt % vanadium, up to about 0.05 wt % titanium, up to about 0.08 wt % zirconium, up to about 2.0 wt % chromium, and a balance of iron and incidental impurities.
THE UNITED STATES OF AMERICA AS REPRESENTED BY THE SECRETARY OF THE NAVY (USA)
Inventor
Sinfield, Matthew
Farren, Jeffrey
Wong, Richard
Martin, William J.
Smith, Richard H.
Para, Shane
Heilmann, James E.
Novotny, Paul M.
Ray, Patrick C.
Deantonio, Dan
Stravinskas, Joe
Abstract
An exemplary welding consumable according to the invention is provided and includes up to about 0.13 wt % carbon, about 0.3 wt % to about 1.4 wt % manganese, about 7.25 wt% to about 11.5 wt % nickel, about 0.6 wt % to about 1.2 wt % molybdenum, about 0.2 wt % to about 0.7 wt % silicon, up to about 0.3 wt % vanadium, up to about 0.05 wt % titanium, up to about 0.08 wt % zirconium, up to about 2.0 wt % chromium, and a balance of iron and incidental impurities.
A steel alloy is disclosed that provides a unique combination of strength, toughness, and fatigue life. The steel alloy has the following composition in weight percent. C about 0.15 to about 0.30 Mn about 1.7 to about 2.3 Si about 0.7 to about 1.1 Cr about 1.85 to about 2.35 Ni about 0.5 to about 0.9 MO+1/2W about 0.1 to about 0.3 Cu about 0.3 to about 0.7 V+5/9xNb about 0.2 to about 0.5 The balance of the alloy is iron, usual impurities, and residual amounts of other elements added during melting for deoxidizing and/or desulfurizing the alloy. A hardened and tempered steel article made from the alloy is also disclosed.
37 - Construction and mining; installation and repair services
Goods & Services
(1) Oil and gas field down-hole equipment tooling, namely, stabilizers, drill collars, subs, hole openers and bottom-hole assembly tools (1) Repair and maintenance of down-hole equipment tooling and assemblies used in the drilling of oil and gas wells; leasing and rental of oil well drilling and production tools, namely, drill collars, stabilizers, subs, hole openers, float valves, baffle plates, sleeves, and drill pipe screens
A magnetic iron alloy and process of making the same. The alloy includes iron, approximately 2 wt.% to approximately 10 wt.% cobalt, approximately 0.05 wt.% to approximately 5 wt.% manganese, and approximately 0.05 wt.% to approximately 5 wt.% silicon. The alloy may also include up to approximately 3 wt.% chromium, up to approximately 2 wt.% vanadium, up to approximately 1 wt.% nickel, up to approximately 0.05 wt.% niobium, and up to approximately 0.02 wt.% carbon.
Disclosed herein is a method comprising disposing on a base article a nickel-titanium alloy; where the nickel is in an amount of about 58 to about 62 weight percent and titanium in an amount of about 38 to about 42 wt %, based on the total weight of the nickel-titanium alloy; and applying a pressure of 12 to 20 kilopounds per square inch at a temperature of 1400 to 2100° F. for a period of 1 to 8 hours to form a nickel-titanium alloy coating on the base article. Disclosed is an article comprising a base article; and a nickel-titanium alloy; where the nickel-titanium alloy is disposed on the base article; where the nickel is in an amount of about 58 to about 62 weight percent and titanium in an amount of about 38 to about 42 wt %, based on the total weight of the nickel-titanium alloy.
C22C 19/03 - Alloys based on nickel or cobalt based on nickel
B32B 15/04 - Layered products essentially comprising metal comprising metal as the main or only constituent of a layer, next to another layer of a specific substance
B32B 37/10 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the pressing technique, e.g. using direct action of vacuum or fluid pressure
B32B 37/06 - Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the heating method
B32B 15/01 - Layered products essentially comprising metal all layers being exclusively metallic
B05D 7/24 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials for applying particular liquids or other fluent materials
B05D 3/02 - Pretreatment of surfaces to which liquids or other fluent materials are to be applied; After-treatment of applied coatings, e.g. intermediate treating of an applied coating preparatory to subsequent applications of liquids or other fluent materials by baking
B05D 7/14 - Processes, other than flocking, specially adapted for applying liquids or other fluent materials to particular surfaces or for applying particular liquids or other fluent materials to metal, e.g. car bodies
B23K 20/02 - Non-electric welding by applying impact or other pressure, with or without the application of heat, e.g. cladding or plating by means of a press
C23C 28/02 - Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of main groups , or by combinations of methods provided for in subclasses and only coatings of metallic material
C23C 30/00 - Coating with metallic material characterised only by the composition of the metallic material, i.e. not characterised by the coating process
A method of manufacturing a ferrous alloy article is disclosed and includes the steps of melting a ferrous alloy composition into a liquid, atomizing and solidifying of the liquid into powder particles, outgassing to remove oxygen from the surface of the powder particles, and consolidating the powder particles into a monolithic article.
B22F 3/17 - Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor by forging
A ferrous alloy is provided for coining. The ferrous alloy includes a composition of: 4.00- 10.80 wt % of chromium (Cr), 8.00-25.00 wt % of nickel (Ni), 3.00-6.00 wt % of copper (Cu), and a balance of iron (Fe) and incidental impurities.
A ferrous alloy is provided for coining The ferrous alloy includes a composition of: 4.00-10.80 wt % of chromium (Cr), 8.00-25.00 wt % of nickel (Ni), 3.00-6.00 wt % of copper (Cu), and a balance of iron (Fe) and incidental impurities.
C22C 38/58 - Ferrous alloys, e.g. steel alloys containing chromium with nickel with more than 1.5% by weight of manganese
C22C 38/34 - Ferrous alloys, e.g. steel alloys containing chromium with more than 1.5% by weight of silicon
B21B 1/02 - Metal rolling methods or mills for making semi-finished products of solid or profiled cross-section; Sequence of operations in milling trains; Layout of rolling-mill plant, e.g. grouping of stands; Succession of passes or of sectional pass alternations for rolling heavy work, e.g. ingots, slabs, billets, in which the cross-sectional form is unimportant
B21D 19/00 - Flanging or other edge treatment, e.g. of tubes
B21D 28/02 - Punching blanks or articles with or without obtaining scrap; Notching
B24B 1/00 - Processes of grinding or polishing; Use of auxiliary equipment in connection with such processes
A precipitation hardenable, martensitic stainless steel alloy is disclosed. The alloy has the following composition in weight percent, about C 0.03 max Mn 1.0 max Si 0.75 max P 0.040 max s 0.020 max Cr 10 - 13 Ni 10.5 - 11.6 Mo 0.25 - 1.5 Co 0.5-1.5 Cu 0.75 max Ti 1.5 - 1.8 Al 0.3 - 0.8 Nb 0.3 - 0.8 B 0.010 max N 0.030 max The balance is iron and usual impurities. The disclosed alloy provides a unique combination of corrosion resistance, strength, and toughness.
A quench and temper steel alloy is disclosed having the following composition in weight percent. C 0.2-0.5 Mn 0.1-1.0 Si 0.1-1.2 Cr 9-14.5 Ni 3.0-5.5 Mo 1-2 Cu 0-1.0 Co 1-4 W 0.2 max. V 0.1-1.0 Ti up to 0.5 Nb 0-0.5 Ta 0-0.5 Al 0-0.25 Ce 0-0.01 La 0-0.01 The balance of the alloy is iron and the usual impurities found in similar grades of quench and temper steels intended for similar use or service, including not more than 0.01% phosphorus, not more than 0.010%) sulfur, and not more than 0.10% nitrogen. A quenched and tempered steel article made from this alloy is also disclosed. The steel article is characterized by having a tensile strength of at least 290 ksi and a fracture toughness (Klc) of at least 65 ksi. The steel article is further characterized by having good resistance to general corrosion as determined by the salt spray test (ASTM Bl 17) and good resistance to pitting corrosion as determined by the cyclic potentiodynamic polarization method (ASTM G61 Modified).
A high strength, high toughness steel alloy is disclosed having the following weight percent composition. Element C 0.30-0.55 Mn 0.6-1.75 Si 0.9-2.8 Cr 0.6-2.5 Ni 2.70-7.0 Mo + ½ W 0.25-1.3 Cu 0.30-1.25 Co 0.01 max. V + (5/9) x Nb 0.10-1.0 Ti 0.01 max. Al 0.015 max. Ca 0.005 max. The alloy further includes a grain refining element selected from the group consisting of 0.0001- 0.01% Mg, 0.001-0.025% Y, and a combination thereof. The balance of the alloy is iron and usual impurities. Also disclosed is a hardened and tempered steel article having very high strength and fracture toughness and formed from the alloy set forth above. The alloy article according to this aspect of the invention is further characterized by being tempered at a temperature of about 500°F to 600°F.
A method and apparatus for producing titanium metal powder from a melt. The apparatus includes an atomization chamber having an inner wall that is coated with or formed entirely of CP-Ti to prevent contamination of titanium metal powder therein. The inner surfaces of all components of the apparatus in a flow path following the atomization chamber may also be coated with or formed entirely of CP-Ti.
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
37 - Construction and mining; installation and repair services
Goods & Services
Oil and gas field down-hole equipment tooling, namely, stabilizers, drill collars, subs, hole openers and bottom-hole assembly tools Repair and maintenance of down-hole equipment tooling and assemblies used in the drilling of oil and gas wells; leasing and rental of oil well drilling and production tools, namely, drill collars, stabilizers, subs, hole openers, float valves, baffle plates, sleeves, and drillpipe screens
A high strength, high toughness steel alloy is disclosed. The alloy has the following weight percent composition. Element C 0.30-0.47 Mn 0.8-1.3 Si 1.5-2.5 Cr 1.5-2.5 Ni 3.0-5.0 Mo + ½ W 0.7-0.9 Cu 0.70-0.90 Co 0.01 max. V + (5/9) x Nb 0.10-0.25 Ti 0.005 max. Al 0.015 max. Fe Balance Included in the balance are the usual impurities found in commercial grades of steel alloys produced for similar use and properties including not more than about 0.01% phosphorus and not more than about 0.001% sulfur. Also disclosed is a hardened and tempered article that has very high strength and fracture toughness. The article is formed from the alloy having the weight percent composition set forth above. The alloy article according to this aspect of the invention is further characterized by being tempered at a temperature of about 500°F to 600°F.
A corrosion resistant, neutron absorbing, austenitic alloy powder is disclosed having the following composition in weight percent. C 0.08 max., Mn up to 3, Si up to 2, P 0.05 max., S 0.03 max., Cr 17-27, Ni 11-20, Mo+(W/1.92) up to 5.2, BEq 0.78-13.0, O 0.1 max., N up to 0.2, Y less than 0.005. The alloy contains at least about 0.25% B, at least about 0.05% Gd, and the balance of the alloy composition is iron and usual impurities. BEq is defined as %>B + 4.35x(%>Gd). An article of manufacture made from consolidated alloy powder is also disclosed which is characterized by a plurality of boride and gadolinide particles dispersed within a matrix. The boride and gadolinide particles are predominantly M2B, M3B2, M3X, and M5X in form, where X is gadolinium or a combination of gadolinium and boron and M is one or more of the elements silicon, chromium, nickel, molybdenum, iron.
A stainless steel strip article is disclosed. The article is formed from a corrosion resistant alloy having the following composition in weight percent, C 0.03 max. Mn 1.0 max. Si 0.75 max. P 0.040 max. S 0.020 max. Cr 10.9-11.1 Ni 10.9-11.1 Mo 0.9-1.1 Ti 1.5-1.6 Al 0.25 max. Nb 0.7-0.8 Cu 1 max. B 0.010 max. N 0.030 max. The balance is iron and usual impurities. The elongated thin strip article provides a room temperature tensile strength of at least 280 ksi (1930.5 MPa) in the solution treated and age hardened condition. A method of making the strip article and a method of using it to make a golf club are also disclosed.
C21D 7/02 - Modifying the physical properties of iron or steel by deformation by cold working
C21D 8/02 - Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips
C21D 8/04 - Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of plates or strips to produce plates or strips for deep-drawing
C22C 38/48 - Ferrous alloys, e.g. steel alloys containing chromium with nickel with niobium or tantalum
C22C 38/50 - Ferrous alloys, e.g. steel alloys containing chromium with nickel with titanium or zirconium
50.
FREE-MACHINING POWDER METALLURGY STEEL ARTICLES AND METHOD OF MAKING SAME
A small diameter, elongated steel article, comprising fully consolidated, prealloyed metal powder is disclosed. The consolidated metal powder has a microstructure that has a substantially uniform distribution of fine grains having a grain size of not larger than about 9 when determined in accordance with ASTM Standard Specification E 112. The microstructure of the consolidated metal powder is further characterized by having a plurality of substantially spheroidal carbides uniformly distributed throughout the consolidated metal powder that are not greater than about 6 microns in major dimension and a plurality of sulfides uniformly distributed throughout the consolidated metal powder wherein the sulfides are not greater than about 2 microns in major dimension. A process for making the elongated steel article is also disclosed.
B22F 5/12 - Manufacture of workpieces or articles from metallic powder characterised by the special shape of the product of tubes or wires
B22F 9/08 - Making metallic powder or suspensions thereof; Apparatus or devices specially adapted therefor using physical processes starting from liquid material by casting, e.g. through sieves or in water, by atomising or spraying
C22C 33/02 - Making ferrous alloys by powder metallurgy
C21D 8/06 - Modifying the physical properties by deformation combined with, or followed by, heat treatment during manufacturing of rods or wires
A high strength, high toughness steel alloy is disclosed. The alloy has the following broad weight percent composition. Included in the balance are the usual impurities found in commercial grades of steel alloys produced for similar use and properties. Also disclosed is a hardened and tempered article that has very high strength and fracture toughness. The article is formed from the alloy having the broad weight percent composition set forth above. The alloy article according to this aspect of the invention is further characterized by being tempered at a temperature of about 500°F to 600°F.
A process for making a precipitation hardenable stainless steel alloy is described. The process includes the step of melting a martensitic steel alloy having the following composition in weight percent, about Carbon 0.03 max. Manganese 1.0 max. Silicon 0.75 max. Phosphorus 0.040 max. Sulfur 0.020 max. Chromium 10-13 Nickel 10.5-11.6 Titanium 1.5-1.8 Molybdenum 0.25-1.5 Copper 0.95 max. Aluminum 0.25 max. Niobium 0.3 max. Boron 0.010 max. Nitrogen 0.030 max. and the balance being iron and usual impurities. The process also includes the step of adding calcium to the alloy while molten. The calcium combines with available sulfur and oxygen to form calcium base inclusions selected from the group consisting of calcium sulfides, calcium oxides, calcium oxysulfides, and combinations thereof. In a further step, the alloy is processed to remove at least a portion of the calcium base inclusions. The alloy is then solidified. As a result of the process, the alloy has a matrix containing a sparse dispersion of said calcium-based inclusions and substantially no rare-earth base inclusions.
An age hardenable, martensitic steel alloy that provides high strength, high toughness, and good low cycle fatigue life and a method of making same are disclosed. The alloy comprises a matrix having a weight percent composition consisting essentially of about Carbon 0.2-0.36 Manganese 0.20 max. Silicon 0.10 max. Phosphorus 0.01 max. Sulfur 0.004 max. Chromium 1.3-4 Nickel 10-15 Molybdenum 0.75-2.7 Cobalt 8-22 Aluminum 0.01 max. Titanium 0.02 max. Calcium 0.001 max. and the balance being iron and usual impurities. The alloy further contains a plurality of inclusions dispersed in the alloy matrix. The inclusions comprise calcium compounds that are about 0.4μm to about 7.0μm in major dimension, they have a median size of at least about 1.6μm in major dimension, and the inclusions contain essentially no rare earth elements.
Medical devices, such as endoprostheses, and methods of making the devices are disclosed. The endoprostheses comprise a tubular member capable of maintaining patency of a bodily vessel. The tubular member includes a mixture of at least two compositions, where the presence of the second composition gives the mixture a greater hardness than that of the first composition alone. The first composition includes less than about 25 weight percent chromium, less than about 7 weight percent molybdenum, from about 10 to about 35 weight percent nickel, and iron. The second composition is different from the first and is present from about 0.1 weight percent to about 5 weight percent of the mixture.
A61L 27/42 - Composite materials, i.e. layered or containing one material dispersed in a matrix of the same or different material having an inorganic matrix
A61L 31/12 - Composite materials, i.e. layered or containing one material dispersed in a matrix of the same or different material
A61L 31/18 - Materials at least partially X-ray or laser opaque
55.
Method of producing high strength, high stiffness and high ductility titanium alloys
A method of producing a high strength, high stiffness and high ductility titanium alloy, comprising combining the titanium alloy with boron so that the boron concentration in the boron-modified titanium alloy does not exceed the eutectic limit. The carbon concentration of the boron-modified titanium alloy is maintained below a predetermined limit to avoid embrittlement. The boron-modified alloy is heated to a temperature above the beta transus temperature to eliminate any supersaturated excess boron. The boron-modified titanium alloy is deformed at a speed slow enough to prevent microstructural damage and reduced ductility.
A corrosion-resistant, free-machining, magnetic stainless steel alloy is described. The alloy has the following weight percent composition: 0.025 max. C, 0.60 max. Mn, 1.0-2.0 Si, 0.035 max. P, 0.1 5-0.40 S, 12.0-14.0 Cr, 0.5 max. Ni, 0.5-1.3 Mo, 0.5-1.3 V, 0.5 max. Cu, 0.020 max. Al, 0.025 max. N, and the balance is iron and usual impurities.
An age hardenable martensitic steel alloy is disclosed. The alloy has the following composition in weight percent. C 0.30-0.36; Mn 0.05 max.; Si 0.05 max.; P 0.01 max.; S 0.0010 max.; Cr 1.30-3.2; Ni 10.0-13.0; Mo 1.0-2.70; Co 13.8-17.4; Ti 0.02 max.; Al 0.005 max.; Ce 0.030 max.; La 0.010 max. The balance is iron and the usual impurities. The composition of this alloy is balanced to provide a unique combination of very high strength, together with good toughness, ductility, and resistance to fatigue.
A corrosion resistant, martensitic steel alloy having very good cold formability is described. The alloy has the following weight percent composition. Carbon 0.10-0.40 Manganese 0.01 -2.0 Silicon 2.0 max. Phosphorus 0.2 max. Sulfur 0.030 max. Chromium 10-15 Nickel 0.5 max. Molybdenum 0.75-4.0 Nitrogen 0.02-0.15 Copper 1 .5-4.0 Titanium 0.01 max. Aluminum 0.01 max. Niobium + 0.10 max. Tantalum Vanadium 0.20 max. Zirconium less than 0.001 Calcium less than 0.001 The balance of the alloy is essentially iron. Nickel and copper are balanced in the alloy such that the ratio Ni/Cu is less than 0.2. A second embodiment of the alloy contains at least about 0.005% sulfur, selenium, or a combination thereof to provide good machinability.
A method of reducing the oxygen content of a powder is provided. A canister is prepared with a getter, filled with the powder to be densified, sealed and evacuated. The canister is subjected to a hydrogen atmosphere at an elevated temperature whereby hydrogen diffuses into the canister through the walls thereof. The hydroge forms moisture when reacted with the oxygen of the powder and the moisture in the reacted with the getter in order to remove oxygen from the powder to the getter. The atmosphere outside the canister is then altered to an inert atmosphere or vacuum, whereby hydrogen diffuses out of the canister. A dense body having a controlled amount of oxygen can thereafter be produced by conventional powder metallurgy techniques.
A martensitic alloy in which the ASTM grain size number is at least 5, including (wt. %) up to about 0.5% C, at least about 5% Cr, at least about 0.5% Ni, up to about 15% Co, up to about 8% Cu, up to about 8% Mn, up to about 4% Si, up to about 6% (Mo + W), up to about 1.5% Ti, up to about 3% V, up to about 0.5% Al, and at least about 40% Fe.