Patent US4030946A successfully refreshed from Google Patents.
US4030946A
Expired / Lapsed
US
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Eliminating prior particle boundary delineation
Assignee: CRS Holdings LLC
•
Filing: 1976-04-13
•
Granted: 1977-06-21
•
Expires: 1996-04-13
Abstract
Abstract The process prevents prior powder particle boundary delineation by providing one or more surfactant elements which prevent nucleation of carbides at the particle surfaces with the result that carbide precipitation occurs within the powder particles rather than predominantly at the particle surfaces. In one embodiment, a small but effective amount of one or more surfactants is added to prealloyed powder before the powder is enclosed and densified at elevated temperature. In another embodiment, the surfactant is added to the melt of the prealloyed powder prior to atomization. The surfactant should be capable of forming a vapor under the conditions of hot densification, should be a strong oxide and/or sulfide former, must be a weak carbide former, should form oxides and/or sulfides which will not nucleate carbides of other elements, and which, if present in the article made from the powder, will not objectionably affect the desired properties. Useful surfactants include magnesium, barium, calcium, cerium, lanthanum, lithium, neodymium, praseodymium, yttrium, and misch metal.
Inventors
- 👤 Donald R. Muzyka
- 👤 Robert F. Walley
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 16:16
CPC Classifications
B; B22; B22F; B22F3/00; B22F3/10; B22F3/1003; Y; Y10; Y10S; Y10S75/00; Y10S75/95
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
138 words
A method for substantially eliminating prior powder particle boundary delineation in articles made from prealloyed powder densified to at least about 99% of theoretical density which includes placing in an enclosure a predetermined amount of the prealloyed powder with a predetermined amount of a surfactant and having substantially less then theoretical density, said surfactant comprising at least one metallic element which is a strong oxide and sulfide former and a weak carbide former as compared to the elements of said prealloyed powder, heating said prealloyed powder and surfactant to a predetermined temperature above the carbide solvus temperature and below the solidus temperature of said prealloyed powder, and densifying said prealloyed powder while it is above said carbide solvus temperature to at least about 99% of theoretical density with said surfactant available at the surfaces of the powder particles.
Claim 2
Independent Claim
138 words
A method for substantially eliminating prior powder particle boundary delineation in articles made from prealloyed powder densified to at least about 99% of theoretical density which includes placing in an enclosure a predetermined amount of the prealloyed powder with a predetermined amount of a surfactant and having substantially less then theoretical density, said surfactant comprising at least one metallic element which is a strong oxide and sulfide former and a weak carbide former as compared to the elements of said prealloyed powder, heating said prealloyed powder and surfactant to a predetermined temperature above the carbide solvus temperature and below the solidus temperature of said prealloyed powder, and densifying said prealloyed powder while it is above said carbide solvus temperature to at least about 99% of theoretical density with said surfactant available at the surfaces of the powder particles.
Claim 3
Dependent Claim
27 words
The method set forth in claim 1 in which at least part of said surfactant is present in vapor form in said enclosure at said predetermined temperature.
Claim 4
Dependent Claim
31 words
The method set forth in claim 2 in which said surfactant is selected from the group consisting of magnesium, barium, calcium, cerium, lanthanum, lithium, neodymium, praseodymium, yttrium, misch metal and potassium.
Claim 5
Dependent Claim
34 words
The method set forth in claim 3 in which said enclosure is evacuated to substantially below atmospheric pressure and then sealed before said prealloyed powder is densified to at least 99% of theoretical density.
Claim 6
Dependent Claim
16 words
The method set forth in claim 3 in which said surfactant is added to said enclosure.
Claim 7
Dependent Claim
30 words
The method set forth in claim 3 in which said surfactant is added to the molten alloy from which said powder is made just before the powder is made therefrom.
Claim 8
Dependent Claim
74 words
The method set forth in claim 3 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.005-0.50 Max.
Manganese 2.0 Max.
Silicon 1.0 Max.
Chromium 25 Max.
Nickel 20-80
Cobalt 25 Max.
Molybdenum 12 Max.
Tungsten 8 Max.
Titanium 0.5-10
Aluminum 0.2-10
Niobium 7 Max.
Boron 0.002-0.30
Tantalum 10 Max.
Zirconium 0.50 Max.
Hafnium 3.0 Max.
Rhenium 5.0 Max.
Vanadium 1.5 Max.
Iron 60 Max.
______________________________________
Claim 9
Dependent Claim
47 words
The method set forth in claim 7 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.02-0.06
Manganese 0.15 Max.
Silicon 0.20 Max.
Chromium 14-16
Cobalt 16-18
Molybdenum 4.5-5.5
Titanium 3.35-3.65
Aluminum 3.85-4.15
Boron 0.02-0.03
Zirconium 0.06 Max.
______________________________________
Claim 10
Dependent Claim
51 words
The method set forth in claim 7 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.05-0.09
Manganese 0.02 Max.
Silicon 0.10 Max.
Chromium 11.9-12.9
Cobalt 18-19
Molybdenum 2.8-3.6
Titanium 4.15-4.50
Aluminum 4.80-5.15
Boron 0.016-0.024
Vanadium 0.58-0.98
Zirconium 0.04-0.08
Iron 1 Max.
______________________________________
Claim 11
Dependent Claim
50 words
The method set forth in claim 7 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.04-0.09
Manganese 0.15 Max.
Silicon 0.20 Max.
Chromium 12-14
Cobalt 7-9
Molybdenum 3.3-3.7
Tungsten 3.3-3.7
Titanium 2.3-2.7
Aluminum 3.3-3.7
Niobium 3.3-3.7
Boron 0.006-0.015
Zirconium 0.03-0.07.
______________________________________
Claim 12
Dependent Claim
51 words
The method set forth in claim 7 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.15-0.20
Manganese 0.02 Max.
Silicon 0.02 Max.
Chromium 8-11
Cobalt 13-17
Molybdenum 2-4
Titanium 4.50-5.0
Aluminum 5.0-6.0
Boron 0.01-0.02
Vanadium 0.70-1.20
Zirconium 0.03-0.09
Iron 1 Max.
______________________________________
Claim 13
Independent Claim
134 words
A method for substantially eliminating prior powder particle boundary delineation in articles made from prealloyed powder densified to at least about 99% of theoretical density which includes placing in an enclosure a predetermined amount of the prealloyed powder with a predetermined amount of a surfactant and having substantially less then theoretical density, said surfactant comprising at least one element selected from the group consisting of magnesium, barium, calcium, cerium, lanthanum, lithium, neodymium, praseodymium, yttrium, misch metal and potassium, heating said prealloyed powder and surfactant to a predetermined temperature above the carbide solvus temperature and below the solidus temperature of said prealloyed powder, and densifying said prealloyed powder while it is above said carbide solvus temperature to at least about 99% of theoretical density with said surfactant available at the surfaces of the powder particles.
Claim 14
Independent Claim
134 words
A method for substantially eliminating prior powder particle boundary delineation in articles made from prealloyed powder densified to at least about 99% of theoretical density which includes placing in an enclosure a predetermined amount of the prealloyed powder with a predetermined amount of a surfactant and having substantially less then theoretical density, said surfactant comprising at least one element selected from the group consisting of magnesium, barium, calcium, cerium, lanthanum, lithium, neodymium, praseodymium, yttrium, misch metal and potassium, heating said prealloyed powder and surfactant to a predetermined temperature above the carbide solvus temperature and below the solidus temperature of said prealloyed powder, and densifying said prealloyed powder while it is above said carbide solvus temperature to at least about 99% of theoretical density with said surfactant available at the surfaces of the powder particles.
Claim 15
Dependent Claim
34 words
The method set forth in claim 12 in which said enclosure is evacuated to substantially below atmospheric pressure and then sealed before said prealloyed powder is densified to at least 99% of theoretical density.
Claim 16
Dependent Claim
16 words
The method set forth in claim 12 in which said surfactant is added to said enclosure.
Claim 17
Dependent Claim
30 words
The method set forth in claim 12 in which said surfactant is added to the molten alloy from which said powder is made just before the powder is made therefrom.
Claim 18
Dependent Claim
74 words
The method set forth in claim 12 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.005-0.50 Max.
Manganese 2.0 Max.
Silicon 1.0 Max.
Chromium 25 Max.
Nickel 20-80
Cobalt 25 Max.
Molybdenum 12 Max.
Tungsten 8 Max.
Titanium 0.5-10
Aluminum 0.2-10
Niobium 7 Max.
Boron 0.002-0.30
Tantalum 10 Max.
Zirconium 0.50 Max.
Hafnium 3.0 Max.
Rhenium 5.0 Max.
Vanadium 1.5 Max.
Iron 60 Max.
______________________________________
Claim 19
Dependent Claim
47 words
The method set forth in claim 16 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.02-0.06
Manganese 0.15 Max.
Silicon 0.20 Max.
Chromium 14-16
Cobalt 16-18
Molybdenum 4.5-5.5
Titanium 3.35-3.65
Aluminum 3.85-4.15
Boron 0.02-0.03
Zirconium 0.06 Max.
______________________________________
Claim 20
Dependent Claim
51 words
The method set forth in claim 16 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.05-0.09
Manganese 0.02 Max.
Silicon 0.10 Max.
Chromium 11.9-12.9
Cobalt 18-19
Molybdenum 2.8-3.6
Titanium 4.15-4.50
Aluminum 4.80-5.15
Boron 0.016-0.024
Vanadium 0.58-0.98
Zirconium 0.04-0.08
Iron 1 Max.
______________________________________
Claim 21
Dependent Claim
50 words
The method set forth in claim 16 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.04-0.09
Manganese 0.15 Max.
Silicon 0.20 Max.
Chromium 12-14
Cobalt 7-9
Molybdenum 3.3-3.7
Tungsten 3.3-3.7
Titanium 2.3-2.7
Aluminum 3.3-3.7
Niobium 3.3-3.7
Boron 0.006-0.015
Zirconium 0.03-0.07.
______________________________________
Claim 22
Dependent Claim
51 words
The method set forth in claim 16 in which the alloy of said prealloyed powder comprises in weight percent about ______________________________________
w/o
______________________________________
Carbon 0.15-0.20
Manganese 0.02 Max.
Silicon 0.02 Max.
Chromium 8-11
Cobalt 13-17
Molybdenum 2-4
Titanium 4.50-5.0
Aluminum 5.0-6.0
Boron 0.01-0.02
Vanadium 0.70-1.20
Zirconium 0.03-0.09
Iron 1 Max.
______________________________________
Claim 23
Dependent Claim
9 words
The article made by the method of claim 1.
Claim 24
Dependent Claim
9 words
The article made by the method of claim 3.
Claim 25
Dependent Claim
9 words
The article made by the method of claim 12.
References Cited (Backward Citations)
US3653982A
Cited
US3720551A
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US3884676A
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US3802938A
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US3953205A
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US3890816A
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1980-06-20 | 1980-12-20 | 1981-06-21 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1984-06-20 | 1984-12-20 | 1985-06-21 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1988-06-20 | 1988-12-20 | 1989-06-21 | $7700.00 | Window Closed / Lapsed |