Production of carbide laden consumables in a graphite mold

Claim 1

A method of producing a carbide laden consumable in the form of a composite rod which comprises, providing a graphite mold having at least one elongated U-shaped groove therein, said at least one groove containing a charge of fusible ingredients comprising a first layer of powdered self-fluxing matrix metal alloy at the bottom of said groove, a second layer of particulate refractory metal carbide on top of said first layer and a third layer of said matrix metal alloy on top of said second layer, said first layer of said powdered matrix metal constituting about 25% to 50% of the total combined first and third layers, with the third layer making up the balance of the total combined first and third layers. the composition of said matrix metal alloy and said refractory carbide together in said mold ranging by weight from about 80% to 30% of said matrix metal alloy and the balance consisting essentially of about 20% to 70% of said refractory metal carbide, said self-fluxing matrix metal alloy being selected from the group consisting of Ni-base, Ni-Cu-base, Fe-base and Co-base alloys containing by weight at least one element selected from the group consisting of about 0.1% to 6% of silicon and about 0.1% to 5% boron and having a melting point ranging up to about 1370° C., said refractory metal carbide being selected from the group consisting of carbides of W, Mo, Cr, Zr, Ti, Hf, Nb, Ta, V, B and Si and mixtures of at least two of said carbides, passing said graphite mold through a furnace having a heating zone maintained at a temperature above the melting point of said matrix alloy, said furnace having a cooling zone immediately after said heating zone, the atmosphere in said furnace being reducing, causing said matrix alloy to melt and infiltrate the interstices in said carbide layer, and passing said graphite mold into said cooling zone immediately after said heating zone to solidify said matrix alloy and inhibit segregation of said refractory carbide to thereby produce a composite rod characterized by improved quality and improved strength.

Claim 2

A method of producing a carbide laden consumable in the form of a composite rod which comprises, providing a graphite mold having at least one elongated U-shaped groove therein, said at least one groove containing a charge of fusible ingredients comprising a first layer of powdered self-fluxing matrix metal alloy at the bottom of said groove, a second layer of particulate refractory metal carbide on top of said first layer and a third layer of said matrix metal alloy on top of said second layer, said first layer of said powdered matrix metal constituting about 25% to 50% of the total combined first and third layers, with the third layer making up the balance of the total combined first and third layers. the composition of said matrix metal alloy and said refractory carbide together in said mold ranging by weight from about 80% to 30% of said matrix metal alloy and the balance consisting essentially of about 20% to 70% of said refractory metal carbide, said self-fluxing matrix metal alloy being selected from the group consisting of Ni-base, Ni-Cu-base, Fe-base and Co-base alloys containing by weight at least one element selected from the group consisting of about 0.1% to 6% of silicon and about 0.1% to 5% boron and having a melting point ranging up to about 1370° C., said refractory metal carbide being selected from the group consisting of carbides of W, Mo, Cr, Zr, Ti, Hf, Nb, Ta, V, B and Si and mixtures of at least two of said carbides, passing said graphite mold through a furnace having a heating zone maintained at a temperature above the melting point of said matrix alloy, said furnace having a cooling zone immediately after said heating zone, the atmosphere in said furnace being reducing, causing said matrix alloy to melt and infiltrate the interstices in said carbide layer, and passing said graphite mold into said cooling zone immediately after said heating zone to solidify said matrix alloy and inhibit segregation of said refractory carbide to thereby produce a composite rod characterized by improved quality and improved strength.

Claim 3

A method of producing a carbide laden consumable in the form of a composite rod which comprises, providing a graphite mold having at least one elongated U-shaped groove therein, said at least one groove containing a charge of fusible ingredients comprising a first layer of powdered self-fluxing matrix metal alloy at the bottom of said groove, a second layer of particulate refractory metal carbide on top of said first layer and a third layer of said matrix metal alloy on top of said second layer, said first layer of said powdered matrix metal constituting about 25% to 50% of the total combined first and third layers, with the third layer making up the balance of the total combined first and third layers, the composition of said matrix metal alloy and said refractory carbide together in said mold ranging by weight from about 80% to 30% of said matrix metal alloy and the balance consisting essentially of about 20% to 70% of said refractory metal carbide, said self-fluxing alloy being selected from the group consisting of: (A) nickel-base matrix alloy containing about 1.5% to 5% Si, about 1.5% to 5% boron, up to about 20% chromium, up to about 7% molybdenum and the balance essentially nickel; (B) cobalt-base matrix alloys containing about 1% to 5% nickel, about 26% to 32% chromium, about 0.5% to 3% silicon, about 1% to 3% boron, about 0.8 to 2% carbon, about 3.5% to 7.5% tungsten, up to about 0.5% molybdenum and the balance essentially cobalt; (C) nickel-copper-base matrix alloys containing about 1% to 5% silicon, about 0.15% to 2.5% boron, about 0.2% to 2% manganese, about 15% to 40% copper and the balance essentially nickel; and (D) nickel silver matrix alloys containing about 2% to 20% nickel, about 28% to 58% zinc, 0.1% to 1% silicon, up to 1% silver and essentially the balance ranging from about 40% to 65% copper, said matrix alloy having a melting point ranging up to about 1370° F., said refractory carbide being selected from the group consisting of W, Mo, Cr, Zr, Ti, Hf, Nb, Ta, V, B and Si and mixtures of at least two of said carbides, passing said graphite mold on a conveyor through a furnace having a heating zone maintained at a temperature above the melting point of said matrix alloy, said furnace having a cooling zone immediately after said heating zone, the atmosphere in said furnace being reducing, causing said matrix alloy to melt and infiltrate the interstices in said carbide layer from said first and third layers, said passing said graphite mold into said cooling zone immediately after said heating zone to solidify said matrix alloy and inhibit segregation of said refractory carbide to thereby produce a composite rod characterized by improved quality and improved strength.

Claim 4

A method of producing a carbide laden consumable in the form of a composite rod which comprises, providing a graphite mold having at least one elongated U-shaped groove therein, said at least one groove containing a charge of fusible ingredients comprising a first layer of powdered self-fluxing matrix metal alloy at the bottom of said groove, a second layer of particulate refractory metal carbide on top of said first layer and a third layer of said matrix metal alloy on top of said second layer, said first layer of said powdered matrix metal constituting about 25% to 50% of the total combined first and third layers, with the third layer making up the balance of the total combined first and third layers, the composition of said matrix metal alloy and said refractory carbide together in said mold ranging by weight from about 80% to 30% of said matrix metal alloy and the balance consisting essentially of about 20% to 70% of said refractory metal carbide, said self-fluxing alloy being selected from the group consisting of: (A) nickel-base matrix alloy containing about 1.5% to 5% Si, about 1.5% to 5% boron, up to about 20% chromium, up to about 7% molybdenum and the balance essentially nickel; (B) cobalt-base matrix alloys containing about 1% to 5% nickel, about 26% to 32% chromium, about 0.5% to 3% silicon, about 1% to 3% boron, about 0.8 to 2% carbon, about 3.5% to 7.5% tungsten, up to about 0.5% molybdenum and the balance essentially cobalt; (C) nickel-copper-base matrix alloys containing about 1% to 5% silicon, about 0.15% to 2.5% boron, about 0.2% to 2% manganese, about 15% to 40% copper and the balance essentially nickel; and (D) nickel silver matrix alloys containing about 2% to 20% nickel, about 28% to 58% zinc, 0.1% to 1% silicon, up to 1% silver and essentially the balance ranging from about 40% to 65% copper, said matrix alloy having a melting point ranging up to about 1370° F., said refractory carbide being selected from the group consisting of W, Mo, Cr, Zr, Ti, Hf, Nb, Ta, V, B and Si and mixtures of at least two of said carbides, passing said graphite mold on a conveyor through a furnace having a heating zone maintained at a temperature above the melting point of said matrix alloy, said furnace having a cooling zone immediately after said heating zone, the atmosphere in said furnace being reducing, causing said matrix alloy to melt and infiltrate the interstices in said carbide layer from said first and third layers, said passing said graphite mold into said cooling zone immediately after said heating zone to solidify said matrix alloy and inhibit segregation of said refractory carbide to thereby produce a composite rod characterized by improved quality and improved strength.