Austenitic manganese steel-containing composite article

Claim 2

A metal composite article comprising: (a) a monolithic skeleton consisting essentially of interconnected granules of a ferroalloy of about 1 to about 100 micrometers mean diameter, having a core of martensitic or perlitic steel and an outer layer of austenitic manganese steel; and (b) a continuous metallic phase occupying the connected porosity in said skeleton, said continuous phase comprising a solid metal or alloy which wets said skeleton and has a melting point below the melting point of said core of said ferroalloy granules; with said manganese representing between about 4 percent and about 70 percent of the total weight of said continuous metallic phase plus said manganese of said layer, said article thereby comprising two intermeshed matrices and being substantially free of voids.

Claim 3

An article according to claim 1, wherein said ferroalloy granules are about 50 to about 80 percent of the volume of said article.

Claim 4

An article according to claim 1, wherein said ferroalloy granules are about 65 to about 75 percent of the volume of said article.

Claim 5

An article according to claim 1, wherein said granules of ferroalloy have a mean diameter of about 1 to about 44 micrometers.

Claim 6

An article according to claim 1, wherein said core of said ferroalloy is A 6 tool steel.

Claim 7

An article according to claim 1, wherein said continuous metallic phase is about 20 to about 50 percent of the volume of said article

Claim 8

An article according to claim 1, wherein said continuous metallic phase is about 25 to about 35 percent of the volume of said article

Claim 9

An article according to claim 1, wherein said continuous metallic phase is copper alloy.

Claim 10

An article according to claim 1, wherein said core is A 6 tool steel and said continuous metallic phase comprises copper-manganese alloy.

Claim 11

An article according to claim 1, wherein said manganese of said layer of austenitic manganese steel is about 15 to about 45 percent of the total weight of said continuous metallic phase plus said manganese of said layer.

Claim 12

An article according to claim 1, wherein said manganese of said layer of austenitic manganese steel is about 20 to about 30 percent of the total weight of said continuous metallic phase plus said manganese of said layer.

Claim 13

A precision molded die cavity comprising: (a) about 50 to about 80 volume percent of a monolithic ferroalloy skeleton of interconnected granules of about 1 to about 44 micrometers mean diameter, said granules consisting essentially of a core of A 6 tool steel and an outer layer of austenitic manganese steel; and (b) about 20 to about 50 volume percent of a continuous metallic phase comprising copper-manganese alloy, said continuous metallic phase occupying the connected porosity in said skeleton; with said manganese of said layer of austenitic manganese steel representing between about 4 percent and about 70 percent of the total weight of said continuous metallic phase plus said manganese of said layer, said article thereby comprising two intermeshed matrices and being substantially free of voids.

Claim 14

A precision molded die cavity comprising: (a) about 50 to about 80 volume percent of a monolithic ferroalloy skeleton of interconnected granules of about 1 to about 44 micrometers mean diameter, said granules consisting essentially of a core of A 6 tool steel and an outer layer of austenitic manganese steel; and (b) about 20 to about 50 volume percent of a continuous metallic phase comprising copper-manganese alloy, said continuous metallic phase occupying the connected porosity in said skeleton; with said manganese of said layer of austenitic manganese steel representing between about 4 percent and about 70 percent of the total weight of said continuous metallic phase plus said manganese of said layer, said article thereby comprising two intermeshed matrices and being substantially free of voids.

Claim 15

A die cavity according to claim 12, wherein said manganese of said layer is about 15 to about 45 percent of the weight of said total weight.

Claim 16

A die cavity according to claim 12, wherein said manganese is about 20 to about 30 percent of the weight of said total weight.

Claim 17

A process for forming a precision molded composite article, comprising the steps of: (a) blending granules of iron powder having about 1 to about 100 micrometers mean diameter with up to 50 volume percent of a heat fugitive, organic binder, thereby forming a uniform mixture; (b) molding the resulting mixture in a heated flexible mold, cooling said mold and its contents to room temperature, and demolding said contents by applying a vacuum to the outside of said mold thereby forming an essentially void-free green molded preform having the size and shape of said mold; (c) heating said green molded preform to thermally remove said binder and form a rigid, handleable skeletal preform; (d) placing said skeletal preform in contact with a metal or alloy infiltrant which will wet said skeleton and which has a melting point less than or equal to the melting point of said iron powder; (e) infiltrating said skeletal preform with said infiltrant by heating said skeletal preform and said infiltrant above the melting point of said infiltrant, but below the melting point of said iron powder, whereby said infiltrant melts and wicks into the connected porosity of said preform by capillary action and fully envelopes said granules of iron powder, with a first proviso that if said iron powder granules are plain iron, then carbon is added to said mixture of step (a), or carbon is present in said infiltrant alloy of step (b), a second proviso that manganese granules are added to said mixture of step (a), or manganese is present in said infiltrant of step (d), and said manganese is about 4 to about 70 percent of the weight of said infiltrant plus the weight of said manganese granules, and a third proviso that said heating of this step (e) is carried out until said manganese diffuses into the outer surface region of said iron powder granules, thereby forming ferroalloy granules consisting essentially of an outer layer of austenitic manganese steel and a core of martensitic or perlitic steel; and (f) cooling the infiltrated part to room temperature to form a substantially void-free precision molded article.

Claim 18

A process for forming a precision molded composite article, comprising the steps of: (a) blending granules of iron powder having about 1 to about 100 micrometers mean diameter with up to 50 volume percent of a heat fugitive, organic binder, thereby forming a uniform mixture; (b) molding the resulting mixture in a heated flexible mold, cooling said mold and its contents to room temperature, and demolding said contents by applying a vacuum to the outside of said mold thereby forming an essentially void-free green molded preform having the size and shape of said mold; (c) heating said green molded preform to thermally remove said binder and form a rigid, handleable skeletal preform; (d) placing said skeletal preform in contact with a metal or alloy infiltrant which will wet said skeleton and which has a melting point less than or equal to the melting point of said iron powder; (e) infiltrating said skeletal preform with said infiltrant by heating said skeletal preform and said infiltrant above the melting point of said infiltrant, but below the melting point of said iron powder, whereby said infiltrant melts and wicks into the connected porosity of said preform by capillary action and fully envelopes said granules of iron powder, with a first proviso that if said iron powder granules are plain iron, then carbon is added to said mixture of step (a), or carbon is present in said infiltrant alloy of step (b), a second proviso that manganese granules are added to said mixture of step (a), or manganese is present in said infiltrant of step (d), and said manganese is about 4 to about 70 percent of the weight of said infiltrant plus the weight of said manganese granules, and a third proviso that said heating of this step (e) is carried out until said manganese diffuses into the outer surface region of said iron powder granules, thereby forming ferroalloy granules consisting essentially of an outer layer of austenitic manganese steel and a core of martensitic or perlitic steel; and (f) cooling the infiltrated part to room temperature to form a substantially void-free precision molded article.

Claim 19

A process according to claim 15, wherein said iron powder granules are selected from the group consisting of A 6 , 1040, 1018, and M 2 tool steels.

Claim 20

A process according to claim 15, wherein manganese is present in said infiltrant of step (d).

Claim 21

A process according to claim 17, wherein said infiltrant comprises copper-manganese alloy.

Claim 22

A process according to claim 15, wherein said manganese is about 15 to 45 percent of the weight of said infiltrant.

Claim 23

A process according to claim 15, wherein said manganese is about 20 to 30 percent of the weight of said infiltrant.

Claim 24

A process according to claim 15, wherein said iron powder granules comprise A 6 tool steel and are between about 65 and about 75 percent of the volume of said article, said infiltrant comprises copper-manganese alloy and is about 25 to about 75 percent of the volume of said article, said manganese is about 15 to about 45 percent of the weight of said infiltrant, and said molded article is a die cavity.

Claim 25

A process according to claim 15, wherein the change in any lineal dimension between the dimensions of said void-free green molded preform and the dimensions of said void-free precision article is less than about 1 percent.

Claim 26

A process according to claim 22, wherein said change in any lineal dimension is less than about 0.5 percent.

Claim 27

A process according to claim 22, wherein said article has a density at least 97 percent of the theoretical density of said article.

Claim 28

A process according to claim 22, wherein said article has a density at least 99 percent of the theoretical density of said article.