Carbosiliconizing ferrous substrates

Claim 2

A process for treating ferrous metals comprising the steps of: exposing the ferrous metal to diffusible carbon, boron and silicon during a single thermal cycle; and controlling the conditions at the ferrous metal surface to initially carburize the ferrous metal surface and subsequently boronize and siliconize the ferrous metal surface, forming a gradual transition between the carburized layer and the boronized and siliconized layer.

Claim 3

The ferrous metal having a surface layer formed by the process of claim 1.

Claim 4

A process for treating a ferrous metal, comprising the steps of: exposing the ferrous metal to diffusible carbon, boron and silicon within a single thermal cycle without an intermediate cooling stage; and varying the temperature at the ferrous metal surface to initially enhance diffusion of carbon into the surface to create a carburized substrate to enhance the heat treatability of the ferrous metal and subsequently enhance diffusion of boron and silicon to form a surface layer with a gradual transition between the substrate and surface layer.

Claim 5

A process for treating a ferrous metal, comprising the steps of: exposing the ferrous metal to diffusible carbon, boron and silicon within a single thermal cycle without an intermediate cooling stage; and varying the temperature at the ferrous metal surface to initially enhance diffusion of carbon into the surface to create a carburized substrate to enhance the heat treatability of the ferrous metal and subsequently enhance diffusion of boron and silicon to form a surface layer with a gradual transition between the substrate and surface layer.

Claim 6

The process of claim 3 wherein the variation of temperature to enhance boron and silicon diffusion operates to create an intermediate surface layer rich with B 6 Si, SiC, Fe 2 B and FeSi and an upper surface layer rich with B 3 Si B 4 C, SiC, FeB and FeSi.

Claim 7

The ferrous metal having a surface layer formed in accordance with the process of claim 3.

Claim 8

A process for treating a ferrous metal, comprising the steps of: exposing the surface of the ferrous metal to diffusible carbon, boron and silicon contained in a composition consisting of 5-20 weight % amorphous boron, 2-10% silicon powder, 2-15% alkyli earth activator, and 70-90% of a carbon bearing compound consisting of a homogenous blend of 10-30% barium carbonate, 5-20% calcium carbonate and the remaining a mixture consisting of 70-90% bonded and crushed hardwood charcoal and coke 5-20%; and varying the temperature at the ferrous metal surface to initially enhance diffusion of carbon to create a carburized substrate to enhance the heat treatability of the ferrous metal and subsequently enhance diffusion of boron and silicon without intermediate cooling to form a surface layer with a gradual transition between the substrate and surface layer.

Claim 9

A process for treating a ferrous metal, comprising the steps of: exposing the surface of the ferrous metal to diffusible carbon, boron and silicon contained in a composition consisting of 5-20 weight % amorphous boron, 2-10% silicon powder, 2-15% alkyli earth activator, and 70-90% of a carbon bearing compound consisting of a homogenous blend of 10-30% barium carbonate, 5-20% calcium carbonate and the remaining a mixture consisting of 70-90% bonded and crushed hardwood charcoal and coke 5-20%; and varying the temperature at the ferrous metal surface to initially enhance diffusion of carbon to create a carburized substrate to enhance the heat treatability of the ferrous metal and subsequently enhance diffusion of boron and silicon without intermediate cooling to form a surface layer with a gradual transition between the substrate and surface layer.

Claim 10

The process of claim 6 wherein said step of varying the temperature includes the step of maintaining the ferrous metal surface at a temperature in the range 1400°-1650° F. for enhanced carbon , diffusion and elevating the temperature to within the range 1650°-2000° F. to enhance boron and silicon diffusion.

Claim 11

The method of claim 6 wherein the alkyli earth activator comprises sodiumfluoro silicide.

Claim 12

The method of claim 6 wherein said alkyli earth activator comprises potassium fluoride.

Claim 13

The process of claim 7 wherein the rate of temperature elevation is set to provide a gradation between the carbide substrate and surface layer to resist surface cracking.

Claim 14

The method of claim 6 wherein silicon carbide is substituted for silicon powder.

Claim 15

The ferrous metal having a surface treated by the process of claim 6.

Claim 16

A ferrous metal, comprising: an outer surface layer having a carburized substrate and a boronized and siliconized outer surface layer with a gradual transition therebetween formed by exposing the ferrous metal to diffusible carbon, boron and silicon during a single thermal cycle without intermediate cooling between the diffusion of carbon and boron and controlling the thermal conditions at the ferrous metal surface to initially enhance carbon diffusion to form the carburized substrate and subsequently enhance boron and silicon diffusion to form the outer surface layer.

Claim 17

A ferrous metal, comprising: an outer surface layer having a carburized substrate and a boronized and siliconized outer surface layer with a gradual transition therebetween formed by exposing the ferrous metal to diffusible carbon, boron and silicon during a single thermal cycle without intermediate cooling between the diffusion of carbon and boron and controlling the thermal conditions at the ferrous metal surface to initially enhance carbon diffusion to form the carburized substrate and subsequently enhance boron and silicon diffusion to form the outer surface layer.

Claim 18

A ferrous metal comprising: an outer surface having a carburized substrate and a boronized and siliconized outer surface layer with a gradual transition therebetween formed by exposing the ferrous metal to diffusible carbon, boron and silicon in a furnace at a first temperature enhancing diffusion of the carbon to form a carburized substrate for improved heat treatability characteristics and subsequently elevating the furnace temperature to a second temperature to enhance diffusion of boron and silicon to form the outer layer, the diffusion of carbon, boron and silicon being performed during a single thermal cycle without intermediate cooling between the first and second temperatures, the elevation of temperature providing a gradual transition between the carburized substrate and outer surface layer.

Claim 19

A ferrous metal comprising: an outer surface having a carburized substrate and a boronized and siliconized outer surface layer with a gradual transition therebetween formed by exposing the ferrous metal to diffusible carbon, boron and silicon in a furnace at a first temperature enhancing diffusion of the carbon to form a carburized substrate for improved heat treatability characteristics and subsequently elevating the furnace temperature to a second temperature to enhance diffusion of boron and silicon to form the outer layer, the diffusion of carbon, boron and silicon being performed during a single thermal cycle without intermediate cooling between the first and second temperatures, the elevation of temperature providing a gradual transition between the carburized substrate and outer surface layer.

Claim 20

A process for treating a ferrous metal, comprising the steps of: exposing the ferrous metal to a gas containing diffusible carbon at a first temperature to diffuse carbon into the surface of the ferrous metal to form a carburized substrate; purging the carbon bearing gas from about the ferrous metal with an inert gas; exposing the ferrous metal to a gas containing diffusible boron and silicon at a second temperature without cooling of the ferrous metal from the first temperature to form a boron and silicon rich surface layer with a gradual transition between the base metal, carburized substrate and boron and silicon rich surface.

Claim 21

A process for treating a ferrous metal, comprising the steps of: exposing the ferrous metal to a gas containing diffusible carbon at a first temperature to diffuse carbon into the surface of the ferrous metal to form a carburized substrate; purging the carbon bearing gas from about the ferrous metal with an inert gas; exposing the ferrous metal to a gas containing diffusible boron and silicon at a second temperature without cooling of the ferrous metal from the first temperature to form a boron and silicon rich surface layer with a gradual transition between the base metal, carburized substrate and boron and silicon rich surface.

Claim 22

The process of claim 15 wherein said carbon bearing gas is methane.