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Polymer quenched prealloyed metal powder

Patent ·
OSTI ID:874011
 [1];  [1];  [2]
  1. Midlothian, VA
  2. State College, PA
+ Show Author Affiliations
A powder metallurgical process of preparing a sheet from a powder having an intermetallic alloy composition such as an iron, nickel or titanium aluminide. The sheet can be manufactured into electrical resistance heating elements having improved room temperature ductility, electrical resistivity, cyclic fatigue resistance, high temperature oxidation resistance, low and high temperature strength, and/or resistance to high temperature sagging. The iron aluminide has an entirely ferritic microstructure which is free of austenite and can include, in weight %, 4 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.0.05% Zr .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Ni, .ltoreq.0.75% C, .ltoreq.0.1% B, .ltoreq.1% submicron oxide particles and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1% rare earth metal, and/or .ltoreq.3 % Cu. The process includes forming a non-densified metal sheet by consolidating a powder having an intermetallic alloy composition such as by roll compaction, tape casting or plasma spraying, forming a cold rolled sheet by cold rolling the non-densified metal sheet so as to increase the density and reduce the thickness thereof and annealing the cold rolled sheet. The powder can be a water, polymer or gas atomized powder which is subjecting to sieving and/or blending with a binder prior to the consolidation step. After the consolidation step, the sheet can be partially sintered. The cold rolling and/or annealing steps can be repeated to achieve the desired sheet thickness and properties. The annealing can be carried out in a vacuum furnace with a vacuum or inert atmosphere. During final annealing, the cold rolled sheet recrystallizes to an average grain size of about 10 to 30 .mu.m. Final stress relief annealing can be carried out in the B2 phase temperature range.
Research Organization:
LOCKHEED MARTIN ENRGY SYST INC
DOE Contract Number:
AC05-84OR21400
Assignee:
Chrysalis Technologies Incorporated (Richmond, VA)
Patent Number(s):
US 6293987
OSTI ID:
874011
Country of Publication:
United States
Language:
English

References (4)

The effect of ternary additions on the vacancy hardening of FeAl journal April 1994
Microstructure and tensile properties of Fe-40 At. pct Al alloys with C, Zr, Hf, and B additions journal September 1989
Powder Processing of Fe 3 Al-Based Iron-Aluminide Alloys journal January 1990
A review of recent developments in Fe 3 Al-based alloys journal August 1991

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Related Subjects

/75/
05
10
30
32
75
achieve
additions
alloy
alloy composition
aluminide
annealing
annealing step
annealing steps
atmosphere
atomized
atomized powder
austenite
average
average grain
b2
binder
blending
carried
casting
ceramic
ceramic particle
ceramic particles
cold
cold rolled
cold rolling
compaction
composition
conductive
conductive covalent
consolidating
consolidation
consolidation step
covalent
covalent ceramic
cu
cyclic
cyclic fatigue
density
desired
ductility
earth
earth metal
electrical
electrical resistance
electrical resistivity
electrically
electrically conductive
electrically insulating
elements
entirely
entirely ferritic
fatigue
fatigue resistance
ferritic
ferritic microstructure
final
forming
free
furnace
gas
gas atomized
grain
grain size
gtoreq
heating
heating element
heating elements
improved
increase
inert
inert atmosphere
insulating
intermetallic
intermetallic alloy
iron
iron aluminide
ltoreq
manufactured
metal
metal powder
metal sheet
metallic alloy
metallurgical
metallurgical process
microstructure
nickel
non-densified
optional
optional additions
oxidation
oxidation resistance
oxide
oxide particle
oxide particles
partially
particles
phase
phase temperature
plasma
plasma spray
plasma spraying
polymer
powder
powder metallurgical
prealloyed
prealloyed metal
preparing
prior
process
properties
quenched
range
rare
rare earth
recrystallizes
reduce
relief
repeated
resistance
resistance heat
resistance heating
resistivity
roll
roll compaction
rolled
rolled sheet
rolling
sagging
sheet
sheet thickness
sieving
sintered
size
spraying
step
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strength
stress
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subjecting
submicron
tape
tape cast
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temperature
temperature ductility
temperature oxidation
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temperature sagging
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thickness
titanium
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vacuum
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zr