Method of manufacturing iron aluminide by thermomechanical processing of elemental powders

Deevi, Seetharama C; Sikka, Vinod K; Hajaligol, Mohammed R

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Title: Method of manufacturing iron aluminide by thermomechanical processing of elemental powders

Abstract

A powder metallurgical process of preparing iron aluminide useful as 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 %, 20 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.05% Zr or ZrO.sub.2 stringers extending perpendicular to an exposed surface of the heating element, .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Zr, .ltoreq.1% C, .ltoreq.0.1% B, .ltoreq.30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1 % rare earth metal, .ltoreq.1% oxygen, and/or .ltoreq.3% Cu. The process includes forming a mixture of aluminum powder and iron powder, shaping the mixture into an article such as by cold rolling the mixture into a sheet, and sintering the article at a temperature sufficient to react the iron and aluminum powders and form iron aluminide. The sintering can be followed by hot or cold rolling to reduce porosity created during the sintering step and optional annealing steps in a vacuum or inert atmosphere.

Inventors:

Deevi, Seetharama C ^[1]; Lilly, Jr., A. Clifton ^[2]; Sikka, Vinod K ^[3]; Hajaligol, Mohammed R ^[4]

Midlothian, VA
(Chesterfield, VA)
Oak Ridge, TN
Richmond, VA

Issue Date:: 2000-01-01

Research Org.:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

OSTI Identifier:: 872891

Patent Number(s):: 6033623

Assignee:: Philip Morris Incorporated (New York, NY)

Patent Classifications (CPCs):: B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER

C - CHEMISTRY C22 - METALLURGY C22C - ALLOYS

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B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
B22F2998/00 - Supplementary information concerning processes or compositions relating to powder metallurgy
B22F2998/10 - Processes characterised by the sequence of their steps
B22F3/18 - by using pressure rollers
B22F3/22 - for producing castings from a slip
B22F3/23 - involving a self-propagating high-temperature synthesis or reaction sintering step {

C - CHEMISTRY C22 - METALLURGY C22C - ALLOYS
C22C33/0278 - {with at least one alloying element having a minimum content above 5%}
C22C38/06 - containing aluminium

Show less

DOE Contract Number:: AC05-84OR21400

Resource Type:: Patent

Country of Publication:: United States

Language:: English

Subject:: method; manufacturing; iron; aluminide; thermomechanical; processing; elemental; powders; powder; metallurgical; process; preparing; useful; electrical; resistance; heating; elements; improved; temperature; ductility; resistivity; cyclic; fatigue; oxidation; strength; sagging; entirely; ferritic; microstructure; free; austenite; weight; 20; 32; optional; additions; ltoreq; gtoreq; 05; zr; zro; stringers; extending; perpendicular; exposed; surface; element; 30; oxide; dispersoid; electrically; insulating; conductive; covalent; ceramic; particles; rare; earth; metal; oxygen; cu; forming; mixture; aluminum; shaping; article; cold; rolling; sheet; sintering; sufficient; react; form; followed; hot; reduce; porosity; created; step; annealing; steps; vacuum; inert; atmosphere; temperature sagging; aluminum powder; oxide dispersoid; iron powder; optional additions; aluminide useful; entirely ferritic; fatigue resistance; ferritic microstructure; conductive covalent; cyclic fatigue; covalent ceramic; temperature strength; heating elements; resistance heating; exposed surface; oxidation resistance; temperature ductility; heating element; ceramic particles; electrically insulating; electrically conductive; rare earth; earth metal; electrical resistance; temperature sufficient; inert atmosphere; electrical resistivity; iron aluminide; cold rolling; annealing steps; powder metallurgical; ceramic particle; temperature oxidation; annealing step; reduce porosity; metallurgical process; stringers extending; elemental powders; extending perpendicular; form iron; thermomechanical processing; resistance heat; mechanical process; preparing iron; /419/

Citation Formats


                    Deevi, Seetharama C, Lilly, Jr., A. Clifton, Sikka, Vinod K, and Hajaligol, Mohammed R. Method of manufacturing iron aluminide by thermomechanical processing of elemental powders.  United States: N. p., 2000. 
        Web.

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                    Deevi, Seetharama C, Lilly, Jr., A. Clifton, Sikka, Vinod K, & Hajaligol, Mohammed R. Method of manufacturing iron aluminide by thermomechanical processing of elemental powders.  United States.

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                    Deevi, Seetharama C, Lilly, Jr., A. Clifton, Sikka, Vinod K, and Hajaligol, Mohammed R. Sat .  
        "Method of manufacturing iron aluminide by thermomechanical processing of elemental powders".  United States.  https://www.osti.gov/servlets/purl/872891.

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@article{osti_872891,

  title        = {Method of manufacturing iron aluminide by thermomechanical processing of elemental powders},

  author       = {Deevi, Seetharama C and Lilly, Jr., A. Clifton and Sikka, Vinod K and Hajaligol, Mohammed R},

  abstractNote = {A powder metallurgical process of preparing iron aluminide useful as 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 %, 20 to 32% Al, and optional additions such as .ltoreq.1% Cr, .gtoreq.05% Zr or ZrO.sub.2 stringers extending perpendicular to an exposed surface of the heating element, .ltoreq.2% Ti, .ltoreq.2% Mo, .ltoreq.1% Zr, .ltoreq.1% C, .ltoreq.0.1% B, .ltoreq.30% oxide dispersoid and/or electrically insulating or electrically conductive covalent ceramic particles, .ltoreq.1 % rare earth metal, .ltoreq.1% oxygen, and/or .ltoreq.3% Cu. The process includes forming a mixture of aluminum powder and iron powder, shaping the mixture into an article such as by cold rolling the mixture into a sheet, and sintering the article at a temperature sufficient to react the iron and aluminum powders and form iron aluminide. The sintering can be followed by hot or cold rolling to reduce porosity created during the sintering step and optional annealing steps in a vacuum or inert atmosphere.},

  doi          = {},

  journal      = {},
number       = ,

  volume       = ,

  place        = {United States},

  year         = {2000},

  month        = {1}

}

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Works referenced in this record:

Selected properties of iron aluminides
report, September 1994

Schneibel, J. H.
https://doi.org/10.2172/10178848

A review of recent developments in Fe ₃ Al-based alloys
journal, August 1991

McKamey, C. G.; DeVan, J. H.; Tortorelli, P. F.
Journal of Materials Research, Vol. 6, Issue 8
https://doi.org/10.1557/JMR.1991.1779

Powder Processing of Fe ₃ Al-Based Iron-Aluminide Alloys
journal, January 1990

Sikka, V. K.; Baldwin, R. H.; Reinshagen, J. H.
MRS Proceedings, Vol. 213
https://doi.org/10.1557/PROC-213-901

Microstructure and tensile properties of Fe-40 At. pct Al alloys with C, Zr, Hf, and B additions
journal, September 1989

Gaydosh, D. J.; Draper, S. L.; Nathal, M. V.
Metallurgical Transactions A, Vol. 20, Issue 9
https://doi.org/10.1007/BF02663202

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Title: Method of manufacturing iron aluminide by thermomechanical processing of elemental powders

Abstract

Citation Formats

Selected properties of iron aluminides report, September 1994

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Powder Processing of Fe 3 Al-Based Iron-Aluminide Alloys journal, January 1990

Microstructure and tensile properties of Fe-40 At. pct Al alloys with C, Zr, Hf, and B additions journal, September 1989

Selected properties of iron aluminides
report, September 1994

A review of recent developments in Fe ₃ Al-based alloys
journal, August 1991

Powder Processing of Fe ₃ Al-Based Iron-Aluminide Alloys
journal, January 1990

Microstructure and tensile properties of Fe-40 At. pct Al alloys with C, Zr, Hf, and B additions
journal, September 1989