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Title: Polymer quenched prealloyed metal powder

Abstract

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 priormore » 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.« less

Inventors:
 [1];  [1];  [2]
  1. (Midlothian, VA)
  2. (State College, PA)
Issue Date:
Research Org.:
LOCKHEED MARTIN ENRGY SYST INC
OSTI Identifier:
874011
Patent Number(s):
6293987
Assignee:
Chrysalis Technologies Incorporated (Richmond, VA) ORNL
DOE Contract Number:  
AC05-84OR21400
Resource Type:
Patent
Country of Publication:
United States
Language:
English
Subject:
polymer; quenched; prealloyed; metal; powder; metallurgical; process; preparing; sheet; intermetallic; alloy; composition; iron; nickel; titanium; aluminide; manufactured; electrical; resistance; heating; elements; improved; temperature; ductility; resistivity; cyclic; fatigue; oxidation; strength; sagging; entirely; ferritic; microstructure; free; austenite; weight; 32; optional; additions; ltoreq; gtoreq; 05; zr; 75; submicron; oxide; particles; electrically; insulating; conductive; covalent; ceramic; rare; earth; cu; forming; non-densified; consolidating; roll; compaction; tape; casting; plasma; spraying; cold; rolled; rolling; increase; density; reduce; thickness; annealing; water; gas; atomized; subjecting; sieving; blending; binder; prior; consolidation; step; partially; sintered; steps; repeated; achieve; desired; properties; carried; vacuum; furnace; inert; atmosphere; final; recrystallizes; average; grain; size; 10; 30; stress; relief; b2; phase; range; temperature sagging; metallic alloy; average grain; optional additions; atomized powder; gas atomized; entirely ferritic; fatigue resistance; ferritic microstructure; conductive covalent; cyclic fatigue; covalent ceramic; vacuum furnace; temperature strength; heating elements; resistance heating; alloy composition; intermetallic alloy; plasma spray; oxidation resistance; temperature ductility; heating element; ceramic particles; electrically insulating; temperature range; electrically conductive; rare earth; metal sheet; grain size; earth metal; electrical resistance; inert atmosphere; electrical resistivity; plasma spraying; oxide particles; iron aluminide; metal powder; titanium aluminide; cold rolled; cold rolling; annealing steps; powder metallurgical; ceramic particle; tape casting; temperature oxidation; rolled sheet; annealing step; metallurgical process; sheet thickness; phase temperature; roll compaction; stress relief; consolidation step; resistance heat; oxide particle; tape cast; prealloyed metal; /75/

Citation Formats

Hajaligol, Mohammad R., Fleischhauer, Grier, and German, Randall M. Polymer quenched prealloyed metal powder. United States: N. p., 2001. Web.
Hajaligol, Mohammad R., Fleischhauer, Grier, & German, Randall M. Polymer quenched prealloyed metal powder. United States.
Hajaligol, Mohammad R., Fleischhauer, Grier, and German, Randall M. Mon . "Polymer quenched prealloyed metal powder". United States. https://www.osti.gov/servlets/purl/874011.
@article{osti_874011,
title = {Polymer quenched prealloyed metal powder},
author = {Hajaligol, Mohammad R. and Fleischhauer, Grier and German, Randall M.},
abstractNote = {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.},
doi = {},
journal = {},
number = ,
volume = ,
place = {United States},
year = {2001},
month = {1}
}

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