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Title: Thermomechanical processing of plasma sprayed intermetallic sheets

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 prior tomore » 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.

Inventors:
 [1];  [2];  [3];  [1];  [1];  [4];  [5]
+ Show Inventor Affiliations
  1. Midlothian, VA
  2. Cheshire, CT
  3. Oak Ridge, TN
  4. (Chesterfield, VA)
  5. State College, PA
Issue Date:
Research Org.:
Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)
OSTI Identifier:
874183
Patent Number(s):
6332936
Assignee:
Chrysalis Technologies Incorporated (Richmond, VA)
Patent Classifications (CPCs):
B - PERFORMING OPERATIONS B22 - CASTING B22F - WORKING METALLIC POWDER
C - CHEMISTRY C21 - METALLURGY OF IRON C21D - MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS
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DOE Contract Number:  
AC05-84OR21400
Resource Type:
Patent
Country of Publication:
United States
Language:
English
Subject:
thermomechanical; processing; plasma; sprayed; intermetallic; sheets; powder; metallurgical; process; preparing; sheet; alloy; composition; iron; nickel; titanium; aluminide; manufactured; electrical; resistance; heating; elements; improved; temperature; ductility; resistivity; cyclic; fatigue; oxidation; strength; andor; sagging; entirely; ferritic; microstructure; free; austenite; weight; 32; optional; additions; ltoreq1; gtoreq005; zr; ltoreq2; ltoreq075; ltoreq01; submicron; oxide; particles; electrically; insulating; conductive; covalent; ceramic; rare; earth; metal; ltoreq3; forming; non-densified; consolidating; roll; compaction; tape; casting; spraying; cold; rolled; rolling; increase; density; reduce; thickness; annealing; water; polymer; gas; atomized; subjecting; sieving; blending; binder; prior; consolidation; step; partially; sintered; steps; repeated; achieve; properties; carried; vacuum; furnace; inert; atmosphere; final; recrystallizes; average; grain; size; 10; 30; mum; stress; relief; b2; phase; range; electrically conductive; rare earth; temperature range; electrical resistance; earth metal; inert atmosphere; grain size; metal sheet; electrically insulating; heating element; cold rolled; titanium aluminide; powder metallurgical; metallic alloy; metallurgical process; mechanical process; /148/419/

Citation Formats

Hajaligol, Mohammad R, Scorey, Clive, Sikka, Vinod K, Deevi, Seetharama C, Fleischhauer, Grier, Lilly, Jr., A. Clifton, and German, Randall M. Thermomechanical processing of plasma sprayed intermetallic sheets. United States: N. p., 2001. Web.
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Hajaligol, Mohammad R, Scorey, Clive, Sikka, Vinod K, Deevi, Seetharama C, Fleischhauer, Grier, Lilly, Jr., A. Clifton, & German, Randall M. Thermomechanical processing of plasma sprayed intermetallic sheets. United States.
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Hajaligol, Mohammad R, Scorey, Clive, Sikka, Vinod K, Deevi, Seetharama C, Fleischhauer, Grier, Lilly, Jr., A. Clifton, and German, Randall M. Mon . "Thermomechanical processing of plasma sprayed intermetallic sheets". United States. https://www.osti.gov/servlets/purl/874183.
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@article{osti_874183,
title = {Thermomechanical processing of plasma sprayed intermetallic sheets},
author = {Hajaligol, Mohammad R and Scorey, Clive and Sikka, Vinod K and Deevi, Seetharama C and Fleischhauer, Grier and Lilly, Jr., A. Clifton 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 = {Mon Jan 01 00:00:00 EST 2001},
month = {Mon Jan 01 00:00:00 EST 2001}
}
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Works referenced in this record:

Processing, properties, and wear resistance of aluminides
report, March 1993

The effect of ternary additions on the vacancy hardening of FeAl
journal, April 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

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