INFILTRATED FERROUS MATERIALS
Metallic alloys and methods for the preparation of free-standing metallic materials in a layerwise manner. The resulting layerwise construction provides a metallic skeleton of selected porosity which may be infiltrated with a second metal to provide a free-standing material that has a volume loss of less than or equal to 130 mm3 as measured according to ASTM G65-04(2010).
1 . A method for layer-by-layer formation of a free-standing metallic part comprising:
supplying metallic alloy particles comprising, in weight percent:
17.0<Cr<22.0;
8.0<Mo<12.0;
2.0<B<5.0;
3.0<W<7.0;
0.5<C<2.0;
1.0<Mn<4.0;
1.0<Si<3.0; and
balance Fe;
mixing the metallic alloy particles with a binder wherein the binder bonds the powder particles and forming a layer of the free-standing metallic part wherein the layer has a porosity of in the range of 20% - 60%;
heating the metallic alloy powder and the binder and forming a bond between the particle;
sintering the metallic alloy powder and the binder by heating and removing the binder and cooling and forming a porous metallic skeleton; and
infiltrating the porous metallic skeleton with a second material and forming the free-standing metallic part wherein the part has a volume loss of less than or equal to 130 mm3 as measured according to ASTM G65-04(2010).