Recrystallization, refinement, and strengthening mechanisms for production of advanced high strength metal alloys

1. A method comprising:

a. supplying a metal alloy wherein said alloy contains Fe at a level of 55.0 to 88.0 atomic percent, B at a level of 0.5 to 3.8 atomic percent, Si at a level of 0.5 to 12.0 atomic percent and Mn at a level of 1.0 to 19.0 atomic percent;

b. melting said alloy and solidifying to provide a matrix grain size of 200 nm to 200,000 nm wherein said solidified alloy has a thickness of 1 mm to 500 mm;

c. heating said alloy to form a refined matrix grain size of 50 nm to 5000 nm where the alloy has a yield strength of 200 MPa to 1225 MPa and a thickness of 1 mm to 500 mm;

d. stressing said alloy by cold rolling, cold stamping, hydroforming or roll forming that exceeds said yield strength of 200 MPa to 1225 MPa wherein said alloy after stressing results in a thickness reduction to produce a thickness of 0.1 mm to 25 mm and indicates a tensile strength of 400 MPa to 1825 MPa and an elongation of 1.0% to 59.2%;

e. wherein said alloy in step (d) is heated to a temperature in the range 700° C. and below the melting point of said alloy and grain growth occurs and forming an alloy having grains of 100 nm to 50,000 nm, borides of 20 nm to 10000 nm in size, precipitations of 1 nm to 200 nm in size and said alloy has a yield strength of 200 MPa to 1650 MPa; and

f. wherein said alloy formed in step (e) is stressed above yield and forms an alloy having grain sizes of 10 nm to 2500 nm, borides of 20 nm to 10000 nm in size, precipitations of 1 nm to 200 nm in size and indicates a yield strength of 200 MPa to 1650 MPa, tensile strength of 400 MPa to 1825 MPa and an elongation of 1.0% to 59.2%.

2. The method of claim 1 wherein said alloy heated in step (c) has a melting point and heating to form said refined grain size comprises heating a temperature of at least 700° C. and below said melting point of said alloy.

3. The method of claim 1 wherein, in step (b), borides are formed having a size of 20 nm to 10000 nm.

4. The method of claim 1 , wherein in step (c), precipitations are formed having a size of 1 nm to 200 nm and borides of 20 nm to 10000 nm in size are present.

5. The method of claim 1 , wherein in step (d), said alloy has refined grain size of 25 nm to 2500 nm, borides of 20 nm to 10000 nm in size and precipitations at 1 nm to 200 nm in size.

6. The method of claim 1 further including one or more of the following:

Ni at a level of 0.1 to 9.0 atomic percent;

Cr at a level of 0.1 to 19.0 atomic percent;

Cu at a level of 0.1 to 6.00 atomic percent;

Ti at a level of 0.1 to 1.00 atomic percent; and

C at a level of 0.1 to 4.0 atomic percent.

7. The method of claim 1 wherein said alloy has a melting point in the range of 1000° C. to 1450° C.

8. The method of claim 1 wherein said alloy is positioned in a vehicle.

9. The method of claim 1 wherein said alloy formed in step (f) is positioned in a vehicle.

10. The method of claim 1 wherein said alloy is positioned in one of a drill collar, drill pipe, pipe casing, tool joint, wellhead, compressed gas storage tank or liquefied natural gas canister.

11. The method of claim 1 wherein steps (e) and (f) are repeated to further decrease said alloy thickness.

12. The method of claim 11 wherein steps (e) and (f) are repeated 2 to 20 times.

13. A method comprising:

a. supplying a metal alloy comprising Fe at a level of 55.0 to 88.0 atomic percent, B at a level of 0.5 to 3.8 atomic percent, Si at a level of 0.5 to 12.0 atomic percent and Mn at a level of 1.0 to 19.0 atomic percent;

b. melting said alloy and solidifying to provide a matrix grain size of 200 nm to 200,000 nm and borides having a size of 20 nm to 10,000 nm and said alloy has a thickness of 1 mm to 500 mm;

c. heating said alloy to form a refined matrix grain size of 50 nm to 5000 nm where the alloy has a yield strength of 200 MPa to 1225 MPa and a thickness of 1 mm to 500 mm;

d. stressing said alloy by cold rolling, cold stamping, hydroforming or roll forming that exceeds said yield strength of 200 MPa to 1225 MPa wherein said alloy after stressing results in a thickness reduction and indicates a tensile strength of 400 MPa to 1825 MPa and an elongation of 1.0% to 59.2% and a thickness of 0.1 mm to 25 mm;

e. wherein said alloy in step (d) has a melting point and is heated to a temperature in the range of 700° C. and below said melting point of said alloy and grain growth occurs and forming an alloy having grains of 100 nm to 50,000 nm, borides of 20 nm to 10,000 nm in size, precipitations of 1 nm to 200 nm in size and said alloy has a yield strength of 200 MPa to 1650 MPa;

f. wherein said alloy formed in step (e) is stressed above yield and forms an alloy having grain sizes of 10 nm to 2500 nm, borides of 20 nm to 10000 nm in size, precipitations of 1 nm to 200 nm in size and indicates a yield strength of 200 MPa to 1650 MPa, tensile strength of 400 MPa to 1825 MPa and an elongation of 1.0% to 59.2%.

14. The method of claim 13 wherein in step (c) precipitations are formed having a size of 1 nm to 200 nm and borides of 20 nm to 10,000 nm in size are present.

15. The method of claim 13 wherein in step (d) said alloy has refined grain size of 25 nm to 2500 nm, borides of 20 nm to 10,000 nm in size and precipitations at 1 nm to 200 nm in size.

16. The method of claim 13 further including one or more of the following:

Ni at a level of 0.1 to 9.0 atomic percent

Cr at a level of 0.1 to 19.0 atomic percent

Cu at a level of 0.1 to 6.0 atomic percent

Ti at a level of 0.1 to 1.0 atomic percent

C at a level of 0.1 to 4.0 atomic percent.

17. The method of claim 13 wherein said alloy is positioned in a vehicle.

18. The method of claim 13 wherein steps (e) and (f) are repeated to further decrease said alloy thickness.

19. The method of claim 18 wherein steps (e) and (f) are repeated 2 to 20 times.