Powder metal compositions for wear and temperature resistance applications and method of producing same

Inventors: Denis B. Christopherson, Jr. (Waupun, WI); Leslie John Farthing (Rugby, GB); Todd Schoenwetter (Waupun, WI); Gilles L'Esperance (Quebec, CA); Philippe Beaulieu (Montreal, CA)

Assignees: Federal-Mogul Corporation; La Corporation De L'Ecole Polytechnique De Montreal

B22F1/0003 B22F3/12 B22F9/082 C22C1/02 C22C33/0285 C22C37/06 B22F2009/0828 B22F2998/10

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Quick Facts

Patent No.: US 9,162,285
App. No.: 13/837,549
Granted: Oct 20, 2015
Kind: B2

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Abstract

A powder metal composition for high wear and temperature applications is made by atomizing a melted iron based alloy including 3.0 to 7.0 wt. % carbon; 10.0 to 25.0 wt. % chromium; 1.0 to 5.0 wt. % tungsten; 3.5 to 7.0 wt. % vanadium; 1.0 to 5.0 wt. % molybdenum; not greater than 0.5 wt. % oxygen; and at least 40.0 wt. % iron. The high carbon content reduces the solubility of oxygen in the melt and thus lowers the oxygen content to a level below which would cause the carbide-forming elements to oxidize during atomization. The powder metal composition includes metal carbides in an amount of at least 15 vol. %. The microhardness of the powder metal composition increases with increasing amounts of carbon and is typically about 800 to 1,500 Hv50.

Claims (15)

1. A powder metal composition, consisting of:

3.8 wt. % carbon, 13.0 wt. % chromium, 2.5 wt. % tungsten, 6.0 wt. % vanadium, 1.5 wt. % molybdenum, 0.2 wt. % oxygen, 70.0 to 80.0 wt. % iron, and impurities in an amount not greater than 2.0 wt. %, based on the total weight of the powder metal composition.

2. The powder metal composition of claim 1 including metal carbides in an amount of at least 15.0 vol. %, based on the total volume of the powder metal material.

3. The powder metal composition of claim 2 , wherein the metal carbides are selected from the group consisting of: M 8 C 7 , M 7 C 3 , M 6 C, wherein M is at least one metal atom and C is carbon.

4. The powder metal composition of claim 3 , wherein M 8 C 7 is (V 63 Fe 37 ) 8 C 7 ; M 7 C 3 is selected from the group consisting of: (Cr 34 Fe 66 ) 7 C 3 , Cr 3.5 Fe 3.5 C 3 , and Cr 4 Fe 3 C 3 ; M 6 C is selected from the group consisting of: Mo 3 Fe 3 C, Mo 2 Fe 4 C, W 3 Fe 3 C, and W 2 Fe 4 C.

5. A sintered material including a powder metal composition, wherein the powder metal composition consists of:

6. The sintered material of claim 5 including metal carbides in an amount of at least 15.0 vol. %, based on the total volume of the powder metal composition.

7. The sintered material of claim 6 , wherein the metal carbides are selected from the group consisting of: M 8 C 7 , M 7 C 3 , M 6 C, wherein M is at least one metal atom and C is carbon.

8. The sintered material of claim 7 , wherein M 8 C 7 is (V 63 Fe 37 ) 8 C 7 ; M 7 C 3 is selected from the group consisting of: (Cr 34 Fe 66 ) 7 C 3 , Cr 3.5 Fe 3.5 C 3 , and Cr 4 Fe 3 C 3 ; and M 6 C is selected from the group consisting of: Mo 3 Fe 3 C, Mo 2 Fe 4 C, W 3 Fe 3 C, and W 2 Fe 4 C.

9. The sintered material of claim 6 , wherein the metal carbides include vanadium-containing carbides in an amount of about 5.0 to 10.0 vol. % and chromium-containing carbides in an amount of about 40.0 to 45.0 vol. %, based on the total volume of the powder metal composition.

10. The sintered material of claim 6 wherein the metal carbides have a diameter between 1 and 2 micrometers.

11. The sintered material of claim 5 having a microhardness of 800 to 1500 Hv50 and a melting point of about 1,235° C. (2,255° F.).

12. The sintered material of claim 5 further including at least 30.0 wt. % of an additional powder metal different from the powder metal composition, wherein the additional powder metal is an alloyed steel powder.

13. The powder metal composition of claim 1 having a melting point of about 1,235° C. (2,255° F.).

Assignments (23)

ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Aug 20, 2025

From: TENNECO INC.

To: FEDERAL-MOGUL POWERTRAIN LLC

Reel/Frame 072553/0043 →

MERGER Recorded Oct 25, 2023

From: FEDERAL-MOGUL LLC (DELAWARE)

To: TENNECO INC

Reel/Frame 065337/0273 →

PATENT SECURITY AGREEMENT (ABL) Recorded Apr 7, 2023

From: TENNECO INC.; DRIV AUTOMOTIVE INC.; FEDERAL-MOGUL CHASSIS LLC; FEDERAL-MOGUL IGNITION LLC; FEDERAL-MOGUL MOTORPARTS LLC; FEDERAL-MOGUL POWERTRAIN LLC; FEDERAL-MOGUL WORLD WIDE LLC; TENNECO AUTOMOTIVE OPERATING COMPANY INC.; THE PULLMAN COMPANY

To: CITIBANK, N.A., AS COLLATERAL AGENT

Reel/Frame 063268/0506 →

NOTICE OF GRANT OF SECURITY INTEREST IN PATENTS (FIRST LIEN) Recorded Nov 22, 2022

From: DRIV AUTOMOTIVE INC.; FEDERAL-MOGUL CHASSIS LLC; FEDERAL-MOGUL IGNITION LLC; FEDERAL-MOGUL MOTORPARTS LLC; FEDERAL-MOGUL POWERTRAIN LLC; FEDERAL-MOGUL WORLD WIDE LLC; TENNECO AUTOMOTIVE OPERATING COMPANY INC.; TENNECO INC.; THE PULLMAN COMPANY

To: CITIBANK, N.A., AS COLLATERAL AGENT

Reel/Frame 061989/0689 →

RELEASE OF SECURITY INTEREST Recorded Nov 19, 2022