Chrome composite materials

• US 20050132843A1
• Filed: 12/22/2003
• Published: 06/23/2005
• Est. Priority Date: 12/22/2003
• Status: Abandoned Application

• Current Assignee: Caterpillar Incorporated
• Original Assignee: Caterpillar Incorporated
• Inventors: Jiang, Xiangyang, Smith, William C., Beardsley, M. Brad
• Application Number:
  US10/740,452
• Publication Number:
  US 20050132843A1
• Time in Patent Office: Days
• US Class Current: 75/252
• CPC Class Codes: B22F 1/17 Metallic particles coated with metal
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 9/026 Spray drying of solutions or suspensions
• CPC Class Codes: B22F 9/04 starting from solid material, e.g. by crushing, grinding or milling C22C1/1084 takes precedence; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C
• CPC Class Codes: B22F 9/305 of metal carbonyls
• CPC Class Codes: C22C 1/051 Making hard metals based on borides, carbides, nitrides, oxides or silicides; Preparation of the powder mixture used as the starting material therefor
• CPC Class Codes: C22C 29/067 comprising a particular metallic binder
• CPC Class Codes: C23C 4/06 Metallic material
• CPC Class Codes: Y10T 428/12181 Composite powder [e.g., coated, etc.]

Abstract

A method of making a composite chrome powder is provided. The method includes selecting a ferrochrome material. The ferrochrome material is mixed together with a nickel-based material, and a composite chrome powder is generated from the mixture.

Claims

1-14. -14. (canceled)

15. A chrome composite powder, comprising:

a high carbon ferrochrome component;

a nickel-based component; and

at least one of activated carbon and graphite powder.

16. The composite powder of claim 15, wherein the high carbon ferrochrome component contains iron up to about 65% by weight.

17. The composite powder of claim 15, wherein the high carbon ferrochrome component contains carbon up to about 14% by weight.

18. The composite powder of claim 15, wherein the high carbon ferrochrome component has a chrome content of about 15 percent by weight to about 75 percent by weight.

19. The composite powder of claim 15, wherein the high carbon ferrochrome component has an iron content less than about 35% by weight.

20. The composite powder of claim 15, wherein the high carbon ferrochrome component has a total weight percentage of no more than about 5 percent by weight provided by one or more of the following elements:

silicon, titanium, niobium, vanadium, tantalum, molybdenum, tungsten, and manganese.

21-24. -24. (canceled)

25. A chrome composite powder, comprising:

a plurality of particles, wherein at least some of the particles include;

a carbide-metal matrix composite structure having;

a matrix material including at least one of nickel, nickel-chromium, and iron chrome; and

a plurality of Fe—

Cr-carbide particles dispersed in the matrix material;

wherein the Fe—

Cr particles include at least one of (CrFe)₇C₃, (CrFe)₂₃C₆, and (CrFe)₃C₂.

26. A chrome composite powder, comprising:

a plurality of particles, wherein at least some of the particles include;

a ferrochrome core material; and

at least one of a nickel layer and a nickel-chromium layer clad on the ferrochrome core material

wherein the ferrochrome core material includes at least one of (CrFe₇C₃, (CrFe)₂₃C₆, and (CrFe)₃C₂.

27. A composite material, comprising:

a nickel-based component;

a ferrochrome component dispersed within the nickel-based component; and

at least one of activated carbon and graphite.

28. The composite material of claim 27, wherein the ferrochrome component contains iron up to about 35 percent by weight.

30. The composite material of claim 27, wherein the ferrochrome component contains carbon up to about 14 percent by weight.

31. The composite material of claim 27, wherein the ferrochrome component has a chrome content of between about 15% and about 75% by weight.

32. The composite material of claim 27, further including no more than about 5 percent by weight provided by any one of silicon, titanium, niobium, vanadium, tantalum, molybdenum, tungsten, and manganese.

33. The composite material of claim 27, further including no more than about 10 percent by weight provided by any combination of silicon, titanium, niobium, vanadium, tantalum, molybdenum, tungsten, and manganese.

29. (canceled)

34. A composite material comprising:

a nickel-based material forming a nickel matrix; and

a plurality of carbon ferrochrome particles dispersed in the nickel matrix;

wherein at least some of the carbon ferrochrome particles include at least one of (CrFe)₇C₃, (CrFe)₂₃C₆, and (CrFe)₃C₂.

35. The composite material of claim 34, wherein the composite material has a Knoop hardness value of between about 950 to 1200 HK.

36. The composite material of claim 34, wherein the plurality of carbon ferrochrome particles dispersed in the nickel matrix are disposed as a coating on a substrate material.

37. The composite material of claim 36, wherein the substrate material includes an engine component.

38. The composite material of claim 36, wherein the substrate material includes a bearing.

39. A composite material comprising:

a nickel-based material forming a nickel matrix, and

a plurality of carbon ferrochrome particles dispersed in the nickel matrix;

wherein the plurality of carbon ferrochrome particles dispersed in the nickel matrix are disposed as a coating on a substrate material, and the substrate material includes an axle.

40. A method of forming a coating on a substrate, the method comprising:

mixing a ferrochrome material with a nickel-based material to form a mixture;

generating a composite chrome powder from the mixture;

supplying the composite chrome powder to a coating apparatus; and

forming a chrome-including composite material coating on at least one surface of the substrate;

wherein the ferrochrome material includes at least one of (CrFe)₇C₃, (CrFe)₂₃C₆, and (CrFe)₃C₂.

41. The method of claim 40, wherein the coating apparatus includes a high velocity oxy-fuel (HVOF) system.

42. The method of claim 40, wherein the coating apparatus includes a detonation spray system.

43. The method of claim 40, wherein the chrome-including composite material coating has a Knoop hardness value of between about 950 to 1200 HK.

44. The method of claim 40, wherein the substrate includes an engine component.

45. The method of claim 40, wherein the substrate includes a bearing.

48. The method of claim 40, wherein the ferrochrome material has an iron to chrome weight ratio of from about 0.2 to 0.5 by weight and a carbon to chrome ratio of from about 0 to 0.2 by weight.

49. The method of claim 40, wherein the chrome-including composite material coating includes a plurality of ferrochrome particles dispersed in a nickel matrix.

46. A method of forming a coating on a substrate, the method comprising:

mixing a ferrochrome material with a nickel-based material to form a mixture;

generating a composite chrome powder from the mixture;

supplying the composite chrome powder to a coating apparatus; and

forming a chrome-including composite material coating on at least one surface of the substrate;

wherein the substrate includes an axle.

47. (canceled)