An iron powder and method of making an iron powder. The method includes a step of neutralizing an acidic aqueous solution containing a trivalent iron ion and a phosphorus-containing ion, with an alkali aqueous solution, so as to provide a slurry of a precipitate of a hydrated oxide, or a step of adding a phosphorus-containing ion to a slurry containing a precipitate of a hydrated oxide obtained by neutralizing an acidic aqueous solution containing a trivalent iron ion with an alkali aqueous solution. A silane compound is added to the slurry so as to coat a hydrolysate of the silane compound on the precipitate of the hydrated oxide. The precipitate of the hydrated oxide after coating is recovered through solid-liquid separation, the recovered precipitate is heated to provide iron particles coated with a silicon oxide, and a part or the whole of the silicon oxide coating is dissolved and removed.

This invention relates to powder metallurgy, more specifically, to methods of fabricating hard alloy items. The invention can be used as an iron, cobalt or nickel base binder for the fabrication of diamond cutting tools for the construction industry and stone cutting, including segmented cutting discs of different designs and wires for reinforced concrete and asphalt cutting used in the renovation of highway pavements, runways in airports, upgrading of metallurgical plants, nuclear power plants, bridges and other structures, monolithic reinforced concrete cutting drills, as well as discs and wires for the quarry production of natural stone and large scale manufacturing of facing construction materials. This invention achieves the objective of providing binders for the fabrication of diamond tools having higher wear resistance without a significant increase in the sintering temperature, as well as higher hardness, strength and impact toughness. The achievement of these objectives by adding an iron group metal as the main component of the binder composition and alloying additives in the form of nanosized powder in accordance with this invention is illustrated with several examples of different type binders for the fabrication of diamond tools.

A method for manufacturing a powder magnetic core includes: a step of preparing a soft magnetic powder and an oxide powder and preparing, as a raw material powder, a mixed powder of the soft magnetic powder and the oxide powder, the soft magnetic powder containing composite soft magnetic particles containing pure iron and an Fe-α alloy having an element α more oxidizable than Fe, the composite soft magnetic particles each having a core-shell structure where a core is made of one of pure iron and the Fe-α alloy and a shell is made of the other, the oxide powder containing oxide particles containing at least one selected from Fe and an element β that forms an oxide having higher electrical resistance than Fe.sub.3O.sub.4; a step of compacting the mixed powder into a green compact; and a step o sintering the green compact at 900° C. or more and 1300° C. or less.

A method for manufacturing a powder magnetic core includes: a step of preparing a soft magnetic powder and an oxide powder and preparing, as a raw material powder, a mixed powder of the soft magnetic powder and the oxide powder, the soft magnetic powder containing composite soft magnetic particles containing pure iron and an Fe-α alloy having an element α more oxidizable than Fe, the composite soft magnetic particles each having a core-shell structure where a core is made of one of pure iron and the Fe-α alloy and a shell is made of the other, the oxide powder containing oxide particles containing at least one selected from Fe and an element β that forms an oxide having higher electrical resistance than Fe.sub.3O.sub.4; a step of compacting the mixed powder into a green compact; and a step o sintering the green compact at 900° C. or more and 1300° C. or less.

Methods of applying an inorganic material to a metal substrate that includes a metallic material having an austenite transformation temperature. The method includes depositing inorganic particles onto a surface of the metal substrate. In some embodiments, methods may include depositing inorganic particles at a deposition temperature that does not cause the metallic material to exceed the austenite transformation temperature. The inorganic particles deposited onto the surface of the metal substrate may form an abrasion-resistant coating on the surface of the metal substrate. The difference between the coefficient of thermal expansion of the metallic material and the coefficient of thermal expansion of the abrasion-resistant coating may be 10×10.sup.−6/degrees C. or less.

Methods of applying an inorganic material to a metal substrate that includes a metallic material having an austenite transformation temperature. The method includes depositing inorganic particles onto a surface of the metal substrate. In some embodiments, methods may include depositing inorganic particles at a deposition temperature that does not cause the metallic material to exceed the austenite transformation temperature. The inorganic particles deposited onto the surface of the metal substrate may form an abrasion-resistant coating on the surface of the metal substrate. The difference between the coefficient of thermal expansion of the metallic material and the coefficient of thermal expansion of the abrasion-resistant coating may be 10×10.sup.−6/degrees C. or less.

A soft magnetic alloy powder which is a soft magnetic alloy powder having a low coercivity, and with which it is possible to obtain a green compact magnetic core having a high magnetic permeability. A soft magnetic alloy powder including a composition formula (Fe(1−(α+β))X1 αX2 β) (1−(a+b+c+d+e+f)) MaBbPcSidCeSf. XI is one or more elements selected from the group consisting of Co and Ni, X2 is one or more elements selected from the group consisting or Al, Mn, Ag, Zn, Sn, As, Sb, Cu, Cr, Bi, N, O and rare earth elements, and M is one or more elements selected from the group consisting of Nb, Hf, Zr, Ta, Mo, W, Ti and V. The amount of each component contained is within a specified range. The amorphous rate X (%) is at least 85%.

The present invention relates to an iron-based alloy that is able to provide a coating on a substrate, the coating having simultaneously high hardness and wear resistance. The iron-based alloy consists of 3.0-7.0% by weight Cr; 1.3-3.0% by weight C; 0.2-2.0% by weight B; 2.0-10.0% by weight V; optionally 1.5% by weight or less Si; optionally 1.0% by weight or less Mn, optionally 2.0% by weight or less Mo; optionally 1.5% by weight or less Ni; the balance being Fe and unavoidable impurities. The present invention further relates to an article comprising a substrate and coating formed thereon, the coating being formed from the alloy, and to a method for forming a coated article. The method preferably employs HVOF, laser cladding or plasma cladding.

The present invention relates to an iron-based alloy that is able to provide a coating on a substrate, the coating having simultaneously high hardness and wear resistance. The iron-based alloy consists of 3.0-7.0% by weight Cr; 1.3-3.0% by weight C; 0.2-2.0% by weight B; 2.0-10.0% by weight V; optionally 1.5% by weight or less Si; optionally 1.0% by weight or less Mn, optionally 2.0% by weight or less Mo; optionally 1.5% by weight or less Ni; the balance being Fe and unavoidable impurities. The present invention further relates to an article comprising a substrate and coating formed thereon, the coating being formed from the alloy, and to a method for forming a coated article. The method preferably employs HVOF, laser cladding or plasma cladding.

A multi-metallic pressure-controlling component and a hot isostatic pressure (HIP) manufacturing process and system are disclosed. An example multi-metallic component for use in the oil field services industry includes a first metal alloy that forms a first portion of the multi-metallic pressure-controlling component, and a second metal alloy that forms a second portion of the multi-metallic pressure-controlling component. A diffusion bond is disposed at an interface between the first metal alloy and the second metal alloy that joins the first metal alloy to the second metal alloy within the multi-metallic pressure-controlling component.