The present invention pertains to a non-magnesium process to produce Compacted Graphite Iron (CGI) by placing a treatment alloy into a treatment ladle, and then placing an inoculant over die treatment alloy in the treatment ladle and pouring a molten base metal there over. The treatment alloy comprises iron, silicon and, lanthanum, wherein lanthanum is 3-30% by weight of the treatment alloy, silicon is 40-50% by weight of the treatment alloy, and the remaining is Iron. Lanthanum in the treatment alloy makes the graphite precipitate as vermiculite (compacted form) instead of flake or spheroids. With extended process window offered by this new process (0.03-0.1% residual lanthanum in the metal) required to make CGI, this new process removes the stringent process control (0.01-0.02% residual magnesium in the metal) dictated by the magnesium process of making CGI.

The present invention pertains to a non-magnesium process to produce Compacted Graphite Iron (CGI) by placing a treatment alloy into a treatment ladle, and then placing an inoculant over die treatment alloy in the treatment ladle and pouring a molten base metal there over. The treatment alloy comprises iron, silicon and, lanthanum, wherein lanthanum is 3-30% by weight of the treatment alloy, silicon is 40-50% by weight of the treatment alloy, and the remaining is Iron. Lanthanum in the treatment alloy makes the graphite precipitate as vermiculite (compacted form) instead of flake or spheroids. With extended process window offered by this new process (0.03-0.1% residual lanthanum in the metal) required to make CGI, this new process removes the stringent process control (0.01-0.02% residual magnesium in the metal) dictated by the magnesium process of making CGI.

One aspect of the disclosure provides an iron-based hardfacing layer which includes hard or wear resistant phases resulting at least in part from dissolution of silicon and/or boron carbide particles into a liquid iron-based metal during the fabrication process. In an embodiment, the hardfacing layer is formed by a fusion welding process in which carbide particles are added to the molten weld pool. In an example, the filler metal supplied to the welding process is a mild steel. In an embodiment, the hardness as measured at the surface of the hardfacing ranges from 40 to 65 HRC. In an example, the iron-based hardfacing layer also includes tungsten carbide particles.

One aspect of the disclosure provides an iron-based hardfacing layer which includes hard or wear resistant phases resulting at least in part from dissolution of silicon and/or boron carbide particles into a liquid iron-based metal during the fabrication process. In an embodiment, the hardfacing layer is formed by a fusion welding process in which carbide particles are added to the molten weld pool. In an example, the filler metal supplied to the welding process is a mild steel. In an embodiment, the hardness as measured at the surface of the hardfacing ranges from 40 to 65 HRC. In an example, the iron-based hardfacing layer also includes tungsten carbide particles.

A disc/brake friction torque for railway vehicles consisting of at least one pad comprising at least one friction element and a disc. The friction element is made of a sintered material comprising copper, iron, graphite, 0.02 to 1.5% by weight of molybdenum, 1 to 3% by weight of chrome and a porosity ranging from 20 to 35%; and the disc is made of cast iron comprising 0.05 to 2% by weight of chrome, 0.05 to 2% by weight of molybdenum, 0.1 to 2% by weight of nickel.

A disc/brake friction torque for railway vehicles consisting of at least one pad comprising at least one friction element and a disc. The friction element is made of a sintered material comprising copper, iron, graphite, 0.02 to 1.5% by weight of molybdenum, 1 to 3% by weight of chrome and a porosity ranging from 20 to 35%; and the disc is made of cast iron comprising 0.05 to 2% by weight of chrome, 0.05 to 2% by weight of molybdenum, 0.1 to 2% by weight of nickel.

Discussed herein are systems and methods of forming hardfacing coatings and films containing Q-carbon diamond particles for use in downhole drilling tooling and other tools where wear-resistant coating is desirable. The Q-carbon diamond-containing layers may be coated with matrix material and/or disposed in a matrix to form the coating, or the Q-carbon diamond layer may be formed directly from a diamond-like-carbon on a substrate.

Discussed herein are systems and methods of forming hardfacing coatings and films containing Q-carbon diamond particles for use in downhole drilling tooling and other tools where wear-resistant coating is desirable. The Q-carbon diamond-containing layers may be coated with matrix material and/or disposed in a matrix to form the coating, or the Q-carbon diamond layer may be formed directly from a diamond-like-carbon on a substrate.

The present invention pertains to a non-magnesium process to produce Compacted Graphite Iron (CGI) by placing a treatment alloy into a treatment ladle, and then placing an inoculant over the treatment alloy in the treatment ladle and pouring a molten base metal there over. The treatment alloy comprises iron, silicon and lanthanum, wherein lanthanum is 3-30% by weight of the treatment alloy, silicon is 40-50% by weight of the treatment alloy, and the remaining is Iron. Lanthanum in the treatment alloy makes the graphite precipitate as vermiculite (compacted form) instead of flake or spheroids. With extended process window offered by this new process (0.03-0.1% residual lanthanum in the metal) required to make CGI, this new process removes the stringent process control (0.01-0.02% residual magnesium in the metal) dictated by the magnesium process of making CGI.

The present invention pertains to a non-magnesium process to produce Compacted Graphite Iron (CGI) by placing a treatment alloy into a treatment ladle, and then placing an inoculant over the treatment alloy in the treatment ladle and pouring a molten base metal there over. The treatment alloy comprises iron, silicon and lanthanum, wherein lanthanum is 3-30% by weight of the treatment alloy, silicon is 40-50% by weight of the treatment alloy, and the remaining is Iron. Lanthanum in the treatment alloy makes the graphite precipitate as vermiculite (compacted form) instead of flake or spheroids. With extended process window offered by this new process (0.03-0.1% residual lanthanum in the metal) required to make CGI, this new process removes the stringent process control (0.01-0.02% residual magnesium in the metal) dictated by the magnesium process of making CGI.