A metal powder having a composition including the following elements, expressed in content by weight: 6.5%≤Si≤10%, 4.5%≤Nb≤10%, 0.2%≤B≤2.0%, 0.2%≤Cu≤2.0%, C≤2% and optionally containing Ni≤10 wt % and/or Co≤10 wt % and/or Cr≤7 wt % and/or Zr as a substitute for any part of Nb on a one-to-one basis and/or Mo as a substitute for any part of Nb on a one-to-one basis and/or P as a substitute for any part of Si on a one-to-one basis, the balance being Fe and unavoidable impurities resulting from the elaboration, the metal powder having a microstructure including at least 5% in area fraction of an amorphous phase, the balance being made of crystalline ferritic phases with a grain size below 20 μm and possible precipitates, the metal powder having a mean sphericity SPHT of at least 0.80.

In some embodiments, a coating applied to steel reinforcement bar (e.g., steel rebar) that could considerably extend the lifetime of concrete structures by reducing steel rebar corrosion is disclosed. The coating includes a thin, passivating steel (e.g., stainless steel) layer that is applied to the outside of conventional steel rebar. The coating can be applied in-line through metal cold spray manufacturing, which is a high throughput coating technique that can be integrated into existing steel manufacturing plants. Furthermore, a novel, high performance ferritic steel with tailored resistance to corrosion from chlorides is described. The new ferritic steel is distinct from other commercial and experimental steels, and is better suited for coating low-cost steel structures like rebar. Multiple alloying elements including Cr, Al, and Si will each form protective oxides independently, increasing the total amount of protection and extending it over much wider ranges of pH and electrical potential.

A series of solid solutions AlFe.sub.2.sub._.sub.xMnxB.sub.2 have been synthesized by arc-melting and characterized by powder X-ray diffraction, and magnetic measurements. All the compounds adopt the parent AlFe.sub.2B.sub.2-type structure, in which infinite zigzag chains of B atoms are connected by Fe atoms into [Fe.sub.2B.sub.2] slabs that alternate with layers of Al atoms along the b axis. The parent AlFe.sub.2B.sub.2 is a ferromagnet with T.sub.c=282 K. A systematic investigation of solid solutions AlFe.sub.2.sub._.sub.xMn.sub.x.B.sub.2 showed a non-linear change in the structural and magnetic behavior. The ferromagnetic ordering temperature is gradually decreased as the Mn content (x) increases. The substitution of Mn for Fe offers a convenient method for the adjustment of the ferromagnetic ordering temperature of AlFe.sub.2B.sub.2.

A series of solid solutions AlFe.sub.2.sub._.sub.xMnxB.sub.2 have been synthesized by arc-melting and characterized by powder X-ray diffraction, and magnetic measurements. All the compounds adopt the parent AlFe.sub.2B.sub.2-type structure, in which infinite zigzag chains of B atoms are connected by Fe atoms into [Fe.sub.2B.sub.2] slabs that alternate with layers of Al atoms along the b axis. The parent AlFe.sub.2B.sub.2 is a ferromagnet with T.sub.c=282 K. A systematic investigation of solid solutions AlFe.sub.2.sub._.sub.xMn.sub.x.B.sub.2 showed a non-linear change in the structural and magnetic behavior. The ferromagnetic ordering temperature is gradually decreased as the Mn content (x) increases. The substitution of Mn for Fe offers a convenient method for the adjustment of the ferromagnetic ordering temperature of AlFe.sub.2B.sub.2.

A 2-step high temperature process for recovering Ni, Co, and Mn from various sources comprises preparing a metallurgical charge comprising materials containing Ni, Co, and Mn, and Si, Al, Ca and Mg as slag formers; smelting the charge with slag formers in first reducing conditions, thereby obtaining a Ni—Co alloy comprising a major part of at least one of Co and Ni, with Si<0.1%, and a first slag comprising the major part of the Mn; separation of the first slag from the alloy; and, smelting the first slag in second reducing conditions, more reducing than said first reducing conditions, thereby obtaining a Si—Mn alloy comprising the major part of the Mn, with Si>10%, and a second slag. A Ni—Co alloy is produced, and a Si—Mn alloy is produced. The second slag is essentially free of heavy metals and therefore suitable for reuse.

A 2-step high temperature process for recovering Ni, Co, and Mn from various sources comprises preparing a metallurgical charge comprising materials containing Ni, Co, and Mn, and Si, Al, Ca and Mg as slag formers; smelting the charge with slag formers in first reducing conditions, thereby obtaining a Ni—Co alloy comprising a major part of at least one of Co and Ni, with Si<0.1%, and a first slag comprising the major part of the Mn; separation of the first slag from the alloy; and, smelting the first slag in second reducing conditions, more reducing than said first reducing conditions, thereby obtaining a Si—Mn alloy comprising the major part of the Mn, with Si>10%, and a second slag. A Ni—Co alloy is produced, and a Si—Mn alloy is produced. The second slag is essentially free of heavy metals and therefore suitable for reuse.

Disclosed in the present disclosure is an ultrahigh-strength dual-phase steel. The matrix structure of the ultrahigh-strength dual-phase steel is ferrite and martensite, wherein the ferrite and the martensite are evenly distributed in an island shape. The ultrahigh-strength dual-phase steel contains the following chemical elements in percentage by mass: 0.12-0.2% of C, 0.5-1.0% of Si, 2.5-3.0% of Mn, 0.02-0.05% of Al, 0.02-0.05% of Nb, 0.02-0.05% of Ti, and 0.001-0.003% of B. Further disclosed in the present disclosure is a manufacturing method for the ultrahigh-strength dual-phase steel, comprising the steps of smelting and continuous casting, hot rolling, cold rolling, annealing, tempering, and leveling. The ultrahigh-strength dual-phase steel in the present disclosure has not only good mechanical properties but also excellent delayed cracking resistance and low initial hydrogen content, and can be suitable for manufacturing of vehicle safety structural parts.

Disclosed in the present disclosure is an ultrahigh-strength dual-phase steel. The matrix structure of the ultrahigh-strength dual-phase steel is ferrite and martensite, wherein the ferrite and the martensite are evenly distributed in an island shape. The ultrahigh-strength dual-phase steel contains the following chemical elements in percentage by mass: 0.12-0.2% of C, 0.5-1.0% of Si, 2.5-3.0% of Mn, 0.02-0.05% of Al, 0.02-0.05% of Nb, 0.02-0.05% of Ti, and 0.001-0.003% of B. Further disclosed in the present disclosure is a manufacturing method for the ultrahigh-strength dual-phase steel, comprising the steps of smelting and continuous casting, hot rolling, cold rolling, annealing, tempering, and leveling. The ultrahigh-strength dual-phase steel in the present disclosure has not only good mechanical properties but also excellent delayed cracking resistance and low initial hydrogen content, and can be suitable for manufacturing of vehicle safety structural parts.

A supersaturated solid solution soft magnetic material and a preparation method thereof are provided, belonging to the field of metal soft magnetic technologies. The supersaturated solid solution soft magnetic material is soft magnetic alloy with proportions of 72.0˜78.0 at % Fe, 12.0˜18.0 at % Si, 4.0˜12.0 at % Co and 1.0˜3.0 at % Ti. The preparation method uses molten glass purification or electromagnetic levitation melting to an alloy melt with a target supercooling degree, increases the solid solubility of the Ti element in α-Fe (Si, Co), and promotes the formation of supersaturated solid solution of Ti, thereby achieving the goal that the magnetocrystalline anisotropy constant and the magnetostriction coefficient tend to be zero. Ti element is uniformly distributed in the α-Fe (Si, Co) after supercooled solidification analyzed by X-ray energy spectrometer, a supersaturated solid solution alloy without Ti precipitation is obtained, and the soft magnetic alloy has low coercivity and high permeability.

The present disclosure relates to a wear part made in a foundry. The wear part has a reinforced portion comprising a ferrous alloy reinforced with metal carbides, nitrides, borides, or intermetallic alloys. The reinforced portion includes inserts of metal carbides, nitrides, metal, or intermetallic compounds manufactured beforehand with a defined geometry and inserted into an infiltrable structure of agglomerated grains including the reagents needed for the formation of metal or intermetallic carbides, nitrides, borides according to an in situ self-propagating thermal reaction initiated during the casting of the ferrous alloy.