HYPEREUTECTIC WHITE IRON ALLOY COMPRISING CHROMIUM, BORON AND NITROGEN AND CRYOGENICALLY HARDENED ARTICLES MADE THEREFROM

Abstract

A hypereutectic chromium white iron alloy which comprises, in weight percent based on the total weight of the alloy, from 1.5 to 2.85 carbon, from 0.01 to 1.2 nitrogen, from 0.1 to 1.4 boron, from 3 to 34 chromium, from 0.1 to 7.5 Ni, and from 0.1 to 4 Si. The alloy may optionally comprise one or more additional elements, i.e., manganese, cobalt, copper, molybdenum, tungsten, vanadium, niobium, titanium, zirconium, magnesium and/or calcium, one or more rare earth elements, and one or more of tantalum, hafnium, aluminum. The remainder of the alloy is constituted by iron and unavoidable (incidential) impurities. Articles cast from the alloy, especially cryogenically hardened articles, are also disclosed.

Claims

1. A hypereutectic white iron alloy, wherein the alloy comprises, in weight percent based on a total weight of the alloy: TABLE-US-00045 C from 1.5 to 2.85 B from 0.1 to 1.4 N from 0.01 to 1.2 Cr from 3 to 34 Ni from 0.1 to 7.5 Si from 0.1 to 4 Mn from 0 to 8 Co from 0 to 5 Cu from 0 to 5 Mo from 0 to 5 W from 0 to 6 V from 0 to 12 Nb from 0 to 6 Ti from 0 to 5 Zr from 0 to 2 (Mg + Ca) from 0 to 0.2 one or more rare earth elements from 0 to 3 one or more of Ta, Hf, Al from 0 to 3, remainder Fe and incidental impurities.

2. The alloy of claim 1, wherein the alloy comprises from 1.8% to 2.75% C.

3. The alloy of claim 1, wherein the alloy comprises from 1.9% to 2.72% C.

4. The alloy of claim 1, wherein the alloy comprises from 2.0% to 2.65% C.

5. The alloy of claim 1, wherein the alloy comprises from 2.1% to 2.60% C.

6. The alloy of claim 1, wherein the alloy comprises from 0.3% to 1.4% B.

7. The alloy of claim 1, wherein the alloy comprises from 0.02% to 0.5% N.

8. The alloy of claim 1, wherein the alloy comprises from 6% to 28% Cr.

9. The alloy of claim 1, wherein the alloy comprises from 0.3% to 5% Ni.

10. The alloy of claim 1, wherein the alloy comprises from 0.3% to 3% Si.

11. The alloy of claim 1, wherein the alloy comprises: TABLE-US-00046 C from 2.15 to 2.72 B from 0.4 to 1.4 N from 0.01 to 0.4 Cr from 8 to 28 Ni from 0.3 to 5 Si from 0.4 to 3 Mn from 0.5 to 1.4 Co from 0 to 5 Cu from 0 to 0.9 Mo from 0 to 3 W from 0 to 6 V from 0 to 2 Nb from 0 to 2 Ti from 0 to 5 Zr from 0 to 2 (Mg + Ca) from 0 to 0.2 one or more rare earth elements from 0 to 3 one or more of Ta, Hf, Al from 0 to 3, remainder Fe and incidental impurities.

12. The alloy of claim 1, wherein the alloy has one of the following compositions 1 to 4: TABLE-US-00047 Composition 1 2 3 4 C 2.2-2.7 1.6-2.0 1.9-2.6 2.0-2.7 Si 0.5-0.7 0.4-0.6 2.0-2.3 0.4-1.0 Mn 0.6-1.3 0.6-1.0 0.5-1.2 0.5-1.0 Cr 26.0-27.0 25-26 8-9 16-17 Mo 0.5-1.0 0.0-1.0 0.0-0.6 2.0-2.8 Ni 0.3-0.5 0.5-1.3 .sup. 4-4.5 0.5-0.8 Cu 0.5-0.7 0.0-0.3 0.2-0.6 0.2-0.8 V 0.0-1.4 0.0-1.0 1.0-1.5 0.0-1.2 Nb 0.0-1.4 0.0-1.0 0.8-1.0 0.0-1.2 B 0.4-1.1 0.4-1.0 0.7-1.2 0.4-1.0 N 0.05-0.4  0.03-0.2   0.01-0.025 0.02-0.08

13. The alloy of claim 1, wherein the alloy has a carbide-boride-nitride volume fraction (CBNVF) of from higher than 35 to lower than 50, calculated according to the following equation:
CBNVF=C.sub.E×12.33+(% Cr+% M)×0.55−15.2 with M=total percentage of V, Mo, Nb, and Ti, and
C.sub.E=% C+F % N+(f×% B), where f=1.8 for B concentrations from 0.1% to 0.49% 2.6 for B concentrations from 0.5% to 0.99% 3.2 for B concentrations from 1.0% to 1.4%.

14. The alloy of claim 1, wherein a Vickers hardness (HV) of an article cast from the alloy can be increased by at least 15% by a cryogenic hardening of the article.

15. The alloy of claim 1, wherein a Brinell hardness (HB) of an article sand-cast from the alloy can be increased by at least 10% by a cryogenic hardening of the article.

16. An article cast from the alloy of claim 1.

17. The article of claim 16, wherein a Brinell hardness (HB) of a sand-cast article is at least 600.

18. The article of claim 16, wherein the article has been sand-cast, followed by cryogenic hardening.

19. A method of hardening an article cast from the alloy of claim 1, wherein the method comprises subjecting the article to cryogenic hardening.

20. The method of claim 19, wherein the cryogenic hardening comprises cooling the article at a cooling rate of from about 20° C. to about 40° C. per hour until a temperature of the article has reached from about −75° C. to about −90° C. and keeping the article at that temperature for about 15 minutes to about 35 minutes for every cm of thickness of the article.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0021] The present invention is further described in the detailed description which follows, in reference to the drawings wherein:

[0022] FIG. 1 is a photograph which shows the microstructure of a sample made, from Alloy 3 set forth below in Example 1 after hardening by heating; and

[0023] FIG. 2 is a photograph which shows the microstructure of a sample made from Alloy 3 after cryogenic hardening.

DETAILED DESCRIPTION OF EMBODIMENTS OF THE PRESENT INVENTION

[0024] The particulars shown herein are by way of example and for purposes of illustrative discussion of the embodiments of the present invention only and are presented in the cause of providing what is believed to be the most useful and readily understood description of the principles and conceptual aspects of the present invention. In this regard, no attempt is made to show structural details of the present invention in more detail than is necessary for the fundamental understanding of the present invention, the description taken with the drawings making apparent to those skilled in the art how the several forms of the present invention may be embodied in practice.

[0025] As used herein, the singular forms “a,” “an,” and “the” include the plural reference unless the context clearly dictates otherwise. For example, reference to “an alloy” would also mean that combinations of two or more alloys can be present unless specifically excluded.

[0026] Except where otherwise indicated, all numbers expressing quantities of ingredients, reaction conditions, etc. used in the instant specification and appended claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the specification and claims are approximations that may vary depending upon the desired properties sought to be obtained by the present invention. At the very least, each numerical parameter should be construed in light of the number of significant digits and ordinary rounding conventions.

[0027] Additionally, the disclosure of numerical ranges within this specification is considered to be a disclosure of all numerical values and ranges within that range. For example, if a range is from 1 to 50, it is deemed to include, for example, 1, 7, 34, 46.1, 23.7, or any other value or range within the range.

[0028] The various embodiments disclosed herein can be used separately and in various combinations unless specifically stated to the contrary.

[0029] In addition to iron, the alloy of the invention comprises six required components, i.e., C, B, N, Cr, Si and Ni. The weight percentage of C in the alloy of the invention is at least 1.5%, e.g., at least 1.6%, at least 1.7%, at least 1.8%, at least 1.9%, at least 2.0%, at least 2.1%, at least 2.15%, at least 2.16%, at least 2.17%, or at least 2.18% but not higher than 2.85%, e.g., not higher than 2.8%, not higher than 2.75%, not higher than 2.72%, not higher than 2.68%, not higher than 2.65%, not higher than 2.63%, not higher than 2.60%, not higher than 2.57%, not higher than 2.55%, not higher than 2.53%, or not higher than 2.50%.

[0030] The weight percentage of Cr in the alloy of the invention is at least 3%, but not higher than 34%. The weight percentage of Cr usually is at least 4%, at least 5%, at least 6%, at least 7%, at least 7.5%, or at least 8%, but not higher than 30%, e.g., not higher than 28%, or not higher than 27%.

[0031] The weight percentage of N in the alloy of the invention is at least 0.01%, e.g., at least 0.02%, at least 0.03%, at least 0.04%, at least 0.05%, at least 0.06%, at least 0.07%, at least 0.08%, at least 0.09%, at least 0.1%, at least 0.15%, at least 0.2%, at least 0.25%, or at least 0.3%, but not higher than 1.2%, e.g., not higher than 1.1%, not higher than 1.0%, not higher than 0.9%, not higher than 0.8%, not higher than 0.7%, not higher than 0.6%, not higher than 0.5%, or not higher than 0.45%.

[0032] The weight percentage of B in the alloy of the invention is at least 0.1%, e.g., at least 0.15%, at least 0.2%, at least 0.25%, at least 0.3%, at least 0.35%, at least 0.4%, at least 0.45%, at least 0.5%, at least 0.6%, at least 0.7%, at least 0.8%, at least 0.9%, or at least 1% but not higher than 1.4%, e.g., not higher than 1.35%, not higher than 1.3%, not higher than 1.25%, or not higher than 1.2%.

[0033] The weight percentage of Ni in the alloy of the invention is at least 0.1%, e.g., at least 0.2%, at least 0.3%, at least 0.4%, at least 0.45%, or at least 0.5%, but not higher than 7.5%, e.g., not higher than 7%, not higher than 6.5%, not higher than 6%, not higher than 5.5%, not higher than 5%, or not higher than 4.5%.

[0034] The weight percentage of Si in the alloy of the invention is at least 0.1%, e.g., at least 0.15%, at least 0.2%, at least 0.25%, at least 0.3%, at least 0.35%, or at least 0.4% but not higher than 4%, e.g., not higher than 3.8%, not higher than 3.6%, not higher than 3.4%, not higher than 3.2%, not higher than 3%, not higher than 2.8%, not higher than 2.6%, or not higher than 2.4%.

[0035] The alloy of the invention usually comprises one or more additional elements, i.e., in addition to Fe, Cr, C, B, N, Ni and Si. For example, often the alloy will also comprise at least one or more (and frequently all or at least two, three or four) of V, Mn, Mo, Nb, Ti and Al. However, other elements such as one or more (e.g., two, three or four) of W, Co, Cu, Mg, Ca, Ta, Zr, Hf, rare earth elements may (and often will) be present as well.

[0036] If employed, the weight percentage of V in the alloy of the invention usually is at least 0.5%, e.g., at least 0.6%, at least 0.7%, at least 0.8%, or at least 0.9%, but usually not more than 4%, e.g., not more than 3.5%, not more than 3%, not more than 2.5%, not more than 2%, or not more than 1.5%.

[0037] If employed, Mn is usually present in the alloy of the invention in a weight percentage of at least 0.2%, e.g., at least 0.3%, at least 0.4%, at least 0.5%, at least 0.6%, or at least 0.65%, but usually not higher than 8%, e.g., not higher than 6%, not higher than 4%, not higher than 3%, not higher than 2%, or not higher than 1.5%.

[0038] If employed, Co is usually present in the alloy of the invention in a weight percentage of at least 0.1%, e.g., at least 0.15%, at least 0.2%, at least 0.25%, or at least 0.3%, but usually not higher than 4%, e.g., not higher than 3%, not higher than 2%, not higher than 1.5%, not higher than 1%, or not higher than 0.5%.

[0039] If employed, Cu is usually present in the alloy of the invention in a weight percentage of at least 0.1%, e.g., at least 0.2%, at least 0.3%, at least 0.4%, at least 0.45%, or at least 0.5%, but usually not higher than 5%, e.g., not higher than 4%, not higher than 3%, not higher than 2%, not higher than 1.5%, or not higher than 1.2%.

[0040] If employed, Mo and/or W are usually present in the alloy of the invention in a combined weight percentage of at least 0.3%, e.g., at least 0.5%, at least 0.6%, or at least 0.7%, but usually not higher than 5%, e.g., not higher than 4%, not higher than 3%, not higher than 2.5%, or not higher than 2.2%. If only one of Mo and W is to be present, preference is usually given to Mo, which in this case is usually present in weight percentages not higher than 3.5%, e.g., not higher than 3%, not higher than 2.5%, or not higher than 2.2%.

[0041] If employed, Nb is usually present in the alloy of the invention in a weight percentage of at least 0.1%, e.g., at least 0.2%, at least 0.3%, at least 0.4%, at least 0.5%, or at least 0.55%, but usually not higher than 5%, e.g., not higher than 4%, not higher than 3%, not higher than 2%, or not higher than 1.5%.

[0042] If employed, Ti is usually present in the alloy of the invention in a weight percentage of at least 0.1%, e.g., at least 0.2%, at least 0.3%, at least 0.4%, or at least 0.5%, but usually not higher than 5%, e.g., not higher than 4%, not higher than 3%, not higher than 2%, or not higher than 1%.

[0043] If employed, Zr is usually present in the alloy of the invention in a weight percentage of at least 0.05%, e.g., at least 0.1%, at least 0.15%, at least 0.2%, or at least 0.25%, but usually not higher than 2%, e.g., not higher than 1.8%, not higher than 1.6%, not higher than 1.3%, or not higher than 1%.

[0044] If employed, Al is usually present in the alloy of the invention in a weight percentage of at least 0.05%, e.g., at least 0.1%, at least 0.15%, at least 0.17%, at least 0.18%, at least 0.19%, at least 0.2%, at least 0.3%, or at least 0.4% but usually not higher than 2%, e.g., not higher than 1.5%, not higher than 1%, not higher than 0.9%, or not higher than 0.8%.

[0045] If employed at all, Mg and/or Ca are usually present in the alloy of the invention in a combined weight percentage of at least 0.01%, e.g., at least 0.02%, at least 0.03%, or at least 0.04% but usually not higher than 0.2%, e.g., not higher than 0.18%, not higher than 0.15%, or not higher than 0.12%. Each of Mg and Ca may be present in an individual weight percentage of at least 0.02% and not higher than 0.08%.

[0046] If employed, one or more rare earth elements are usually present in the alloy of the invention in a combined weight percentage of at least 0.05%, e.g., at least 0.08%, at least 0.1%, or at least 0.15%, but usually not higher than 2%, e.g., not higher than 1%, not higher than 0.9%, or not higher than 0.8%.

[0047] If employed, Ta, Zr, Hf, and Al are usually present in the alloy of the invention in a combined weight percentage of at least 0.01%, e.g., at least 0.05%, at least 0.08%, or at least 0.1%, but usually not higher than 3%, e.g., not higher than 2.5%, not higher than 2%, or not higher than 1.5%.

[0048] Among the unavoidable impurities which are usually present in the alloy of the invention, sulfur and phosphorus may be mentioned. Their concentrations are preferably not higher than 0.2%, e.g., not higher than 0.1%, or not higher than 0.06% by weight each.

[0049] The alloy of the invention is particularly suitable for the production of parts which must have a high wear (abrasion) resistance and are suitably produced by a process such as sand casting and chill casting. Non-limiting examples of such parts include slurry pump components, such as casings, impellers, suction liners, pipes, nozzles, agitators, valve blades. Other components which may suitably be made, at least in part, from the alloy of the present invention include, for example, shell liners and lifter bars in ball mills and autogenous grinding mills, and components of coal pulverizers.

[0050] Any conventional casting technology may be used to produce the alloy of the invention. For example, the alloy may be cast into sand molds. Alternatively, the alloy may be subjected to chill casting, for example, by pouring the alloy into a copper mold. This often affords a hardness which is significantly higher (e.g., by at least 20, and in some cases at least 50 Brinell units) than the hardness obtained by casting into a sand mold. If a hardening treatment is to be carried out, the preferred hardening method for the alloy of the invention is by cryogenic treatment: cooling to a temperature of, for example, about −100° F. to about −300° F., and maintaining at this temperature for a time of, for example, one hour per one inch of casting wall thickness. The cryogenic hardening process may be performed with equipment and machinery that is conventional in the thermal cycling treatment field. First, the articles-under-treatment are placed in a treatment chamber which is connected to a supply of cryogenic fluid, such as liquid nitrogen or a similar low temperature fluid. Exposure of the chamber to the influence of the cryogenic fluid lowers the temperature until the desired level of hardness is reached.

[0051] To sum up, the present invention provides: [0052] 1. A hypereutectic white iron alloy, wherein the alloy comprises, in weight percent based on a total weight of the alloy:

TABLE-US-00003 C from 1.5 to 2.85 B from 0.1 to 1.4 N from 0.01 to 1.2 Cr from 3 to 34 Ni from 0.1 to 7.5 Si from 0.1 to 4 Mn from 0 to 8 Co from 0 to 5 Cu from 0 to 5 Mo from 0 to 5 W from 0 to 6 V from 0 to 12 Nb from 0 to 6 Ti from 0 to 5 Zr from 0 to 2 (Mg + Ca) from 0 to 0.2 one or more rare earth elements from 0 to 3 one or more of Ta, Hf, Al from 0 to 3, remainder Fe and incidential impurities. [0053] 2. The alloy of item 1, wherein the alloy comprises from 1.8% to 2.75% C. [0054] 3. The alloy of item 1, wherein the alloy comprises from 1.9% to 2.72% C. [0055] 4. The alloy of item 1, wherein the alloy comprises from 2.0% to 2.65% C. [0056] 5. The alloy of item 1, wherein the alloy comprises from 2.1% to 2.60% C. [0057] 6. The alloy of any one of items 1 to 5, wherein the alloy comprises at least 0.3% B (e.g., at least 0.7% B). [0058] 7. The alloy of any one of items 1 to 6, wherein the alloy comprises from 0.02% to 0.5% N. [0059] 8. The alloy of any one of items 1 to 7, wherein the alloy comprises from 6% to 28% Cr. [0060] 9. The alloy of any one of items 1 to 8, wherein the alloy comprises from 0.3% to 5% Ni. [0061] 10. The alloy of any one of items 1 to 9, wherein the alloy comprises from 0.3% to 3% Si. [0062] 11. The alloy of any one of items 1 to 10, wherein the alloy comprises:

TABLE-US-00004 C from 2.15 to 2.72 B from 0.4 to 1.4 N from 0.01 to 0.4 Cr from 8 to 28 Ni from 0.3 to 5 Si from 0.4 to 3 Mn from 0.5 to 1.4 Co from 0 to 5 Cu from 0 to 0.9 Mo from 0 to 3 W from 0 to 6 V from 0 to 2 Nb from 0 to 2 Ti from 0 to 5 Zr from 0 to 2 (Mg + Ca) from 0 to 0.2 one or more rare earth elements from 0 to 3 one or more of Ta, Hf, Al from 0 to 3, remainder Fe and incidential impurities. [0063] 12. The alloy of any one of items 1 to 11, wherein the alloy has one of the following compositions 1 to 4:

TABLE-US-00005 Composition 1 2 3 4 C 2.2-2.7 1.6-2.0 1.9-2.6 2.0-2.7 Si 0.5-0.7 0.4-0.6 2.0-2.3 0.4-1.0 Mn 0.6-1.3 0.6-1.0 0.5-1.2 0.5-1.0 Cr 26.0-27.0 25-26 8-9 16-17 Mo 0.5-1.0 0.0-1.0 0.0-0.6 2.0-2.8 Ni 0.3-0.5 0.5-1.3 .sup. 4-4.5 0.5-0.8 Cu 0.5-0.7 0.0-0.3 0.2-0.6 0.2-0.8 V 0.0-1.4 0.0-1.0 1.0-1.5 0.0-1.2 Nb 0.0-1.4 0.0-1.0 0.8-1.0 0.0-1.2 B 0.4-1.1 0.4-1.0 0.7-1.2 0.4-1.0 N 0.05-0.4  0.03-0.2   0.01-0.025 0.02-0.08 [0064] 13. The alloy of any one of items 1 to 12, wherein an article cast from the alloy can be hardened by cryogenic hardening. [0065] 14. The alloy of item 13 wherein a Vickers hardness (HV) of an article cast from the alloy can be increased by at least 15% by a cryogenic hardening of the article. [0066] 15. The alloy of item 13 or item 14, wherein a Brinell hardness (HB) of an article sand-cast from the alloy can be increased by at least 10% by a cryogenic hardening of the article. [0067] 16. The alloy of any one of items 1 to 15, wherein the alloy has a carbide-boride-nitride volume fraction (CBNVF) of from higher than 35 (e.g., not less than 36, 37, 38, 39 or 40) to lower than 50 (e.g., not more than 49, 48, 47, 46 or 45), calculated according to the following equation:

CBNVF=C.sub.E×12.33+(% Cr+% M)×0.55−15.2

with M=total percentage of V, Mo, Nb, and Ti, and

CE=% C+% N+(f×% B), where [0068] f=1.8 for B concentrations from 0.1% to 0.49% [0069] 2.6 for B concentrations from 0.5% to 0.99% [0070] 3.2 for B concentrations from 1.0% to 1.4%. [0071] 17. An article cast from the alloy of any one of items 1 to 16. [0072] 18. The article of item 17, wherein a Brinell hardness (HB) of the sand-cast article is at least 600. [0073] 19. The article of item 17 or item 18, wherein the sand-cast article has been hardened by cryogenic hardening. [0074] 20. The article of any one of items 17 to 19, wherein the article has been cryogenically hardened. [0075] 21. The article of item 20, wherein the metal matrix microhardness represented by the Vickers Hardness (HV) of the cryogenically hardened article is at least 15% higher than the article before the cryogenic hardening. [0076] 22. The article of item 20 or item 21, wherein the Brinell Hardness (HB) of the cryogenically hardened article is at least 10% higher than the article before the cryogenic hardening. [0077] 23. The article of any one of items 20 to 22, wherein HV and/or HB of the cryogenically hardened article is at least as high as HV and/or HB of an article hardened at temperatures of from 1000° C. to 1100° C. [0078] 24. A method of hardening an article cast from the alloy of any one of items 1 to 16, wherein the method comprises subjecting the article to cryogenic hardening. [0079] 25. The method of item 24, wherein the cryogenic hardening comprises cooling the article at a cooling rate of from about 20° C. to about 40° C. per hour until a temperature of the article has reached from about -75° C. to about -90° C. and keeping the article at that temperature for about 15 minutes to about 35 minutes for every cm of thickness of the article. [0080] 26. The method of item 25, wherein cooling the article comprises contacting it with liquid nitrogen or liquid air. [0081] 27. A method of producing an article from an alloy of any one of items 1 to 16, wherein the method comprises pouring the molten alloy into a sand mold or a copper mold, allowing the alloy to cool to about ambient temperature and subjecting the resultant article to cryogenic hardening. [0082] 28. The method of item 27, wherein the cryogenic hardening comprises cooling the article at a cooling rate of from about 20° C. to about 40° C. per hour until a temperature of the article has reached from about -75° C. to about -90° C. and keeping the article at that temperature for about 15 minutes to about 35 minutes for every cm of thickness of the article.

EXAMPLES

[0083] In the following examples the procedures used for determining the Vickers Hardness (HV) and the Brinell Hardness (HB) were as follows:

[0084] Vickers Hardness (HV)

[0085] The Vickers Hardness was determined by the method set forth in ASTM E384. In this method, a pyramid shaped diamond indenter is applied smoothly into the surface of the material. The indenter is held in place for 10 to 15 seconds and then fully retreated. Using a microscope, the diagonals of resulting indentation are measured, and the hardness value is calculated by dividing the load by the surface area of the indentation.

[0086] A LECO LM 700AT microhardness tester with ConfiDent software was used. Samples for the microindentation hardness test were cut out of the bulk sample using a bench-top abrasive saw. Small pieces were then mounted in a thermoset phenolic compound using a Buehler SimpliMet 3000 mounting press. Mounted samples were then ground flat and polished with the help of an EcoMet 300 Pro grinder-polisher. Right before hardness testing, the surface of the sample was chemically etched to aid in distinguishing between different metallic phases of the material.

[0087] The final hardness number was based on the average of 8-20 different indentations. The number of times each sample has to be tested is usually based on the thermal treatment of the sample. As cast samples tend to require larger number of indentations because their hardness values tend to vary greatly. Heat and cryogenically treated samples are usually more consistent in their micro hardness.

[0088] Brinell Hardness (HB) vs. Micro-Indentation Vickers Hardness (HV)

[0089] The Brinell hardness is used to measure the bulk hardness of a material. The test consists of pressing a 10 mm tungsten carbide ball against the surface of the metal with a 300 kg force. In white irons this results in round indentation with diameter usually between 2.1 mm to 3.4 mm. The lower the diameter is, the higher the hardness value. Because of the relatively large size of the indentation this is considered bulk hardness (carbides and metal matrix hardness together).

[0090] The micro-indentation Vickers hardness values reported below were usually obtained by using a load of less than 1 kg, namely 25 g. With the lower hardness the indentation is small enough to test different phases separately. All the Vickers hardness test results refer to the Metal Matrix Hardness.

[0091] The carbide hardness is not affected by the hardening method (heat or cryogenic treatment). The change is in the metal matrix hardness. Therefore, the micro-indentation hardness HV allows a more accurate assessment of the effect of the cryogenic/freezing vs thermal treatment of the sample.

[0092] Preparation of Samples

[0093] The molten alloys were poured at a temperature of 2550° F.±10° F. into sand molds with dimensions of 20 mm×20 mm×110 mm to obtain samples for testing of each alloy. For chill casting each alloy was poured into a copper mold (30 mm diameter×35 mm height). The castings were cooled to ambient temperature both in the sand molds and the chill molds.

[0094] Cryogenic Treatment of Cast Samples

[0095] The procedure involved placing the casting in an enclosed and insulated box and then spraying liquid nitrogen over its entire area. The cooling rate was 50° F. per hour. Once the casting temperature reached −150° F. it was held at that temperature for 1 hour per every inch of its thickness.

[0096] The concentration numbers in the following tables are in percent by weight.

Example 1

[0097]

TABLE-US-00006 Alloy C Si Mn P S Cr Mo Ni Cu Nb B N Fe 1 2.66 0.55 0.61 0.018 0.031 16.43 2.07 0.58 0.26 1.08 0.46 0.03 75.1 2 2.37 0.51 0.56 0.019 0.030 16.37 2.05 0.53 0.25 1.19 0.65 0.03 75.4 3 2.15 0.48 0.54 0.02 0.028 16.33 2.05 0.49 0.25 1.18 0.85 0.03 75.5

[0098] Vickers Hardness (HV)

TABLE-US-00007 Alloy As Cast Frozen Heat Treated 1 435 635 802 2 432 647 804 3 455 680 811

[0099] Brinell Hardness (HB)—Sand Cast

TABLE-US-00008 Tempered (500° F. and Tempered Alloy As Cast Frozen Heat Treated 800° F.) (1000° F.) 1 578 712 712! 745! 682  2 601 712 712! 712! 697! 3 653 780 745! 712! 682!

[0100] Brinell Hardness (HB)—Chill Cast

TABLE-US-00009 Tempered (500° F. and Tempered Alloy As Cast Frozen Heat Treated 800° F.) (1000° F.) 1 682 780 817! 817! 712! 2 682 817 856! 817! 712! 3 712 899 817! 817! 712!

[0101] “!” indicates some observed cracks on the sample surface caused by indentation

[0102] From the results shown above it can be seen that the samples that were heat treated are on average 151 Vickers units harder than the cryogenically treated samples, which is believed to be due to the formation of secondary carbides during the heat treatment, making the metal matrix brittle. The formation of secondary carbides depletes carbon from the matrix, thereby making the remaining martensite softer. Furthermore, a heat treatment does not completely transform the matrix, increasing the percentage of retained austenite. Retained austenite makes the casting more prone to spalling. Spalling occurs when high velocity particles impact the surface of the casting, transforming the impacted area of austenite to martensite. This transformation causes the affected area to break off the casting because of the difference in volume between austenite and martensite. A cryogenic hardening treatment vastly reduces the percentage of retained austenite. With a lower percentage of retained austenite the resistance of the casting to spalling increases greatly.

[0103] The above Alloy 3 was divided into two samples. Sample 1 was hardened by conventional high temperature heat treatment where the sample is heated to above the austenitizing temperature and held at this temperature. During austenitizing, precipitation of secondary carbides occurs through diffusion as shown in FIG. 1. This results in a lower carbon matrix and destabilization of austenite. The alloy was then air quenched and the destabilization of the mostly austenitic matrix resulted in a higher martensite transformation temperature and a higher percentage of austenite which is available for transformation during the quenching. However, the carbon content in the transformed martensite is moderate, therefore the hardness of the martensite is moderate as well.

[0104] Sample 2 was hardened by freezing. This is a diffusion-less transformation which occurs over a temperature range of 300° F., for example from 300° F. to −300° F. The starting temperature of the transformation varies depending on the stability of the austenite, which varies based on the composition of the alloy. Based on FIG. 2 and in view of the microhardness readings of Sample 1 and Sample 2 being within the same range with the reading of Sample 2 slightly higher than the reading of Sample 1, it can be concluded that the boron augmentation destabilizes the austenite to achieve almost full transformation from austenite to martensite over the freezing temperature range. Because carbon was not precipitated out of the matrix in the freezing treatment, the martensite in Sample 2 is more saturated in carbon than Sample 1, which results in a higher martensite hardness.

[0105] When the Brinell hardness of both samples was tested, Sample 1 exhibited microcracks, whereas Sample 2 did not. This is indicative of a lower fracture toughness of Sample 1 than that of Sample 2. The secondary carbides precipitated during the high temperature heat treatment have an embrittling effect on the alloy, whereas the saturated martensite is similar, or higher in hardness, but more ductile.

[0106] Regarding FIG. 1 (Sample 1), the fine white grains which can be seen throughout the matrix are secondary carbides precipitated during heat treatment.

[0107] Regarding FIG. 2 (Sample 2), the needle like structure which can be seen throughout the matrix is martensite transformed from austenite during freezing.

Example 2

[0108]

TABLE-US-00010 Alloy C Si Mn P S Cr Mo Ni Cu V B N Fe 4 2.63 0.45 0.64 0.016 0.019 16.79 2.09 0.71 0.72 0.91 0.56 0.03 74.4 5 2.39 0.45 0.61 0.016 0.019 16.68 2.08 0.69 0.72 0.89 0.75 0.03 74.6 6 2.18 0.45 0.60 0.017 0.019 16.64 2.08 0.70 0.74 0.87 0.94 0.03 74.7

[0109] Vickers Hardness

TABLE-US-00011 Heat Treated Alloy As Cast Frozen Heat Treated then Frozen 4 432 698 707 — 5 450 719 689 714 6 593 735 677 709

[0110] Brinell Hardness (HB)—Sand Cast

TABLE-US-00012 Alloy As Cast Heat Treated 4 614 728 5 653 745 6 682 745

[0111] Brinell Hardness (HB)—Chill Cast

TABLE-US-00013 Alloy As Cast Heat Treated 4 712 836 ! 5 745 856 ! 6 .sup.  745 ! 836 !

[0112] “!” indicates some observed cracks on the sample surface caused by indentation

[0113] As can be taken from the above results, the Vickers hardness of the frozen samples of Alloys 5 and 6 is higher than the Vickers hardness of the samples of the corresponding heat treated alloys. This is believed to be due to the fact that the heat treated samples contained undesirable amounts of retained austenite. When the heat treated samples were frozen, the Vickers hardness thereof decreased compared to that of the samples which were only frozen, which is believed to be due to a transformation of at least some of the retained austenite to martensite.

Example 3

[0114]

TABLE-US-00014 C Si Mn P S Cr Mo Ni Cu V B Nb N Fe 7 2.52 2.22 0.65 0.017 0.017 8.65 0.56 4.11 0.53 1.22 0.82 0.76 0.02 78.3 8 2.38 2.24 0.66 0.018 0.017 8.66 0.54 4.11 0.53 1.24 0.93 0.78 0.02 78.4 9 2.16 2.29 0.68 0.018 0.017 8.65 0.54 4.12 0.54 1.23 1.04 0.81 0.02 78.5

[0115] Vickers Hardness (HV)

TABLE-US-00015 Alloy As Cast Frozen 7 386 692 8 407 695 9 399 698

[0116] Brinell Hardness (HB)—Sand Cast

TABLE-US-00016 Alloy As Cast Frozen 7 653 780 8 653 780 9 653 745

[0117] Brinell Hardness (HB)—Chill Cast

TABLE-US-00017 Alloy As Cast Frozen 7 745 780 8 745 780 9 682 780

[0118] “!” indicates some observed cracks on the sample surface caused by indentation

Example 4

[0119]

TABLE-US-00018 Alloy C Si Mn P S Cr Mo Ni Cu V B Nb N Fe 10 2.38 2.37 0.70 0.015 0.015 8.79 0.51 4.15 0.60 1.33 0.97 0.78 0.02 78.1 11 2.36 2.31 0.67 0.016 0.014 9.95 0.51 4.18 0.59 1.31 0.94 0.76 0.02 77.1 12 2.35 2.28 0.66 0.015 0.014 11.16 0.49 4.09 0.58 1.29 0.93 0.76 0.02 76.1

[0120] Vickers Hardness (HV)

TABLE-US-00019 As Cast Frozen 10 460 732 11 487 686 12 425 701

[0121] Brinell Hardness (HB)—Sand Cast

TABLE-US-00020 As Cast Frozen 10 653 745 11 653 745 12 627 745

[0122] Brinell Hardness (HB)—Chill Cast

TABLE-US-00021 As Cast Frozen 10 712 817 11 712 817 12 745 817

Example 5

[0123]

TABLE-US-00022 Alloy C Si Mn P S Cr Mo Ni Cu W B Nb N Fe 13 2.32 2.54 0.69 0.017 0.019 8.58 0.51 4.11 0.59 1.11 0.95 0.75 0.02 77.6 14 2.21 2.43 0.67 0.017 0.020 8.48 0.49 4.06 0.58 2.42 0.95 0.73 0.02 76.7

[0124] Vickers Hardness (HV)

TABLE-US-00023 Alloy As Cast Frozen 13 405 708 14 423 722

[0125] Brinell Hardness (HB)—Sand Cast

TABLE-US-00024 Alloy As Cast Frozen 13 653 780 14 653 780

[0126] Brinell Hardness (HB)—Chill Cast

TABLE-US-00025 Alloy As Cast Frozen 13 745 817 14 682 780

Example 6

[0127]

TABLE-US-00026 Alloy C Si Mn P S Cr Mo Ni Cu B Nb N Fe 15 2.47 0.65 1.29 0.019 0.039 27.02 0.61 0.42 0.63 0.55 1.36 0.31 64.8 16 2.27 0.62 1.20 0.021 0.035 27.06 0.55 0.41 0.59 0.66 1.41 0.30 65.2 17 2.18 0.59 1.11 0.021 0.035 27.03 0.53 0.39 0.58 0.70 1.46 0.31 65.3

[0128] Vickers Hardness (HV)

TABLE-US-00027 As Cast Frozen 15 573 680 16 531 684 17 544 691

[0129] Brinell Hardness (HB)—Sand Cast

TABLE-US-00028 As Cast Frozen 15 578 682 16 601 712 17 627 .sup.  712!

[0130] Brinell Hardness (HB)—Chill Cast

TABLE-US-00029 As Cast Frozen 15 745 780 16 745 780 17 712  780!

[0131] “!” indicates some observed cracks on the sample surface caused by indentation

Example 7 (Comparative)

[0132]

TABLE-US-00030 Alloy C Si Mn P S Cr Mo Ni Cu B Fe 18 1.97 0.48 0.77 0.013 0.028 25.34 0.02 0.91 0.14 0.01 70.1 19 1.95 0.51 0.78 0.015 0.029 25.38 0.02 0.91 0.15 0.56 69.4 20 1.81 0.49 0.72 0.015 0.029 25.32 0.02 0.98 0.15 0.63 69.6 21 1.72 0.47 0.66 0.016 0.031 25.36 0.02 1.08 0.15 0.73 69.5

[0133] Vickers Hardness (HV)

TABLE-US-00031 Alloy As Cast Heat treated Frozen 18 468 738 392 19 524 740 535 20 496 756 496 21 485 749 529

[0134] Brinell Hardness (HB)—Sand Cast

TABLE-US-00032 Alloy As Cast Frozen 18 429 444 19 555 653 20 566 653 21 601 653

[0135] Brinell Hardness (HB)—Chill Cast

TABLE-US-00033 Alloy As Cast Frozen 18 437 514 19 627 653 20 627 653 21 627 682

[0136] As can be taken from the above results, the absence of nitrogen in Alloys 18-21 causes the cryogenic hardening of the cast alloys to be almost ineffective.

Example 8

[0137]

TABLE-US-00034 Alloy C Si Mn P S Cr Mo Ni Cu V B Ce La Nb Mg N Fe 22 2.72 2.17 0.59 0.017 0.01 8.61 0.58 4.17 0.44 1.28 1.12 0.31 0.12 0.71 0.019 0.02 77.6 23 2.72 2.13 0.59 0.016 0.01 8.61 0.58 4.18 0.44 1.28 1.12 0.61 0.25 0.71 0.018 0.02 77.3

[0138] Vickers Hardness (HV)

TABLE-US-00035 As Cast Frozen 22 582 714 23 560 709

[0139] Brinell Hardness (HB)—Sand Cast

TABLE-US-00036 As Cast Frozen 22 712 798 23 712 798

[0140] Brinell Hardness (HB)—Chill Cast

TABLE-US-00037 As Cast Frozen 22 817 856 .sup.  23 817 856 !

[0141] “!” indicates some observed cracks on the sample surface caused by indentation

Example 9 (Comparative)

[0142]

TABLE-US-00038 Alloy C Si Mn P S Cr Mo Ni Cu V B Ce La Nb Ti N Fe 24 2.89 2.31 0.72 0.023 0.019 8.46 0.37 4.19 0.46 1.19 1.17 0.31 0.14 0.66 0.07 0.02 77.9 25 2.88 2.28 0.72 0.023 0.019 8.49 0.37 4.18 0.46 1.19 1.17 0.33 0.15 0.65 0.07 0.02 77.9 26 2.88 2.23 0.71 0.023 0.016 8.47 0.36 4.18 0.46 1.18 1.15 0.43 0.19 0.65 0.07 0.02 77.9

[0143] Vickers Hardness (HV)

TABLE-US-00039 As Cast Frozen 24 534 610 25 528 706 26 518 707

[0144] Brinell Hardness (HB)—Sand Cast

TABLE-US-00040 As Cast Frozen 24 780 817 25 745 817 26 745 817

[0145] Brinell Hardness (HB)—Chill Cast

TABLE-US-00041 As Cast Frozen 24 780 856 ! 25 780 856 ! 26 780 817 !

[0146] “!” indicates some observed cracks on the sample surface caused by indentation

Example 10

[0147]

TABLE-US-00042 Alloy C Si Mn P S Cr Mo Ni Cu B Nb N V Fe 9 2.16 2.29 0.68 0.02 0.02 8.65 0.54 4.12 0.54 1.04 0.81 0.02 1.23 78.5 27 3.25 2.15 1.40 0.03 0.05 8.41 0.46 5.50 0.38 0.80 0.72 0.02 1.20 76.7

[0148] Vickers Hardness (HV)

TABLE-US-00043 As Cast Frozen 9 405 708 27 380 430

[0149] Brinell Hardness (HB)—Sand Cast

TABLE-US-00044 As Cast Frozen 9 653 780 27 712 745

[0150] As can be taken from the results set forth above, a concentration of carbon outside the claimed range in Alloy 27 results in a hardness of a cast article in the cryogenically hardened state is lower than that of an article cast from Alloy 9 in the cryogenically hardened state.

[0151] It is noted that the foregoing examples have been provided merely for the purpose of explanation and is in no way to be construed as limiting of the present invention. While the present invention has been described with reference to exemplary embodiments, it is understood that the words which have been used herein are words of description and illustration, rather than words of limitation. Changes may be made, within the purview of the appended claims, as presently stated and as amended, without departing from the scope and spirit of the present invention in its aspects. Although the present invention has been described herein with reference to particular means, materials and embodiments, the present invention is not intended to be limited to the particulars disclosed herein; rather, the present invention extends to all functionally equivalent structures, methods and uses, such as are within the scope of the appended claims.