CASE-HARDENED STEEL PART FOR USE IN AERONAUTICS

Abstract

The present invention relates to a steel part for use in aeronautics, comprising a substrate, the substrate comprising at least carbon, cobalt, aluminium and nickel, and having an average atomic fraction of carbon between 0.09% and 0.17%, an average atomic fraction of cobalt between 15.5% and 18.5%, an average atomic fraction of aluminium less than 0.1%, an average atomic fraction of nickel between 7.2% and 9.8%, the part being case-hardened and also comprising a nitrided layer, the nitrided layer at least partially covering the substrate and having a thickness between 5 μm to 180 μm, preferably between 50 μm and 150 μm.

Claims

1-10. (canceled)

11. A process for manufacturing a steel part for use in aeronautics comprising the consecutive steps of: a) providing a part comprising a substrate, the substrate comprising at least carbon, cobalt, aluminum and nickel, and having an average mass fraction of carbon comprised between 0.09% and 0.17%, an average mass fraction of cobalt comprised between 15.5% and 18.5%, an average mass fraction of aluminum of less than 0.1%, and an average mass fraction of nickel comprised between 7.2% and 9.8 b) case-hardening the part in a controlled atmosphere at a temperature comprised between 900° C. and 1100° C., c) quenching the part and cryogenically treating the part in a controlled atmosphere at a temperature comprised between −50° C. and −100° C., and d) aging the part in a controlled atmosphere at a temperature comprised between 450° C. and 550° C., wherein the aging comprises nitriding the part in an atmosphere comprising ammonia so that the part comprises a nitrided surface, nitriding being simultaneous with aging of the part.

12. The process as claimed in claim 11, wherein the case-hardening of step b) is carried out so that at least a portion of a surface of the part has an average mass fraction of carbon comprised between 0.4% and 0.6%.

13. The process for manufacturing a part as claimed in claim 11, wherein step b) of case-hardening comprises an injection of a carburizing gas into a carburizing chamber containing the part, the carburizing gas being at least selected from propane and acetylene.

14. A steel part for use in aeronautics obtainable by a process as claimed in claim 11, comprising a substrate the substrate comprising at least carbon, cobalt, aluminum and nickel, and having an average mass fraction of carbon comprised between 0.09% and 0.17%, an average mass fraction of cobalt comprised between 15.5% and 18.5%, an average mass fraction of aluminum of less than 0.1%, an average mass fraction of nickel comprised between 7.2% and 9.8%, wherein the part is case-hardened and nitrided, so that it comprises a nitrided layer, the nitrided layer at least partially covering the substrate and the nitrided layer having a thickness comprised between 5 μm and 180 μm, an average mass fraction of carbon comprised between 0.4% and 0.6% and an average mass fraction of nitrogen comprised between 0.6% and 3%.

15. The part as claimed in claim 14, wherein the substrate has: an average mass fraction of carbon comprised between 0.13% and 0.17%, an average mass fraction of cobalt comprised between 17.5% and 18.5%, a sum of an average mass fraction of molybdenum and an average mass fraction of tungsten comprised between 0.9% and 1.3%, an average mass fraction of nickel comprised between 9.2% and 9.8%.

16. The part as claimed in claim 14, wherein the substrate has: an average mass fraction of carbon comprised between 0.09% and 0.13%, an average mass fraction of cobalt comprised between 15.5% and 17%, an average mass fraction of aluminum of less than 0.1%, an average mass fraction of nickel comprised between 7.2% and 7.8%.

17. The part as claimed in claim 14, wherein the nitrided layer comprises at least one element selected from nitride precipitates and carbonitride precipitates.

18. The part as claimed in claim 17, wherein the nitrided layer has a predominantly martensitic phase.

19. A power transmission gear, comprising a steel part as claimed in claim 14.

20. The part as claimed in claim 14, wherein the nitrided layer has a thickness comprised between 50 μm and 150 μm.

Description

DESCRIPTION OF THE FIGURES

[0032] Other features, aims and advantages of the invention will emerge from the following description, which is purely illustrative and non-limiting, and which should be read in conjunction with the appended drawings wherein:

[0033] FIG. 1 schematically illustrates a power transmission gear according to a particular embodiment of the invention.

[0034] FIG. 2 is a microphotograph of a cross-section of a part according to an embodiment of the invention, wherein the part comprises a Ferrium® C61™ substrate.

[0035] FIG. 3 is a microphotograph of a cross-section of a part according to an embodiment of the invention, wherein the part comprises a Ferrium® C64™ substrate.

[0036] FIG. 4 is a diagram illustrating the Vickers hardness profile of two parts according to two particular embodiments of the invention and of two known parts.

[0037] FIG. 5 illustrates a process for manufacturing a part according to a particular embodiment of the invention.

[0038] FIG. 6 schematically illustrates the temperature of a chamber containing a part according to an embodiment of the invention and the controlled nitriding potential in the chamber during aging of the part.

DETAILED DESCRIPTION OF THE INVENTION

[0039] General Architecture of the Part 1

[0040] With reference to FIG. 1, the part 1 is a steel part for use un aeronautics, comprising a substrate 2, a case-hardened layer 3b at least partially covering the substrate 2, and a nitrided layer 3a at least partially covering the substrate 2. The part 1 has an outer surface 5. The nitrided layer 3a may merge at least partially or completely with a case-hardened layer 3b. Indeed, the characteristic penetration lengths of the carbon and nitrogen atoms during case-hardening and nitriding, respectively, result in the formation of a case-hardened layer 3b and a nitrided layer 3a, both formed from the surface 5 of the part 1 and to depths which may be different depending on the layer considered.

[0041] A power transmission gear 4 preferentially comprises the part 1. The power transmission gear 4 may be used to transmit power from an engine to a rotor, for example the main rotor of a helicopter.

[0042] The substrate 2 comprises at least carbon, cobalt, aluminum and nickel, and has an average mass fraction of carbon comprised between 0.09% and 0.17%, an average mass fraction of cobalt comprised between 15.5% and 18.5%, an average mass fraction of aluminum of less than 0.1%, an average mass fraction of nickel comprised between 7.2% and 9.8%. Thus, the substrate 2 is a steel whose mechanical properties are close to or equal to the mechanical properties of Ferrium® C61™ and/or Ferrium® C64™.

[0043] Preferentially, the nitrided layer 3a has an average mass fraction of carbon comprised between 0.4% and 0.6%. Indeed, this fraction of carbon, lower than the fraction of carbon of a case-hardened part of the prior art, makes it possible to nitride the part in such a way as to increase its hardness while avoiding the disadvantages associated with the formation of undesirable phases such as residual austenite and/or intergranular precipitate networks.

[0044] Preferentially, the substrate 2 has an average mass fraction of carbon comprised between 0.13% and 0.17%, an average mass fraction of cobalt comprised between 17.5% and 18.5%, a sum of the average mass fraction of molybdenum and the average mass fraction of tungsten comprised between 0.9% and 1.3%, an average mass fraction of nickel comprised between 9.2% and 9.8%. Thus, the substrate 2 has the mechanical properties of Ferrium® C61™.

[0045] Preferentially and/or alternatively, the substrate 2 has an average mass fraction of carbon comprised between 0.09% and 0.13%, an average mass fraction of cobalt comprised between 15.5% and 17%, an average mass fraction of aluminum of less than 0.1%, an average mass fraction of nickel comprised between 7.2% and 7.8%. Thus, the substrate 2 has the mechanical properties of Ferrium® C64™.

[0046] With reference to FIG. 2 and FIG. 3, the nitrided layer 3a has a thickness comprised between 5 μm and 180 μm, preferentially comprised between 50 and 150 μm, and the average mass fraction of nitrogen in the nitrided layer 3a is comprised between 0.2% and 3% and preferentially between 0.3% and 1%. Thus, the hardness of the part is higher than the hardness of a part made of case-hardened Ferrium® C61™ or case-hardened Ferrium® C64™, while retaining the mechanical properties of Ferrium® C61™ or Ferrium® C64™ (such as temperature resistance) and avoiding the disadvantages associated with shot peening the part.

[0047] With reference to FIG. 2, the composition of the substrate 2 may be that of Ferrium® C61™ at a sufficiently large distance from the surface 5, i.e., at a distance greater than 250 μm from the surface 5, and preferentially greater than 500 μm. The nitrided layer 3a covers the substrate 2, and comprises the surface 5 on the side of the nitrided layer 3a opposite the substrate 2. The nitrided layer 3a has, from the surface 5: [0048] preferentially a surface combination layer, having for example a thickness from the surface comprised between 0 μm and 30 μm, and comprising at least predominantly and preferentially exclusively nitrides, and then [0049] a diffusion layer, for example with a thickness comprised between 50 μm and 150 μm, located under the combination layer.

[0050] The diffusion layer comprises nitrogen, the average mass concentration of nitrogen in the diffusion layer being strictly lower than the mass concentration of nitrogen in the combination layer. In this layer the nitrogen can be disseminated into the case-hardened Ferrium® C61™ or C64™ in the form of nitride precipitates and/or carbonitride precipitates.

[0051] With reference to FIG. 3, the composition of the substrate 2 may be that of Ferrium® C64™ at a sufficiently large distance from the surface 5, i.e., at a distance greater than 250 μm from the surface 5, and preferentially greater than 500 μm. The nitrided layer 3a covers the substrate 2, and comprises the surface 5 on the side of the nitrided layer 3a opposite the substrate 2. The substrate 2 may comprise a diffusion layer in contact with the nitrided layer 3a. The diffusion layer comprises nitrogen, the average mass concentration of nitrogen in the diffusion layer being strictly lower than the mass concentration of nitrogen in the nitrided layer 3a.

[0052] With reference to FIG. 4, the nitrided layer 3a of the part 1 according to an embodiment of the invention significantly increases the hardness of the part 1 compared with a known case-hardened Ferrium® C61™ part and/or a known case-hardened Ferrium® C64™ part. Curve (a) illustrates the hardness profile of the part 1 according to an embodiment of the invention, the part 1 comprising a Ferrium® C64™ substrate. The hardness measured is the Vickers hardness (HV). Curve (b) illustrates the hardness profile of the part 1 according to an embodiment of the invention, the part 1 comprising a Ferrium® C61™ substrate. Curve (c) illustrates the hardness profile of a known case-hardened part comprising a Ferrium® C64™ substrate. Curve (d) illustrates the hardness profile of a known case-hardened part comprising a Ferrium® C61™ substrate. On the surface, the hardness of a part according to an embodiment of the invention may be greater than 200 HV of the hardness of a known case-hardened Ferrium® C61™ or Ferrium® C64™ part.

[0053] The nitrided layer 3a preferentially comprises at least one element selected from nitride precipitates and carbonitride precipitates. Thus, the hardness of the part 1 can be increased.

[0054] Process for Manufacturing the Part 1

[0055] FIG. 5 schematically illustrates a process for manufacturing the part 1 according to an embodiment of the invention. The process comprises a step 101 of providing a part comprising at least carbon, cobalt, aluminum and nickel. The part has an average mass fraction of carbon comprised between 0.09% and 0.17%, an average mass fraction of cobalt comprised between 15.5% and 18.5%, an average mass fraction of aluminum of less than 0.1%, and an average mass fraction of nickel comprised between 7.2% and 9.8%. Preferentially, the part may be made of Ferrium® C61™, i.e., it has an average mass fraction of carbon comprised between 0.13% and 0.17%, an average mass fraction of cobalt comprised between 17.5% and 18.5%, a sum of the average mass fraction of molybdenum and the average mass fraction of tungsten comprised between 0.9% and 1.3%, and an average mass fraction of nickel comprised between 7.2% and 9.8%. Preferentially, the part can also be made of Ferrium® C64™, i.e., it has an average mass fraction of carbon comprised between 0.09% and 0.13%, an average mass fraction of cobalt comprised between 15.5% and 17%, an average mass fraction of aluminum of less than 0.1%, an average mass fraction of nickel comprised between 7.2% and 7.8%.

[0056] The process comprises a step 102 of case-hardening the part in a chamber whose atmosphere is controlled at a temperature comprised between 900° C. and 1100° C. The case-hardening step 102 may preferentially comprise several carbon enrichment cycles 106 of the surface. An enrichment cycle 106 comprises a substep of injecting a carburizing gas 107 and a substep of injecting a neutral gas 108.

[0057] During the substep of injecting a carburizing gas 107, a carburizing gas is injected into the carburizing chamber containing the part, so as to enrich the surface of the part with carbon and to increase the surface carbon content of the part to a predetermined maximum surface carbon content. The temperature in the chamber is maintained between 900° C. and 1100° C., for a time t.sub.1 for example comprised between 60 s and 300 s. The carburizing gas may be selected at least from propane and acetylene. The dilution ratio of the injected carburizing gas may be comprised between 5% and 75%, preferably between 10% and 25%, and the carburizing gas may be injected at a pressure comprised between 0.1 bar and 3 bar, preferably equal to 230±50 mbar. The term “dilution” refers to the dilution of the carburizing gas in a neutral gas, for example argon or dinitrogen.

[0058] During the substep of injecting a neutral gas 108, a neutral gas is injected into the carburizing chamber for a time t.sub.2 comprised between 20 minutes and 3 hours, so as to cause the carbon to diffuse from the surface to the interior of the part, and to decrease the surface carbon content to a predetermined minimum surface carbon content. The neutral gas may be selected from argon and dinitrogen. The succession of enrichment cycles 106 allows the part to be enriched in carbon while preventing the mass fraction of carbon on the surface of the part from exceeding the predetermined upper surface content.

[0059] The case-hardening 102 is followed by a quenching 103. The quenching 103 comprises the injection of a gas, for example a neutral gas, at room temperature, i.e., comprised between 0° C. and 50° C., into the carburizing chamber, so as to stop the carburizing reaction and cause a martensitic transformation. The quenching step 103 makes it possible to transform the austenite predominantly into the martensitic phase.

[0060] The quenching 103 is followed by a cryogenic treatment 104. The cryogenic treatment comprises controlling the temperature in the chamber containing the part at a temperature comprised between −100° C. and −50° C. The cryogenic treatment step 104 makes it possible to transform, in addition to the quenching 103, the residual part of the austenitic phase of the part into the martensitic phase. After the cryogenic treatment 104, the part has at least predominantly a martensitic phase, in particular 90% by volume of martensitic phase, and even more preferentially only a martensitic phase.

[0061] The cryogenic treatment 104 is followed by an aging 105 of the part. The aging 105 of the part is carried out by controlling the temperature in the chamber of the part at a temperature comprised between 450° C. and 550° C., and preferentially at a temperature comprised between 480° C. and 500° C. Even more preferentially, when the substrate 2 of the part has the composition of Ferrium® C61™, the aging temperature is comprised between 480° C. and 485° C. Thus, it is possible to optimize the aging of the part without causing a phase change of the martensitic phase. Even more preferentially, when the substrate 2 of the part has the composition of Ferrium® C64™, the aging temperature is comprised between 490° C. and 500° C. Thus, it is possible to optimize the aging of the part without causing a phase change in the martensitic phase.

[0062] The inventors have discovered that it is possible to combine aging of the part with nitriding of the part. In other words, nitriding is performed in the process according to the embodiment of the invention simultaneously with aging of the part. The simultaneous implementation of aging and nitriding is achieved by injecting ammonia, preferentially dissociated ammonia, into the chamber during the aging of the part. The formation of the nitrided layer 3a is controlled by imposing the nitrogen potential (K.sub.n) in the chamber. For example, the imposition of a K.sub.n equal to 3 for one hour, followed by the imposition of a K.sub.n equal to 0.6 for 11 hours makes it possible to confer a nitrided layer 3a meeting the expectations of increasing the level of hardness of the surface layers while avoiding the formation of undesirable metallurgical phases (such as an intergranular network of carbonitrides for example).

[0063] Indeed, it is impossible to combine aging and nitriding for most steel alloys. Nitriding must be carried out at a temperature lower than the tempering temperature of the steel alloy, in order to avoid the transformation of the martensitic phase of the part via the formation of carbide precipitates responsible for metallurgical softening. However, for most steel alloys used in the case-hardened state for pinioning applications, the tempering temperature is well below the minimum temperature required for nitriding. For example, for a steel alloy having an average mass fraction of carbon equal to 0.16%, an average mass fraction of nickel equal to 3.20%, an average mass fraction of chromium equal to 1.00% and an average mass fraction of molybdenum equal to 0.16%, the tempering temperature in the case-hardened condition is less than or equal to 190° C. This temperature is too low to allow the nitriding of a part in such a steel alloy simultaneously with the tempering of the part. Indeed, nitriding requires a higher temperature, preferentially higher than 450° C. Thus, in the process according to an embodiment of the invention, the simultaneous aging and nitriding makes it possible to simplify the manufacturing process of the part 1.

[0064] With reference to FIG. 6, curve (e) illustrates the controlled temperature in the chamber containing the part with respect to the processing time of the part, during a process according to an embodiment of the invention. Curve (f) illustrates the controlled nitrogen potential K.sub.n in the chamber with respect to the processing time of the part, during a process according to an embodiment of the invention. The term “nitrogen potential” refers to the ratio p.sub.NH3/p.sup.3/2.sub.H2, where p.sub.NH3 is the partial pressure of ammonia which dissociates at the surface 5 of the part to give monoatomic nitrogen which will diffuse into the ferritic matrix, and p.sup.3/2.sub.H2 is the partial pressure of dihydrogen at the surface 5 raised to the power of 3/2.

[0065] During aging 105, the dissociated ammonia may be injected in a first phase at a flow rate allowing a nitrogen potential comprised between 1 and 5, preferentially comprised between 2.5 and 3.5. The duration of the first phase is comprised between 20 min and 2 h, preferentially between 50 min and 70 min. The dissociated ammonia can be injected during a second phase at a flow rate that allows a nitrogen potential comprised between 0.1 and 1, preferentially comprised between 0.3 and 0.8, to be achieved. The duration of the second phase is greater than 5 hours and preferentially comprised between 10 and 12 hours.