A NEW MOLYBDENUM SILICIDE BASED COMPOSITION

Abstract

The present disclosure relates to a molybdenum silicide based composition comprising aluminum oxide (Al.sub.2O.sub.3) and to the use thereof in high temperature applications.

Claims

1. A molybdenum-silicide based composition comprising: Al.sub.2O.sub.3 and 1 to 7 wt % bentonite and balance Mo.sub.1-xCr.sub.xSi.sub.2 and wherein x is 0.05-0.25, wherein Al.sub.2O.sub.3 is present in the amount of from 0.01 to 0.06 wt %.

2. The molybdenum-silicide based composition according to claim 1, wherein the bentonite is present in the amount of 2 to 6 wt %.

3. The molybdenum-silicide based composition according to claim 1, wherein the bentonite is present in the amount of 2 to 5 wt %.

4. The molybdenum-silicide based composition according to claim 1, wherein x is 0.10 to 0.20.

5. The molybdenum-silicide composition according to claim 1, wherein x is 0.15 to 0.20.

6. The molybdenum-silicide composition according to claim 1, wherein Al.sub.2O.sub.3 is in the amount of from 0.02 to 0.05 wt. %.

7. A heating element comprising a sintered molybdenum-silicide based compound which has been manufactured from the molybdenum-silicide based composition according to claim 1.

8. A furnace comprising an object containing a sintered molybdenum-silicide based compound which has been manufactured from the molybdenum-silicide based composition according to claim 1.

9. The molybdenum-silicide based composition according to claim 2, wherein x is 0.10 to 0.20.

10. The molybdenum-silicide composition according to claim 9, wherein Al.sub.2O.sub.3 is in the amount of from 0.02 to 0.05 wt. %.

11. The molybdenum-silicide composition according to claim 2, wherein x is 0.15 to 0.20.

12. The molybdenum-silicide composition according to claim 3, wherein x is 0.15 to 0.20.

13. The molybdenum-silicide composition according to claim 12, wherein Al.sub.2O.sub.3 is in the amount of from 0.02 to 0.05 wt. %.

14. The molybdenum-silicide composition according to claim 3, wherein Al.sub.2O.sub.3 is in the amount of from 0.02 to 0.05 wt. %.

15. The molybdenum-silicide composition according to claim 4, wherein Al.sub.2O.sub.3 is in the amount of from 0.02 to 0.05 wt. %.

Description

DETAILED DESCRIPTION

[0009] The present disclosure presents a molybdenum-silicide based composition comprising: Al.sub.2O.sub.3 and 1 to 7 wt % bentonite and balance Mo.sub.1-xCr.sub.xSi.sub.2 and wherein x is 0.05-0.25 and Al.sub.2O.sub.3 is present in the amount of from 0.01 to 0.06 wt %.

[0010] Bentonite is an aluminum silicate clay consisting mainly of montmorillonite. There are different types of bentonite and they are each named after the respective dominant element. For industrial purposes, two main classes of bentonite exist: sodium and calcium bentonite. Thus, in the present disclosure, the term bentonite is intended to include all types of aluminum silicate, such as sodium and calcium bentonite. Bentonite is added to the molybdenum-silicide based composition in an amount of from 1 to 7 weight % (wt %) in order to improve the workability of the composition and enable the manufacture of heating elements through e.g. extrusion. According to one embodiment, bentonite is present in the amount of from 2 to 6 wt %, such as of from 2 to 5 wt %.

[0011] The balance of the present molybdenum silicide based composition is Mo.sub.1-xCr.sub.xSi.sub.2, According to one embodiment, the composition as defined hereinabove or herein after comprises at least 90 weight % (wt %) Mo.sub.1-xCr.sub.xSi.sub.2, such as at least 92 wt % Mo.sub.1-xCr.sub.xSi.sub.2, such as at least 94 wt % Mo.sub.1-xCr.sub.xSi.sub.2. According to one embodiment, the composition as defined hereinabove or hereinafter comprises Mo.sub.1-xCr.sub.xSi.sub.2 in the range of from 92.94 to 98.99, such as 94.98 to 97. 95. Further, according to the present disclosure, a portion (x) of the molybdenum of the molybdenum silicide is substituted with chromium wherein x is of from 0.05 to 0.25. The substitution will improve the oxidation resistance of the molybdenum silicide based composition as defined hereinabove or hereinafter in the temperature range 400-600 C. and thereby reduce the degradation. According to one embodiment, x is in the range of from 0.10 to 0.20, such as 0.15 to 0.20.

[0012] The molybdenum silicide based composition as defined hereinabove or hereinafter, comprises small amounts of alumina (Al.sub.2O.sub.3), also known as aluminium oxide. The addition of low amounts (0.01 to 0.06 wt %) of alumina has surprisingly shown to have a great impact on the resistance against pest (see FIG. 1). Pest oxidation mostly occurs after a furnace has been in operation during an extended period of time, thus it is not possible to discover pest until a furnace has been operated for several hours. FIG. 1 displays different molybdenum silicide compositions and as can be seen from FIG. 1, the higher the growth rate of the non-wanted oxide, the higher is the inclination of the line. The molybdenum silicide based compositions according to the present disclosure have the lowest inclination and thereby the lowest oxide growth rate and have thereby an improved resistance against pest. According to one embodiment, the amount of Al.sub.2O.sub.3 is of from 0.02 to 0.05 wt %.

[0013] A heating element according to the present disclosure may be readily produced in various shapes and sizes and advantageously replacing existing heating elements in industrial furnaces. The heating elements or any other object comprising a molybdenum silicide based compound are manufactured by sintering the molybdenum silicide composition as defined hereinabove or hereinafter. The sintering may be performed in two steps. The first sintering takes place in inert atmosphere such as hydrogen, nitrogen or argon at a temperature range of from 1000 to 2000 C. and during a time range of from 20 to 240 minutes. During the second sintering process, the composition is heated in air at a temperature range of 1000 to 1600 C. during 1 to 20 minutes.

[0014] The present disclosure is further illustrated by the following non-limiting example:

EXAMPLE

[0015] Mixtures of molybdenum, silicon and chromium powders were prepared and heated under argon atmosphere to form MoSi.sub.2 and Mo.sub.0.85Cr.sub.0.15Si.sub.2, respectively. The reaction products were ground to an average particle diameter of 5 m. Silicide powder was subsequently mixed with 5 wt. % bentonite (Bentolite-L bought from BYK) and water, and in the case for Mo.sub.0.85Cr.sub.0.15Si.sub.2, 0.02, 0.035, 0.05, 0.1 or 0.2 wt. % Al.sub.2O.sub.3 (AKP-30 bought from Sumitomo) was added, to form a paste for extrusion.

[0016] The obtained compositions were extruded into 9 mm diameter rods, which were subsequently dried and pre-sintered in hydrogen for 1 h at 1375 C. A final sintering, resistance heating in air to 1500 C. for 5 minutes, was performed to achieve full density.

[0017] Samples of each composition were ground to remove the protective SiO.sub.2 scale which was formed during final sintering. Samples were placed individually on alumina sample holders to collect potential oxidation products and to include them in the weight measurements. The samples were placed in an electrical furnace heated to 450 C. employing FeCrAl heating elements and utilized with ceramic fiber insulation. Sample and holder were weighed to monitor individual weight changes as function of exposure time.

[0018] The result of the testing is shown in FIG. 1. Pest oxidation mostly occurs after an furnace has be operated for an extended time such as around 1000 h. Heating elements that are considered to be good should have a low growth rate of the non-wanted oxide and thereby a low weight change of the heating element. The larger the weight change is, the thicker oxidation will be formed and the greater is the risk for element failure. As can be seen from FIG. 1, the higher inclination of the lines, the higher is the oxide growth rate and the faster the heating element will be consumed.