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MANUFACTURE of Sic REINFORCED STEELS by SPRAY FORMING John Banhart and Heinrich Grützner Fraunhofer-Institute for Manufacturing and Advanced Materials Wiener Str

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MANUFACTURE of Sic REINFORCED STEELS by SPRAY FORMING John Banhart and Heinrich Grützner Fraunhofer-Institute for Manufacturing and Advanced Materials Wiener Str P/M Science and Technology Briefs 2(3), 5–8 (2000) Editor: A. Bose MANUFACTURE OF SiC REINFORCED STEELS BY SPRAY FORMING John Banhart and Heinrich Grützner Fraunhofer-Institute for Manufacturing and Advanced Materials Wiener Str. 12, 28359 Bremen, Germany ABSTRACT structure and some mechanical properties are dis- Silicon carbide powders were added to the cussed. metal spray during spray forming of two different steels. For this purpose, a specially designed EXPERIMENTAL PROCEDURE device was used which allows for the controlled The powder was injected into the spray cone injection of powder particles directly into the through a specially designed ring of nozzles as atomisation zone where they mix with the metal described in Ref. [4]. A twin screw feeder was droplets. After deposition, the resulting billets used for transporting the powders from a powder were characterised both by micrography, hard- hopper into a mixing chamber at rates between 0 ness measurements and wear resistance tests. and 600 ml per minute from which it was trans- ported to the actual injection nozzle in the spray INTRODUCTION chamber by a stream of nitrogen gas. The powder Spray forming is a process which allows for was injected into the region between the atom- preparing metals and alloys with properties such ising gas and the primary gas stream, which sta- as low oxide content, fine grain size, or a high bilises the atomisation process. This way a very content of metastable alloy phases. This combi- intense contact between the ceramic particles and nation of properties cannot be achieved by con- the metal droplets is ensured. ventional casting methods [1]. One feature makes In a first series of experiments the two steels the spray process appear particularly attractive: were spray formed by using “standard” parame- the possibility for modifying the properties of the ters established for spraying without particle in- sprayed deposit by injecting powders such as jection: in these tests the metal outlet of the tun- oxides, carbides, borides, nitrides or pure metals dish had a diameter of 5 mm. With a constant into the spray cone. The powders are allowed to height of the metal column of 250 mm this react with or to be wetted by the liquid metal yielded an average metal flow of 300 g/s. The droplets and to be incorporated into the metal as substrate was rotated at 1.8 Hz at a distance to the it is deposited onto the substrate. Metal matrix atomiser of 500 mm and was lowered at a rate of composites (MMCs) can be made by adding inert 0.85 mm/s as soon at the deposit reached a height powders such as carbides or oxides. Known of about 50 mm. The first experiments yielded examples of such spray formed MMCs are SiC in quite porous billets mainly due to cracking in the aluminium [2], graphite in copper [3], or alumina cooling phase. Moreover, strong metallurgical in steel [3]. reactions between the silicon carbide particles For making MMCs it is crucial to disperse the and one of the steels (C35) could be observed. powders uniformly in the metal matrix in order to The reason for this was found to be a too high ensure a good contact between particles and liq- melt temperature and too low atomisation uid metal during the deposition process and there- pressures. An adjustment of these parameters lead fore to achieve a good bonding between particles to macroscopically dense billets. However, some and metal. Much care has therefore been taken to residual porosity could still be found in the develop an injection device which allows for an microscopic images. The latest experiments were effective and reliable distribution of particles [4]. therefore carried out at even lower superheats We report on the injection of silicon carbide (120°C) which is actually the limit because an into two different steels. The resulting micro- even lower temperature would increase the 1 P/M Science and Technology Briefs 2(3), 5–8 (2000) Editor: A. Bose Figure 1: Particle morphology and size distributions of the SiC powder used danger of premature solidification in the metal periments. Obviously, the main fraction of the outlet. angular-shaped particles is about 40 μm in size. Powders of this size were found to have suffi- MATERIALS ciently good flow properties for particle injection Steels [4]. Two commercially available steels were used for the experiments: an unalloyed steel containing RESULTS 0.35% carbon (German designation: C35, USA: Microstructure of MMCs SAE 1034) and a ferritic stainless steel containing In first experiments the injection of silicon 0.2% carbon and 13% chromium (German desig- carbide caused an exothermal reaction in the C15 nation: X20Cr13, USA: SAE 51420). The first steel. However, the carbide particles are still visi- steel was chosen because it is an inexpensive ble in the billet and even seem to have bonded material which might have a good application with the metal (see Figure 2). In a second ex- potential as particle reinforced material. The periment the reaction was suppressed by choosing stainless steel is frequently used in machine con- a lower melt temperature. This lead to an im- struction where its processing, e.g. by grinding proved macrostructure with still a good bonding and polishing, gives rise to a large volume of between steel and SiC. In spraying the ferritic waste material. This waste is collected and could steel no metallurgical reactions were observed. be recycled in the spray forming process thus Spray forming experiments with various in- leading both to an upgrading of the material and jection rates of SiC were carried out. The highest to new application fields. powder injection rate applied corresponded to 1.6 kg powder for 35 kg steel. This mass ratio of 1:21 Powders corresponds to a volume ratio of about 1:8. Silicon carbide is an interesting alternative to other common ceramics such as tungsten carbide because it is even harder than WC and because it is available in many different grain sizes at com- paratively low costs. SiC is dissolved in liquid steel at high temperatures but the short exposure to heat during spray forming should not affect it too much. SiC powders of various sizes were taken into consideration. The powders were characterised by means of microscopy and by technological pow- der flow tests. The powder with the best flow properties was then selected for spray forming. Figure 1 shows a micrograph and a particle size distribution of the SiC particles used in the ex- Figure 2: Steel C35 with embedded SiC particles. 2 P/M Science and Technology Briefs 2(3), 5–8 (2000) Editor: A. Bose Figure 3: SiC particles embedded in C35 steel (volume content about 4%) Assuming an equal deposition efficiency for steel billet, and the embedded particles. Especially at and SiC one would therefore expect to find a low particle contents the influence of the former volume fraction of SiC around 12.5% in the steel. factor is important. It was found that hardness However, the maximum contents which could be varied between the different regions of the billets found were below about 6%, indicating that much even if the particle content was quite low. The of the ceramic powder is lost as overspray proba- stainless steel, e.g., showed hardness values be- bly due to the density difference between steel tween HV 300 and 550 in one billet probably (7.8 g/cm3) and SiC (3.1 g/cm3). caused by an influence of different thermal his- The global content of particles in a spray tory of the various parts of the billets formed billet is difficult to determine because (temperature heterogeneities during spraying and local contents obtained from micrographs cannot exposure to heat during cutting of the samples). be extrapolated easily. Even different billets of the same material show The resulting microstructure of one such C35 different hardness values owing to slightly differ- steel with embedded SiC particles is shown in ent spraying parameters (see Table I, where two Figure 3. The SiC particles are needle-shaped and values are given for each MMC). show a tendency to agglomerate in small clusters. Pores in the materials lead to an unpredictable Some residual pores can also be seen. Such pores influence. A hidden pore near the location where could not be completely eliminated in all the ex- hardness is measured can produce unrealistically periments. Probably a mechanical post-treatment, low values. On the other hand, an accidental par- e.g. by rolling, is necessary to obtain completely dense products. Table I: Hardness of various spray formed billets Hardness measurements steel particle HV30 Vickers hardness (HV30) was measured for all Germany USA type (average) the samples. Table I lists some of the results. 9 valued were obtained for each sample from which C35 SAE1034 none 184 an average was calculated. One sees that in some X20Cr13 SAE 51420 none 256 ± 6 cases the scatter is very large. The macroscopical hardness of the spray C35 SAE1034 SiC 240 ± 9 formed billets compared to the unsprayed starting 324 ± 40 material is expected to be determined by various factors: the different microstructures of the X20Cr13 SAE 51420 SiC 328 ± 12 sprayed and unsprayed steel, the porosity of the 306 ± 16 3 P/M Science and Technology Briefs 2(3), 5–8 (2000) Editor: A. Bose produced a pronounced decrease of wear, mean- 0,06 0,05 ing that the hardness increasing effect of the par- 0,04 ticles overcompensates the increased porosity 0,03 0,02 C35 effect. In contrast, spray forming dramatically 0,01 wear (mm)wear increased the wear resistance of the stainless steel 0,00 steel steel, sprayed steel, sprayed + SiC for the particle-free and the reinforced state.
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