Austenitic stainless steels including molybdenum

Abstract

An austenitic stainless steel comprises, by weight, 9 to 23% chromium, 30 to 35% nickel, 1 to 6% molybdenum, 0 to 0.03% titanium, 0.15% to 0.6% aluminum, up to 0.1% carbon, 1 to 1.5% manganese, 0 to less than 0.8% silicon, 0.25 to 0.6% niobium and iron. Embodiments of austenitic stainless steels according to the present invention exhibit enhanced resistance to corrosion. Thus, the stainless steels of the present invention may find broad application as, for example, automotive components and, more particularly, as automotive exhaust system flexible connectors and other components, as well as in other applications in which corrosion resistance is desired.

Description

[0001] The present application claims priority under 35 U.S.C. .sctn. 120 from co-pending U.S. patent application Ser. No. 09 / 641,317, filed Aug. 18, 2000.FEDERALLY SPONSORED RESEARCH[0002] Not ApplicableTECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION[0003] The present invention relates to oxidation and corrosion resistant austenitic stainless steels. More particularly, the present invention relates to austenitic stainless steels adapted for use in high temperature and corrosive environments, such as, for example, use in automotive exhaust system components. The austenitic stainless steels of the invention find particular application in components exposed to temperatures up to 1800.degree. F. (982.degree. C.) and to corrosive environments, such as, for example, chloride-rich waters.DESCRIPTION OF THE INVENTION BACKGROUND[0004] In the manufacture of automotive exhaust system components, concurrent goals are to minimize both cost and weight, while also maintaining the in...

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Benefits of technology

[0004] In the manufacture of automotive exhaust system components, concurrent goals are to minimize both cost and weight, while also maintaining the integrity of the system. Typically, automobile components for these applications are fabricated from thin stainless steel stock in order to minimize the weight of the components and, therefore, the components' resistance to corrosive attack must be high to prevent failure by perforation or other means. Corrosion resistance is complicated by the fact that components used for certain automotive exhaust system applications are exposed to severely corrosive chemical environments at elevated temperatures. In particular, automotive exhaust system components and other automotive engine components are exposed to contamination from road deicing salts under conditions of elevated temperature due to the hot exhaust gases. The stainless steel and other metal components subjected to these conditions are susceptible to a complex mode of corrosive attack known as hot salt corrosion.

[0005] Typically, at higher temperatures, stainless steel components undergo oxidation on surfaces exposed to air to form a protective metal oxide layer. The oxide layer protects the underlying metal and reduces further oxidation and other forms of corrosion. However, road deicing salt deposits may attack and degrade this protective oxide layer. As the protective oxide layer is degraded, the underlying metal may be exposed and become susceptible to severe corrosion.

[0009] Higher cost, more highly alloyed materials are commonly used to fabricate flexible connectors for automotive exhaust systems exposed to higher temperatures. A typical alloy used in the manufacture of flexible connectors that are subjected to elevated temperature corrosive environments is the austenitic nickel-base superalloy of UNS Designation N06625, which is sold commercially as, for example, Allegheny Ludlum ALTEMP.RTM. 625 (hereinafter "AL 625") alloy. AL 625 is an austenitic nickel-based superalloy possessing excellent resistance to oxidation and corrosion over a broad range of corrosive conditions and displaying excellent formability and strength. Alloys of UNS Designation N06625 generally comprise, by weight, approximately 20-25% chromium, approximately 8-12% molybdenum, approximately 3.5% niobium, and 4% iron. Although alloys of this type are excellent choices for automotive exhaust system flexible connectors, they are quite expensive compared to Type 316Ti alloys.

[0011] Thus, there exists a need for a corrosion resistant material for use in high temperature corrosive environments that is not as highly alloyed as, for example, alloys of UNS Designation N06625 and which, therefore, is less costly to produce than such superalloys. More particularly, there exist a need for an iron-base alloy which may be formed into, for example, light-weight flexible connectors and other components for automotive exhaust systems and which will resist corrosion from corrosive substances such as salt deposits and other road deicing products at elevated temperatures.

[0012] The present invention addresses the above described needs by providing an austenitic stainless steel comprising, by weight, 19 to 23% chromium, 30 to 35% nickel, 1 to 6% molybdenum and less than 0.8% silicon. The addition of molybdenum to the iron-base alloys increases their resistance to corrosion at high temperatures.

[0017] Certain embodiments of austenitic stainless steels according to the present invention exhibit enhanced resistance corrosion by salt at a broad temperature range up to at least 1500.degree. F. (816.degree. C.). Articles of manufacture of the austenitic stainless steels as described above are also provided by the present invention. Thus, the stainless steels of the present invention would find broad application as, for example, automotive components and, more particularly, as automotive exhaust system components and flexible connectors, as well as in other applications in which corrosion resistance is desired. The alloys of the present invention exhibits excellent oxidation resistance at elevated temperatures and therefore, finds broad application in high temperature applications, such as heating element sheaths.

Problems solved by technology

Corrosion resistance is complicated by the fact that components used for certain automotive exhaust system applications are exposed to severely corrosive chemical environments at elevated temperatures.

In particular, automotive exhaust system components and other automotive engine components are exposed to contamination from road deicing salts under conditions of elevated temperature due to the hot exhaust gases.

The stainless steel and other metal components subjected to these conditions are susceptible to a complex mode of corrosive attack known as hot salt corrosion.

However, road deicing salt deposits may attack and degrade this protective oxide layer.

As the protective oxide layer is degraded, the underlying metal may be exposed and become susceptible to severe corrosion.

Alloys for use in automotive exhaust system flexible connectors often experience conditions in which elevated temperature exposure occurs after the alloy has been exposed to contaminants such as road deicing salts.

Degradation of the connectors may be quite rapid under such conditions.

Therefore, simple air oxidation testing may be inadequate to reveal true resistance to corrosive degradation in service.

Type 316Ti stainless steel corrodes more rapidly when exposed to elevated temperatures and, therefore, is not generally used in automotive exhaust system flexible connectors when temperatures are greater than approximately 1200.degree. F.

Although alloys of this type are excellent choices for automotive exhaust system flexible connectors, they are quite expensive compared to Type 316Ti alloys.

However, none of those alloys provide high corrosion resistance, especially when exposed to elevated temperatures and corrosive contaminants such as road deicing salts.

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