Alloy Powder Composition Balancing Strength, Corrosion Resistance
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Solution Overview
Problem
Existing high entropy alloys (HEAs) used in oil well equipment face challenges in achieving enhanced mechanical properties and corrosion resistance due to their high hardness and temper softening resistance, making them difficult to process and fabricate into desired shapes, especially in severe drilling environments with increased stress and corrosive conditions.
Innovation Solution
The addition of elements with atomic radii comparable to or larger than Ti and Mo, such as Ta, Nb, Hf, Zr, or Y, to a Co-Cr-Fe-Ni-Mo-based alloy, combined with a manufacturing process involving raw material mixing, melting, atomization, additive manufacturing, pseudo-solution heat treatment, and molding, results in an alloy article with improved mechanical properties and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If high entropy alloy is used to improve corrosion resistance and mechanical strength, then corrosion resistance and strength are improved, but ease of manufacture deteriorates due to high hardness and temper softening resistance
Solution Approach 1:
The patent applies parameter changes by controlling the chemical composition parameters of the alloy, specifically limiting the content of alloying elements (Cr, Mo, Mn, Ni, Cu, Ti, Nb, Ta, Al, Si) to 35% or less by mass, and carbon content to 1.0% or less by mass. This compositional parameter control enables the alloy to maintain corrosion resistance while improving manufacturability by reducing excessive hardness and temper softening resistance.
2Strength
If high entropy alloy is used to improve mechanical strength, then strength is improved, but ease of manufacture deteriorates due to high hardness and temper softening resistance
Solution Approach 1:
The patent controls the parameters of alloying element contents to achieve optimal mechanical strength while maintaining manufacturability. Specifically, the alloy contains Cr: 10-35%, Mo: 5-20%, Mn: 5-20%, Ni: 5-20%, Cu: 5-20%, Ti: 5-20%, Nb: 5-20%, Ta: 5-20%, Al: 5-20%, Si: 5-20%, with carbon at 1.0% or less. This parameter optimization enables the alloy to achieve high strength while avoiding excessive hardness that would hinder manufacturing.
3Reliability
If conventional alloying is used to improve corrosion resistance, then corrosion resistance is improved, but mechanical properties deteriorate compared to high entropy alloys
Solution Approach 1:
The patent creates a composite material system by combining multiple alloying elements (Cr, Mo, Mn, Ni, Cu, Ti, Nb, Ta, Al, Si) in specific proportions within the high entropy alloy framework. This composite approach leverages the synergistic effects of different elements to achieve both excellent corrosion resistance and superior mechanical properties simultaneously, overcoming the limitations of conventional single-element or simple alloying strategies.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting alloy article exhibits better mechanical properties and/or higher corrosion resistance than conventional HEAs, enabling the production of durable products for severe operating environments, such as oil well equipment and fluid machines, without sacrificing existing HEA advantages.
Implementation Method 1
atomic diffusion delay due to complicated microstructure
Implementation Method 2
improved mechanical characteristics resulting from high lattice distortion due to different sizes of constituent atoms
Implementation Method 3
improved mechanical characteristics resulting from high lattice distortion due to different sizes of constituent atoms
Implementation Method 4
improved corrosion resistance as the result of combined effects of coexistence of multiple elements (also referred to as a 'cocktail effect')
Data Source
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AI summary
An objective of the invention to provide an alloy powder for manufacturing an alloy article that exhibits even better mechanical properties and/or even higher corrosion resistance than conventional high entropy articles without sacrificing the attractive properties thereof.