Fe-Based Amorphous Alloy Powder Composition for Thermal Spraying
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing Fe-based amorphous alloy powders face challenges in maintaining a high amorphous phase proportion during manufacturing, especially when subjected to high temperatures, due to limitations in cooling rates and crystallization issues, which affect their mechanical and corrosion-resistant properties.
Innovation Solution
An Fe-based alloy composition comprising iron, chromium, molybdenum, and at least one of carbon and boron, with specific weight ratios, is used to create an amorphous alloy powder that maintains a high amorphous phase proportion even at low cooling rates, achieved through controlled cooling rates and re-melting processes, allowing for the production of shaped bodies with enhanced properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rapid cooling is performed to obtain amorphous alloy powder, then amorphous phase proportion is improved, but manufacturing complexity and equipment requirements increase
Solution Approach 1:
The patent changes the chemical composition parameters of the alloy by adding specific amounts of boron (0.01-5 wt%) and carbon (0.01-5 wt%) to iron-based alloys. This compositional modification lowers the critical cooling rate required for amorphous phase formation, enabling amorphous alloy powder production with simpler cooling equipment while maintaining high amorphous phase proportion (≥80%).
Solution Approach 2:
The patent performs preliminary alloy composition design before the cooling process by pre-determining the optimal ratios of iron, chromium, molybdenum, boron, and carbon. This preliminary compositional preparation ensures that the alloy has inherent high amorphous forming ability, so that subsequent cooling processes (even at moderate rates) can successfully produce amorphous powder without requiring extremely complex rapid cooling systems.
2Stability of the object's composition
If high cooling rate is used during atomizing to maintain amorphous phase, then amorphous phase proportion is improved, but production cost and energy consumption increase
Solution Approach 1:
The patent modifies the alloy composition parameters by incorporating boron and carbon, which fundamentally changes the phase transformation characteristics of the alloy. This compositional change reduces the energy extraction rate needed during atomizing, lowering energy consumption while maintaining amorphous phase proportion ≥80%, thus resolving the contradiction between amorphous phase maintenance and energy loss.
3Ease of manufacture
If conventional alloy composition is used, then manufacturing process is simple, but amorphous forming ability is insufficient leading to crystallization
Solution Approach 1:
The patent optimizes the compositional parameters by specifying precise ranges: iron (balance), chromium (5-20 wt%), molybdenum (2-10 wt%), boron (0.01-5 wt%), and carbon (0.01-5 wt%). This parameter optimization achieves a balance where the alloy has sufficient amorphous forming ability while remaining manufacturable with conventional equipment and processes, resolving the contradiction between manufacturing simplicity and amorphous forming ability.
4Ease of operation
If amorphous alloy powder is thermal sprayed to manufacture coating, then coating application is improved, but crystallization occurs reducing coating quality
Solution Approach 1:
The patent performs preliminary compositional design by adding boron and carbon to the alloy before thermal spraying. This preliminary action ensures the alloy has high amorphous forming ability, so that during thermal spraying operations, the powder can maintain or regain amorphous structure even under the heating and cooling cycles of the spraying process, preventing crystallization and ensuring coating quality.
Solution Approach 2:
The patent changes the chemical composition parameters to include boron and carbon, which modify the phase transformation behavior of the alloy. This compositional change enables the alloy to resist crystallization during thermal spraying, maintaining amorphous phase in the coating and resolving the contradiction between coating application and amorphous phase stability.
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 solution ensures a high amorphous phase proportion in the alloy powder and shaped bodies, resulting in improved density, strength, wear resistance, friction resistance, and corrosion resistance, even under thermal spraying and 3D printing processes.
Implementation Method 1
rapid cooling of the molten alloy is required
Implementation Method 2
an alloy composition having a high amorphous forming ability
Implementation Method 3
when the alloy powder is melted and cooled down
Implementation Method 4
cooling the re-melted alloy powder from a melting point to a glass transition temperature at the cooling rate of 101 to 104 degree/sec
Data Source
AI summary
Disclosed are a composition for an Fe-based alloy and an Fe-based amorphous alloy powder, whereby a high-purity amorphous structure is maintained even after coating by thermal spraying or the like, but also various physical properties are improved. The composition for the Fe-based alloy includes iron, chromium, and molybdenum, wherein per 100 parts by weight of the iron, the chromium is contained in an amount of 25.4 to 55.3 parts by weight, the molybdenum is contained in an amount of 35.6 to 84.2 parts by weight, and at least one of carbon and boron is further contained.