Iron alloy containing molybdenum

Abstract

An iron alloy comprises 1.5-4.5% carbon, 1.5-4.5% silicon, at least 1.0 to 6.5% molybdenum and optionally copper and/or nickel wherein (% Mo+% Ni+% Cu) does not exceed 6.5%, balance iron and incidental impurities. The alloy is preferably spheroidal graphite cast iron. The alloy is especially useful in manufacturing brake disc rotors.

1 - 32 . (canceled)  
     
     
         33 . An as cast component comprising a spheroidal graphite cast iron alloy consisting essentially of, by weight, 1.5 to 4.5% carbon, 1.5 to 4.5% silicon, 1.2% to 6.5% molybdenum, optionally nickel and/or copper and wherein (% molybdenum+% nickel+% copper) does not exceed 6.5%, up to 0.02% of a spheroidizing agent, balance iron and incidental impurities and wherein the alloy contains manganese at incidental impurity levels or less.  
     
     
         34 . An as cast component as claimed in  claim 33  wherein carbon is present in an amount of from 1.5 to 3.8%.  
     
     
         35 . An as cast component as claimed in  claim 33  wherein carbon is present in an amount of 3.0 to 3.5%.  
     
     
         36 . An as cast component as claimed in  claim 33  wherein silicon is present in an amount of from 1.9 to 2.58%.  
     
     
         37 . An as cast component as claimed in  claim 33  wherein silicon is present in an amount of from 2.1 to 2.3%.  
     
     
         38 . An as cast component as claimed in  claim 33  wherein molybdenum is present in an amount of from 1.2 to 4.5%.  
     
     
         39 . An as cast component as claimed in  claim 33  wherein molybdenum is present in an amount of from 1.2 to 3.0%.  
     
     
         40 . An as cast component as claimed in  claim 33  wherein nickel is present in an amount of from 0.1 to 4.5%.  
     
     
         41 . An as cast component as claimed in  claim 33  wherein nickel is present in an amount of from 0.1 to 3.5%.  
     
     
         42 . An as cast component as claimed in  claim 33  wherein copper is present in an amount of from 0.1 to 4.5%.  
     
     
         43 . An as cast component as claimed in  claim 33  wherein copper is present in an amount of from 0.1 to 3.5%.  
     
     
         44 . An as cast component as claimed in  claim 33  wherein the alloy is essentially free of nickel.  
     
     
         45 . An as cast component as claimed in  claim 33  wherein the alloy has substantially no copper.  
     
     
         46 . An as cast component as claimed in  claim 33  wherein the spheroidal graphite cast iron alloy consists essentially of, by weight, 3 to 3.5% carbon, 1.9 to 2.58% silicon and 1.2 to 1.5% molybdenum, up to 0.02% of a spheroidizing agent, balance iron and incidental impurities.  
     
     
         47 . An as cast component as claimed in  claim 33  wherein the spheroidal graphite cast iron alloy consists essentially of, by weight 3 to 3.35% carbon, 1.9 to 2.58% silicon and about 3.0% molybdenum, up to 0.02% of a spheroidizing agent, balance iron and incidental impurities.  
     
     
         48 . An as cast component as claimed in  claim 33  wherein the spheroidal graphite cast iron alloy consists essentially of by weight from 3.5 to 4.5% carbon, from 2.1 to 2.3% silicon and from 2.5 to 3.5% molybdenum, up to 0.02% of a spheroidizing agent, balance iron and incidental impurities.  
     
     
         49 . An as cast component as claimed in  claim 33  wherein the weight percentage of the incidental impurities does not exceed 0.8%.  
     
     
         50 . An as cast component as claimed in  claim 46  wherein the incidental impurities include up to 0.04% sulphur and up to 0.04% phosphorus.  
     
     
         51 . An as cast component as claimed in  claim 33  wherein the as cast component is a disc brake rotor.  
     
     
         52 . A disc brake rotor comprising a spheroidal graphite cast iron alloy consisting essentially of, by weight 1.5 to 4.5% carbon, 1.5 to 4.5% silicon, 1.2% to 6.5% molybdenum, optionally nickel and/or copper and wherein (% molybdenum+% nickel+% copper) does not exceed 6.5%, up to 0.02% of a spheroidizing agent, balance iron and incidental impurities and wherein the alloy contains manganese at incidental impurity levels or less.