Low Cost Amorphous Steel

Abstract

Design and fabrication processes and compositions for iron-based bulk metallic glass materials or amorphous steels. Examples of bulk metallic glasses based on the described compositions may contain approximately 59 to 70 atomic percent of iron, which is allowed with approximately 10 to 20 atomic percent of metalloid elements and approximately 10 to 25 atomic percent of refractory metals. The amorphous steels may exhibit X-ray diffraction patterns as shown in FIG. 1. The compositions can be designed using theoretical calculations of the liquidus temperature to have substantial amounts of refractory metals, while still maintaining a depressed liquidus temperature. The alloying elements are molybdenum, tungsten, chromium, boron, and carbon. Some of the alloys are ferromagnetic at room temperature, while others are non-ferromagnetic. These amorphous steels have increased specific strengths and corrosion resistance compared to conventional high strength steels.

1 . A composite material, comprising a plurality of components defined by:  
       Fe 78-a-b-c C d B e Cr a Mo b W c    wherein (a+b+c)≦17, a ranges from 0 to 10, b from 2 to 8, c from 0 to 6, d from 10 to 20, and e from 3 to 10 and wherein values of a, b, c, d and e are selected so that the atomic percent of iron exceeds 59 atomic %.    
   
   
       2 . The material as in  claim 1 , further comprising Y and wherein a composition of the components is Fe 68 C 10 B 10 Cr 4 Mo 6 W 2 Y 2 .  
   
   
       3 . The material as in  claim 1 , further comprising Y and wherein a composition of the components is Fe 57 C 10 B 10 Cr 13 Mo 7 W 3 Y 2 .  
   
   
       4 . The material as in  claim 1 , wherein a composition of the components is Fe 61 C 12 B 10 Cr 4 Mo 10 W 3 .  
   
   
       5 . The material as in  claim 1 , wherein a composition of the components is Fe 68 C 12 B 3 Cr 5 Mo 10 W 2 .  
   
   
       6 . The material as in  claim 1 , wherein a composition of the components is Fe 60 C 15 B 8 Mo 10 Cr 4 W 3 .  
   
   
       7 . The material in  claim 1 , wherein a composition of the components is Fe 60 C 18 B 5 Mo 10 Cr 4 W 3 .  
   
   
       8 . The material as in  claim 1 , wherein a composition of the components is Fe 61 C 12 B 7 Mo 11 Cr 5 W 4 .  
   
   
       9 . The material as in  claim 1 , wherein a composition of the components is Fe 61 C 12 B 10 Mo 11 Cr 3 W 3 .  
   
   
       10 . The material in  claim 1 , wherein a composition of the components is Fe 64 C 10 B 8 Mo 11 Cr 4 W 3 .  
   
   
       11 . The material in  claim 1 , wherein a composition of the components is Fe 68 C 10 B 8 Mo 11 Cr 4 W 3 .  
   
   
       12 . The material in  claim 1 , wherein a composition of the components is Fe 59 C 12 B 10 Mo 11 Cr 5 W 3 .  
   
   
       13 . The material in  claim 1 , wherein a composition of the components is Fe 61 C 12 B 10 Mo 10 Cr 4 W 3 .  
   
   
       14 . The material in  claim 1 , wherein a composition of the components is Fe 68 C 10 B 10 Cr 4 Mo 6 W 2 .  
   
   
       15 . The material in  claim 1 , wherein a composition of the components is Fe 78-a-b-c C 12 B 10 Cr a Mo b W c .  
   
   
       16 . A method for producing a material in  claim 1 , comprising: 
 melting a mixture of the components into an ingot;    re-melting the ingot to produce a homogeneous molten alloy; and    solidifying the molten ingot to form a bulk amorphous material.    
   
   
       17 . The method in  claim 16 , wherein an arc melting process is used to perform the melting.  
   
   
       18 . The method in  claim 16 , wherein an induction melting process is used to perform the melting.  
   
   
       19 . A composite material, comprising: 
 59 to 70 atomic percent of iron;    10 to 20 atomic percent of a plurality metalloid elements; and    10 to 25 atomic percent of a plurality of refractory metals;    wherein the iron, metalloid elements and refractory metals are alloyed with one another to form an amorphous phase material.    
   
   
       20 . The material as in  claim 19 , further comprising yttrium which is alloyed with the iron, metalloid elements and refractory metals.  
   
   
       21 . The material as in  claim 19 , wherein the metalloid elements comprise C and B.  
   
   
       22 . The material as in  claim 19 , wherein the refractory elements comprise Cr, W and Mo.