Composition and Process for Enhanced Properties of Ferrous Components

Abstract

Components, such as gears and other power transmission components, are formed by near-net-forging a high strength, high toughness ferrous metal alloy, surface processing metal alloy to form a hardened surface region ( 28 ), and coating the surface region with a lubricious coating ( 84 ) as shown in FIG. 9.

1 . A method of producing a component, the method comprising:
 near-net-shape forging a high strength, high toughness ferrous metal alloy to an essentially finished shape component; and   surface processing the component with high current density ion implantation to form a hardened surface region; and   reducing surface roughness of the component with a vibratory, chemo-mechanical superfinishing process.   
     
     
         2 . The method of  claim 1 , wherein the component is a power transmission component. 
     
     
         3 . The method of  claim 2 , wherein the power transmission component is a gear. 
     
     
         4 . The method of  claim 1 , wherein the surface processing comprises at least one of nitriding, nitrocarburizing, carburizing, boronizing, and chromizing. 
     
     
         5 . (canceled) 
     
     
         6 . The method of  claim 1 , and further comprising:
 heat treating the component;   quenching the component;   refrigerating the component; and   tempering the component.   
     
     
         7 . The method of  claim 1 , and further comprising:
 forming a solid lubricious coating over the surface region.   
     
     
         8 . The method of  claim 7 , wherein the solid lubricious coating comprises amorphous hydrogenated carbon. 
     
     
         9 . The method of  claim 8 , wherein the solid lubricious coating includes a transition metal. 
     
     
         10 . The method of  claim 7 , and further comprising:
 forming an intermediate coating over the surface region prior to forming the solid lubricious coating.   
     
     
         11 . The method of  claim 10 , wherein the intermediate coating comprises a metal. 
     
     
         12 . The method of  claim 11  wherein the solid lubricious coating comprises amorphous hydrogenated carbon the metal contained in the intermediate coating. 
     
     
         13 . The method of  claim 1 , wherein the ferrous metal alloy comprises at least 5 wt % cobalt, at least 1.5 wt % nickel, up to 1.0 wt % carbon, and up to 15 wt % of molybdenum, chromium, tungsten, or vanadium and combinations thereof. (canceled) 
     
     
         15 . (canceled) 
     
     
         16 . A method of producing a component, the method comprising:
 near-net-forging a ferrous metal alloy to an essentially finished component shape;   transforming a surface region of the metal alloy to a hardened surface region with a high current density ion implantation process;   forming a coating over the hardened surface region; and   reducing surface roughness with a vibratory, chemo-mechanical superfinishing process, in which said vibratory, chemo-mechanical process is provided before and/or after said coating.   
     
     
         17 . The method of  claim 16 , wherein the metal alloy has a composition comprising at least 5 wt % cobalt and at least 1.5% nickel, 
     
     
         18 . The method of  claim 16 , wherein the metal alloy has a composition comprising up to 1.0 wt % carbon, and up to 15 wt % of molybdenum, chromium, tungsten, or vanadium and combinations thereof. 
     
     
         19 . The method of  claim 16 , wherein the coating comprises an amorphous hydrogenated carbon coating. 
     
     
         20 . The method of  claim 16 , and further comprising
 forming an intermediate coating between the coating and the hardened surface region.   
     
     
         21 . The method of  claim 20 , wherein the intermediate coating comprises a transition metal. 
     
     
         22 . (canceled) 
     
     
         23 . (canceled)