Enhanced wear resistant steel and methods of making the same

Abstract

Improved steel compositions and methods of making the same are provided. The present disclosure provides advantageous wear resistant steel. More particularly, the present disclosure provides high manganese (Mn) steel having enhanced wear resistance, and methods for fabricating high manganese steel compositions having enhanced wear resistance. The advantageous steel compositions/components of the present disclosure improve one or more of the following properties: wear resistance, ductility, crack resistance, erosion resistance, fatigue life, surface hardness, stress corrosion resistance, fatigue resistance, and/or environmental cracking resistance. In general, the present disclosure provides high manganese steels tailored to resist wear and/or erosion.

What is claimed is: 
     
         1 . A method for fabricating a ferrous based component comprising:
 a) providing a composition having from about 5 to about 40 weight % manganese, from about 0.01 to about 3.0 weight % carbon, and the balance iron;   b) heating the composition to a temperature above the austenite recrystallization stop temperature of the composition or to a temperature to homogenize the composition;   c) cooling the composition to a rolling start temperature;   d) deforming the composition while the composition is at a temperature below the austenite recrystallization stop temperature of the composition; and   e) quenching the composition.   
     
     
         2 . The method of  claim 1 , wherein step c includes cooling to a temperature below the T nr  temperature. 
     
     
         3 . The method of  claim 1 , wherein after step e), the carbide precipitate fraction volume of the composition is about 5 volume % or less of the composition. 
     
     
         4 . The method of  claim 1 , wherein after step e), the composition has a microstructure having a refined grain size of about 100 μm or less. 
     
     
         5 . The method of  claim 4 , wherein the microstructure having a refined grain size of about 100 μm or less includes a surface layer of the composition. 
     
     
         6 . The method of  claim 5 , wherein the thickness of the surface layer is from about 10 nm to about 5000 nm. 
     
     
         7 . The method of  claim 5 , wherein the surface layer is formed prior to or during use of the composition. 
     
     
         8 . The method of  claim 5 , wherein the surface layer is comprised of predominantly the austenite phase. 
     
     
         9 . The method of  claim 5 , wherein the surface layer is formed via a surface deformation technique selected from the group consisting of shot peening, laser shock peening, surface burnishing and combinations thereof. 
     
     
         10 . The method of  claim 1 , further comprising after step e) a surface deformation step selected from the group consisting of shot peening, laser shock peening, surface burnishing and combinations thereof. 
     
     
         11 . The method of  claim 1 , wherein prior to step e), the composition is slowly cooled or isothermally held. 
     
     
         12 . The method of  claim 1 , wherein step e) includes rapidly quenching the composition. 
     
     
         13 . The method of  claim 1 , wherein step d) includes deforming the composition while the composition is at a temperature below the austenite recrystallization temperature and above the martensite transformation start temperature. 
     
     
         14 . The method of  claim 1 , wherein step d) includes deforming the composition to induce martensite formation of the composition. 
     
     
         15 . The method of  claim 14 , wherein the composition is deformed at a temperature of from about 18° C. to about 24° C. or form about −196° C. to induce martensite formation of the composition. 
     
     
         16 . The method of  claim 14 , further comprising, after step d), heating the composition to a temperature above the austenite recrystallization stop temperature. 
     
     
         17 . The method of  claim 16 , wherein heating the composition to a temperature above the austenite recrystallization stop temperature after step d) reverses deformation-induced martensite of the composition into ultrafine grained austenite. 
     
     
         18 . The method of  claim 17 , wherein the martensite start temperature of the ultrafine grained austenite is below about 24° C. 
     
     
         19 . The method of  claim 1 , further comprising, after step e), heating the composition to a temperature above the austenite recrystallization stop temperature, and then quenching the composition. 
     
     
         20 . The method of  claim 1 , further comprising, prior to step c), deforming the composition while the composition is at a temperature above the austenite recrystallization stop temperature. 
     
     
         21 . The method of  claim 20 , wherein the composition is deformed at a temperature of from about 700° C. to about 1000° C. 
     
     
         22 . The method of  claim 1 , wherein step b) includes heating the composition to at least about 1000° C. 
     
     
         23 . The method of  claim 1 , wherein step c) includes cooling the composition at a rate of from about 2° C. per second to about 60° C. per second. 
     
     
         24 . The method of  claim 1 , wherein the composition further includes one or more alloying elements selected from the group consisting of chromium, aluminum, silicon, nickel, cobalt, molybdenum, niobium, copper, titanium, vanadium, nitrogen, boron, zirconium, hafnium and combinations thereof. 
     
     
         25 . The method of  claim 24 , wherein the chromium ranges from 0.5 to 30 weight % of the total composition:
 wherein each of the nickel or cobalt ranges from 0.5 to 20 weight % of the total composition;   wherein the aluminum ranges from 0.2 to 15 weight % of the total composition;   wherein each of the molybdenum, niobium, copper, titanium or vanadium ranges from 0.2 to 10 weight % of the total composition;   wherein the silicon ranges from 0.01 to 10 weight % of the total composition;   wherein the nitrogen ranges from 0.01 to 3.0 weight % of the total composition;   wherein the boron ranges from 0.001 to 0.1 weight % of the total composition; and   wherein each of the zirconium or hafnium ranges from 0.2 to 6 weight % of the total composition.   
     
     
         26 . The method of  claim 1 , wherein the composition includes from about 8 to about 20 weight % manganese, from about 0.60 to about 3.0 weight % carbon, from about 0.5 to about 3 weight % chromium, from about 0.5 to about 2.0 weight % copper, from about 0.1 to about 1 weight % silicon, and the balance iron. 
     
     
         27 . The method of  claim 1 , wherein step d) includes transformation induced plasticity or twin-induced plasticity. 
     
     
         28 . A ferrous based component comprising:
 a composition having from about 5 to about 40 weight % manganese, from about 0.01 to about 3.0 weight % carbon, and the balance iron; and   wherein the carbide precipitate fraction volume of the composition is about 5 volume % or less of the composition.   
     
     
         29 . The component of  claim 28 , wherein the composition has a microstructure having a refined grain size of about 100 μm or less. 
     
     
         30 . The component of  claim 29 , wherein the microstructure having a refined grain size of about 100 μm or less includes a surface layer of the composition. 
     
     
         31 . The component of  claim 30 , wherein the thickness of the surface layer is from about 100 nm to about 5000 nm. 
     
     
         32 . The component of  claim 30 , wherein the surface layer is formed prior to or during use of the composition. 
     
     
         33 . The component of  claim 28 , wherein the composition further includes one or more alloying elements chosen from the group consisting of chromium, aluminum, silicon, nickel, cobalt, molybdenum, niobium, copper, titanium, vanadium, nitrogen, boron, zirconium, hafnium and combinations thereof. 
     
     
         34 . The component of  claim 33 , wherein the chromium ranges from 0.5 to 30 weight % of the total composition;
 wherein each of the nickel or cobalt ranges from 0.5 to 20 weight % of the total composition;   wherein the aluminum ranges from 0.2 to 15 weight % of the total composition;   wherein each of the molybdenum, niobium, copper, titanium or vanadium ranges from 0.2 to 10 weight % of the total composition;   wherein the silicon ranges from 0.01 to 10 weight % of the total composition;   wherein the nitrogen ranges from 0.01 to 3.0 weight % of the total composition;   wherein the boron ranges from 0.001 to 0.1 weight % of the total composition; and   wherein each of the zirconium or hafnium ranges from 0.2 to 6 weight % of the total composition.   
     
     
         35 . The component of  claim 28 , wherein the composition includes from about 8 to about 20 weight % manganese, from about 0.60 to about 3.0 weight % carbon, from about 0.5 to about 3 weight % chromium, from about 0.5 to about 2.0 weight % copper, from about 0.1 to about 1 weight % silicon, and the balance iron. 
     
     
         36 . A ferrous based component comprising:
 a composition having from about 5 to about 40 weight % manganese, from about 0.01 to about 3.0 weight % carbon, and the balance iron;   wherein the composition has a microstructure having a refined grain size of about 100 μm or less.   
     
     
         37 . The component of  claim 36 , wherein the microstructure having a refined grain size of about 100 μm or less includes a surface layer of the composition. 
     
     
         38 . The component of  claim 37 , wherein the thickness of the surface layer is from about 10 nm to about 5000 nm. 
     
     
         39 . The component of  claim 37 , wherein the surface layer is formed prior to or during use of the composition. 
     
     
         40 . The component of  claim 36 , wherein the composition further includes one or more alloying elements chosen from the group consisting of chromium, aluminum, silicon, nickel, cobalt, molybdenum, niobium, copper, titanium, vanadium, nitrogen, boron, zirconium, hafnium and combinations thereof. 
     
     
         41 . The component of  claim 36 , wherein the chromium ranges from 0.5 to 30 weight % of the total composition;
 wherein each of the nickel or cobalt ranges from 0.5 to 20 weight % of the total composition;   wherein the aluminum ranges from 0.2 to 15 weight % of the total composition;   wherein each of the molybdenum, niobium, copper, titanium or vanadium ranges from 0.2 to 10 weight % of the total composition;   wherein the silicon ranges from 0.01 to 10 weight % of the total composition;   wherein the nitrogen ranges from 0.01 to 3.0 weight % of the total composition;   wherein the boron ranges from 0.001 to 0.1 weight % of the total composition; and   wherein each of the zirconium or hafnium ranges from 0.2 to 6 weight % of the total composition.   
     
     
         42 . The component of  claim 36 , wherein the composition includes from about 8 to about 20 weight % manganese, from about 0.60 to about 3.0 weight % carbon, from about 0.5 to about 3 weight % chromium, from about 0.5 to about 2.0 weight % copper, from about 0.1 to about 1 weight % silicon, and the balance iron. 
     
     
         43 . A ferrous based component fabricated according to the steps comprising:
 a) providing a composition having from about 5 to about 40 weight % manganese, from about 0.01 to about 3.0 weight % carbon, and the balance iron;   b) heating the composition to a temperature above the austenite recrystallization stop temperature of the composition;   c) cooling the composition to a temperature below the austenite recrystallization stop temperature of the composition;   d) deforming the composition while the composition is at a temperature below the austenite recrystallization stop temperature of the composition; and   e) quenching the composition.   
     
     
         44 . The ferrous based component of  claim 43 , wherein after step e), the carbide precipitate fraction volume of the composition is about 5 volume % or less of the composition. 
     
     
         45 . The ferrous based component of  claim 43 , wherein after step e), the composition has a microstructure having a refined grain size of about 100 μm or less. 
     
     
         46 . The ferrous based component of  claim 45 , wherein the microstructure having a refined grain size of about 100 μm or less includes a surface layer of the composition. 
     
     
         47 . The ferrous based component of  claim 46 , wherein the thickness of the surface layer is from about 10 nm to about 5000 nm. 
     
     
         48 . The ferrous based component of  claim 46 , wherein the surface layer is formed prior to or during use of the composition. 
     
     
         49 . The ferrous based component of  claim 46 , wherein the surface layer is formed via a surface deformation technique selected from the group consisting of shot peening, laser shock peening, surface burnishing and combinations thereof. 
     
     
         50 . The ferrous based component of  claim 43 , further comprising after step e) a surface deformation step selected from the group consisting of shot peening, laser shock peening, surface burnishing and combinations thereof. 
     
     
         51 . The ferrous based component of  claim 43 , wherein prior to step e), the composition is slowly cooled or isothermally held. 
     
     
         52 . The ferrous based component of  claim 43 , wherein step e) includes rapidly quenching the composition. 
     
     
         53 . The ferrous based component of  claim 43 , wherein step d) includes deforming the composition while the composition is at a temperature below the austenite recrystallization temperature and above the martensite transformation start temperature. 
     
     
         54 . The ferrous based component of  claim 43 , wherein step d) includes deforming the composition to induce martensite formation of the composition. 
     
     
         55 . The ferrous based component of  claim 54 , wherein the composition is deformed at a temperature of from about 18° C. to about 24° C. to induce martensite formation of the composition. 
     
     
         56 . The ferrous based component of  claim 54 , further comprising, after step d), heating the composition to a temperature above the austenite recrystallization stop temperature. 
     
     
         57 . The ferrous based component of  claim 56 , wherein heating the composition to a temperature above the austenite recrystallization stop temperature after step d) reverses deformation-induced martensite of the composition into ultrafine grained austenite. 
     
     
         58 . The ferrous based component of  claim 57 , wherein the martensite start temperature of the ultrafine grained austenite is below about 24° C. 
     
     
         59 . The ferrous based component of  claim 43 , further comprising, after step e), heating the composition to a temperature above the austenite recrystallization stop temperature, and then quenching the composition. 
     
     
         60 . The ferrous based component of  claim 43 , further comprising, prior to step c), deforming the composition while the composition is at a temperature above the austenite recrystallization stop temperature. 
     
     
         61 . The ferrous based component of  claim 60 , wherein the composition is deformed at a temperature of from about 700° C. to about 1000° C. 
     
     
         62 . The ferrous based component of  claim 43 , wherein step b) includes heating the composition to at least about 1000° C. 
     
     
         63 . The ferrous based component of  claim 43 , wherein step c) includes cooling the composition at a rate of from about 2° C. per second to about 60° C. per second. 
     
     
         64 . The ferrous based component of  claim 43 , wherein the composition further includes one or more alloying elements selected from the group consisting of chromium, aluminum, silicon, nickel, cobalt, molybdenum, niobium, copper, titanium, vanadium, nitrogen, boron, zirconium, hafnium and combinations thereof. 
     
     
         65 . The ferrous based component of  claim 64 , wherein the chromium ranges from 0.5 to 30 weight % of the total composition;
 wherein each of the nickel or cobalt ranges from 0.5 to 20 weight % of the total composition;   wherein the aluminum ranges from 0.2 to 15 weight % of the total composition;   wherein each of the molybdenum, niobium, copper, titanium or vanadium ranges from 0.2 to 10 weight % of the total composition;   wherein the silicon ranges from 0.01 to 10 weight % of the total composition;   wherein the nitrogen ranges from 0.01 to 3.0 weight % of the total composition;   wherein the boron ranges from 0.001 to 0.1 weight % of the total composition; and   wherein each of the zirconium or hafnium ranges from 0.2 to 6 weight % of the total composition.   
     
     
         66 . The ferrous based component of  claim 43 , wherein the composition includes from about 8 to about 20 weight % manganese, from about 0.60 to about 3.0 weight % carbon, from about 0.5 to about 3 weight % chromium, from about 0.5 to about 2.0 weight % copper, from about 0.1 to about 1 weight % silicon, and the balance iron. 
     
     
         67 . The ferrous based component of  claim 43 , wherein step d) includes transformation induced plasticity or twin-induced plasticity.