High fluidity iron alloy forming process and articles therefrom

Abstract

A process of casting an article includes an iron alloy being heated to a pour temperature of between 1460° C. and 1650° C. and a fluidity length of greater than 23 millimeters to form a melt. The melt is poured into a mold and allowed to solidify to the article. The article is then removed from the mold. A process of forging an article is also provided that includes an iron alloy workpiece being heated to a temperature of between 600° C. and 1200° C. The heated workpiece is then placed into a die set and repeatedly struck with a forging die. The workpiece flows into the die cavity in response to the striking. The workpiece is then removed from the die cavity. The resulting articles and the alloy from which such articles are formed are also provided.

1 . A process of casting an article comprising:
 heating an iron alloy to a pour temperature of between 1460° C. and 1650° C. and a fluidity length of greater than 23 millimeters to form a melt;   pouring the melt into a mold;   allowing the melt to solidify to the article; and   removing the article from the mold.   
     
     
         2 . A process of forging an article comprising:
 heating an iron alloy workpiece to a temperature of between 600° C. and 1200° C.;   inserting the heated workpiece into a die set;   repeatedly striking the workpiece with a forging die;   allowing the workpiece flow into the die cavity; and   removing the workpiece from the die cavity.   
     
     
         3 . The process of  claim 1  wherein the mold has a minimal interior dimension reflected in the article of between 1 and 5 millimeters. 
     
     
         4 . (canceled) 
     
     
         5 . (canceled) 
     
     
         6 . The process of  claim 1  wherein the pour temperature is between 1460° C. and 1650° C. 
     
     
         7 . The process of  claim 1  wherein the alloy composition is about 90% Fe, 0.1-2.0% C, 1.5-5% Si, 0.1-0.6% Mn, 0.1-2% Cu, 0.5-5% Ni, 0.01-1% Mo, with the remainder being trace elements and a liquidus temperature (T liquidus ) of less than 1515° C. 
     
     
         8 . The process of  claim 1  wherein T liquidus  is 1536-K(% C)-8(% Si)-5(% Mn)-30(% P)-25(% S)-1.7(% Al)-5(% Cu)-1.5(% Cr)-4(% Ni)-2(% V)-1(% W)-1.7(% Co)-12.8(% Zr)-7(% Nb)-3(% Ta)-14(% Ti) where K is a coefficient of 88 for % C greater than 0.5% and is 65 for % C less than or equal to 0.5%. 
     
     
         9 . (canceled) 
     
     
         10 . (canceled) 
     
     
         11 . (canceled) 
     
     
         12 . (canceled) 
     
     
         13 . (canceled) 
     
     
         14 . (canceled) 
     
     
         15 . A steel alloy for a low alloy, medium carbon, for the production of cast and forged products with a chemical composition (in weight %) comprising: about 90% Fe, 0.1-2.0% C, 1.5-5% Si, 0.1-0.6% Mn, 0.1-2% Cu, 0.5-5% Ni, 0.01-1% Mo, with the remainder being trace elements, having a liquidus temperature that is less than 1515° C. 
     
     
         16 . The steel alloy of  claim 15  further comprising an additional 0.05-5% Al content by weight percentage. 
     
     
         17 . The steel alloy of  claim 15  further comprising an additional 0.05-5% Al content by weight percent, and less than 0.01% Si by weight. 
     
     
         18 . The process of  claim 2  wherein the mold has a minimal interior dimension reflected in the article of between 1 and 5 millimeters. 
     
     
         19 . The process of  claim 2  wherein the pour temperature is between 1460° C. and 1650° C. 
     
     
         20 . The process of  claim 2  wherein the alloy composition is about 90% Fe, 0.1-2.0% C, 1.5-5% Si, 0.1-0.6% Mn, 0.1-2% Cu, 0.5-5% Ni, 0.01-1% Mo, with the remainder being trace elements and a liquidus temperature (T liquidus ) of less than 1515° C. 
     
     
         21 . The process of  claim 2  wherein T liquidus  is 1536-K(% C)-8(% Si)-5(% Mn)-30(% P)-25(% S)-1.7(% Al)-5(% Cu)-1.5(% Cr)-4(% Ni)-2(% V)-1(% W)-1.7(% Co)-12.8(% Zr)-7(% Nb)-3(% Ta)-14(% Ti) where K is a coefficient of 88 for % C greater than 0.5% and is 65 for % C less than or equal to 0.5%. 
     
     
         22 . The steel alloy of  claim 15  having a tensile strength of at least 750 MPa. 
     
     
         23 . The steel alloy of  claim 15  formed to a minimum thickness of between 1 and 5 millimeters. 
     
     
         24 . The steel alloy of  claim 15  formed having a surface area to volume ratio of between 2 and 20.