Gray cast iron system for scroll machines

Abstract

A system for making a gray cast iron scrolls using a high performance inoculant.

What is claimed is:  
     
       1. A gray cast iron scroll for use in a scroll machine, comprising: 
       a) a base portion; and  
       b) a vane portion adjoining said base portion;  
       said base portion and said vane portion being composed of a material comprising:  
       i) carbon;  
       ii) silicon;  
       iii) manganese;  
       iv) a high performance inoculant including strontium present in an amount of about 3 to about 100 ppm; and  
       v) the balance iron;  
       said base portion and said vane portion having a microstructure of type A graphite and , a pearlite matrix, and regions that are substantially free of steadite that can be resolved optically at  400  times magnification in an etched state, throughout substantially their entire structure; and  
       said base portion and said vane portion being capable of exhibiting said microstructure substantially throughout said scroll.  
     
     
       2. A gray cast iron scroll according to  claim 1  wherein said high-performance inoculant further comprises a lanthanide series rare earth element. 
     
     
       3. A gray cast iron scroll according to  claim 1  wherein said high-performance inoculant is strontium in an amount of about 3 to about 100 ppm. 
     
     
       4. A gray cast iron scroll according to  claim 1  wherein said microstructure is substantially free of steadite. 
     
     
       5. A gray cast iron scroll according to  claim 1  wherein said microstructure is substantially free of type C, type D and type E graphite. 
     
     
       6. A gray cast iron scroll according to  claim 1  wherein the required finished stock on said scroll is less than about 1 millimeter. 
     
     
       7. A scroll machine, comprising: 
       a) a first scroll; and  
       b) a second scroll in coacting combination with said first scroll, at least one of said scrolls:  
       i) being composed of a gray cast iron having a high performance inoculant present in an amount of about 3 to about 100 ppm; and  
       ii) having a microstructure of type A graphite and , a pearlite matrix, and regions that are substantially free of steadite that can be resolved optically at  400  times magnification in an etched state.  
     
     
       8. A scroll machine according to  claim 7 , wherein said high performance inoculant is selected from strontium, a lanthanide series rare earth element or mixtures thereof. 
     
     
       9. A scroll machine according to  claim 7 , wherein said high performance inoculant is selected from strontium, cerium, yttrium, scandium, neodymium, lanthanum, or mixtures thereof. 
     
     
       10. A scroll machine according to  claim 7 , wherein said high performance inoculant is strontium. 
     
     
       11. A scroll machine according to  claim 7 , wherein said high performance inoculant is strontium in an amount of about 6 to about 70 ppm. 
     
     
       12. A scroll machine according to  claim 7 , wherein said high performance inoculant is cerium. 
     
     
       13. A scroll machine according to  claim 7 , wherein said high performance inoculant is yttrium. 
     
     
       14. A scroll machine according to  claim 7 , wherein said high performance inoculant is scandium. 
     
     
       15. A scroll machine according to  claim 7 , wherein said high performance inoculant is neodymium. 
     
     
       16. A scroll machine according to  claim 7 , wherein said high performance inoculant is lanthanum. 
     
     
       17. A scroll machine according to  claim 7 , wherein said high performance inoculant includes an element selected from barium, calcium, titanium, zirconium, or mixtures thereof. 
     
     
       18. A scroll machine according to  claim 7 , wherein said scroll machine is a scroll compressor. 
     
     
       19. A scroll machine, comprising: 
       a) a first scroll; and  
       b) a second scroll in coacting combination with said first scroll, at least one of said scrolls;  
       i) being composed of a gray cast iron;  
       ii) having a high performance inoculant present in an amount of about 3 to about 100 ppm;  
       iii) having a microstructure of type A graphite and , a pearlite matrix, and regions that are substantially free of steadite that can be resolved optically at  400  times magnification in an etched state; and  
       iv) having a tensile strength of about 250 MPa.  
     
     
       20. A scroll machine according to  claim 19 , wherein said high performance inoculant is selected from strontium, a lanthanide series rare earth element or mixtures thereof. 
     
     
       21. A scroll machine according to  claim 19 , wherein said high performance inoculant is selected from strontium, cerium, yttrium, scandium, neodymium, lanthanum, or mixtures thereof. 
     
     
       22. A scroll machine according to  claim 19 , wherein said high performance inoculant is strontium. 
     
     
       23. A scroll machine according to  claim 19 , wherein said high performance inoculant is strontium in an amount of about 6 to about 70 ppm. 
     
     
       24. A scroll machine according to  claim 19 , wherein said high performance inoculant is cerium. 
     
     
       25. A scroll machine according to  claim 19 , wherein said high performance inoculant is yttrium. 
     
     
       26. A scroll machine according to  claim 19 , wherein said high performance inoculant is scandium. 
     
     
       27. A scroll machine according to  claim 19 , wherein said high performance inoculant is neodymium. 
     
     
       28. A scroll machine according to  claim 19 , wherein said high performance inoculant is lanthanum. 
     
     
       29. A scroll machine according to  claim 19 , wherein said high performance inoculant includes an element selected from barium, calcium, titanium, zirconium, or mixtures thereof. 
     
     
       30. A scroll machine according to  claim 19 , wherein said at least one of said fixed scroll and said orbiting scroll has a hardness (Bhn) of about 187 to about 241. 
     
     
       31. A scroll machine according to  claim 30 , wherein said at least one of said fixed scroll and said orbiting scroll has an average hardness differential of no greater than about 15 points (Bhn) throughout said scroll. 
     
     
       32. A scroll machine according to  claim 19 , wherein said scroll machine is a scroll compressor. 
     
     
       33. A scroll, comprising: 
       a) a base portion; and  
       b) a vane portion adjoining said base portion; said vane portion and said base portion:  
       i) being composed of a cast iron;  
       ii) having a high performance inoculant present in an amount of about 3 to about 100 ppm;  
       iii) having a microstructure of graphite, a pearlite matrix and regions that are substantially free of ferrite, steadite, eutectic carbide, pearlite  that cannot  can be resolved optically at 400× magnification in an etched state, type C graphite, type D graphite, type E graphite and porosity; and  
       iv) having a tensile strength of at least about 250 MPa.  
     
     
       34. A scroll according to  claim 33 , wherein said high performance inoculant is selected from strontium, a lanthanide series rare earth element or mixtures thereof. 
     
     
       35. A scroll according to  claim 33 , wherein said high performance inoculant is selected from strontium, cerium, yttrium, scandium, neodymium, lanthanum, or mixtures thereof. 
     
     
       36. A scroll according to  claim 33 , wherein said high performance inoculant is strontium. 
     
     
       37. A scroll according to  claim 33 , wherein said high performance inoculant is strontium in an amount of about 6 to about 70 ppm. 
     
     
       38. A scroll according to  claim 33 , wherein said high performance inoculant is cerium. 
     
     
       39. A scroll according to  claim 33 , wherein said high performance inoculant is yttrium. 
     
     
       40. A scroll according to  claim 33 , wherein said high performance inoculant is scandium. 
     
     
       41. A scroll according to  claim 33 , wherein said high performance inoculant is neodymium. 
     
     
       42. A scroll according to  claim 33 , wherein said high performance inoculant is lanthanum. 
     
     
       43. A scroll according to  claim 33 , wherein said high performance inoculant includes an element selected from barium, calcium, titanium, zirconium, or mixtures thereof. 
     
     
       44. A scroll machine, comprising: 
       a) a first scroll; and  
       b) a second scroll in coacting combination with said first scroll;  
       at least one of said scrolls having a microstructure of graphite and a pearlite matrix substantially free of steadite that can be resolved optically at  400  times magnification in an etched state, throughout substantially its entire structure, and being composed of a material having a final composition comprising:  
       i) carbon in an amount of about 3.0 to about 3.9% by weight;  
       ii) silicon in an amount of about 1.5 to about 3.2% by weight;  
       iii) manganese in an amount of about 0.2 to about 1.25% by weight;  
       iv) a high performance inoculant present in an amount of about 3 to about 100 ppm; and  
       v) the balance iron.  
     
     
       45. A scroll machine according to  claim 44 , wherein said high performance inoculant is selected from strontium, a lanthanide series rare earth element or mixtures thereof. 
     
     
       46. A scroll machine according to  claim 44 , wherein said high performance inoculant is selected from strontium, cerium, yttrium, scandium, neodymium, lanthanum, or mixtures thereof. 
     
     
       47. A scroll machine according to  claim 44 , wherein said high performance inoculant is strontium. 
     
     
       48. A scroll machine according to  claim 44 , wherein said high performance inoculant is strontium in an amount of about 6 to about 70 ppm. 
     
     
       49. A scroll machine according to  claim 44 , wherein said high performance inoculant is cerium. 
     
     
       50. A scroll machine according to  claim 44 , wherein said high performance inoculant is yttrium. 
     
     
       51. A scroll machine according to  claim 44 , wherein said high performance inoculant is scandium. 
     
     
       52. A scroll machine according to  claim 44 , wherein said high performance inoculant is neodymium. 
     
     
       53. A scroll machine according to  claim 44 , wherein said high performance inoculant is lanthanum. 
     
     
       54. A scroll machine according to  claim 44 , wherein said high performance inoculant includes an element selected from barium, calcium, titanium, zirconium, or mixtures thereof. 
     
     
       55. A scroll machine according to  claim 44 , wherein said scroll machine is a scroll compressor. 
     
     
       56. A scroll machine, comprising: 
       a) a first scroll; and  
       b) a second scroll in coacting combination with said first scroll, at least one of said scrolls:  
       i) being composed of a gray cast iron having a high performance inoculant present in an amount of about 3 to about 100 ppm;  
       ii) having a microstructure of graphite and , a pearlite matrix, and regions that are substantially free of steadite that can be resolved optically at  400  times magnification in an etched state; and  
       iii) having possessed a finish stock of less than about 1 millimeter.  
     
     
       57. A scroll machine according to  claim 56 , wherein said high performance inoculant is selected from strontium, a lanthanide series rare earth element or mixtures thereof. 
     
     
       58. A scroll machine according to  claim 56 , wherein said high performance inoculant is selected from strontium, cerium, yttrium, scandium, neodymium, lanthanum, or mixtures thereof. 
     
     
       59. A scroll machine according to  claim 56 , wherein said high performance inoculant is strontium. 
     
     
       60. A scroll machine according to  claim 56 , wherein said high performance inoculant is strontium in an amount of about 6 to about 70 ppm. 
     
     
       61. A scroll machine according to  claim 56 , wherein said high performance inoculant is cerium. 
     
     
       62. A scroll machine according to  claim 56 , wherein said high performance inoculant is yttrium. 
     
     
       63. A scroll machine according to  claim 56 , wherein said high performance inoculant is scandium. 
     
     
       64. A scroll machine according to  claim 56 , wherein said high performance inoculant is neodymium. 
     
     
       65. A scroll machine according to  claim 56 , wherein said high performance inoculant is lanthanum. 
     
     
       66. A scroll machine according to  claim 56 , wherein said high performance inoculant includes an element selected from barium, calcium, titanium, zirconium, or mixtures thereof. 
     
     
       67. A scroll machine according to  claim 56 , wherein said scroll machine is a scroll compressor. 
     
     
       68. A scroll machine, comprising: 
       a scroll having a base portion; and  
       a vane portion adjoining said base portion;  
       said base portion and said vane portion being composed of a material comprising:  
       i) carbon;  
       ii) silicon;  
       iii) manganese;  
       iv) a high performance inoculant present in an amount of about 3 to about 100 ppm; and  
       v) the balance iron;  
       said base portion and said vane portion including a microstructure of graphite and a pearlite matrix substantially free of steadite that can be resolved optically at  400  times magnification in an etched state.  
     
     
       69. A scroll machine according to  claim 68 , wherein said high performance inoculant is selected from strontium, a lanthanide series rare earth element or mixtures thereof. 
     
     
       70. A scroll machine according to  claim 68 , wherein said high performance inoculant is selected from strontium, cerium, yttrium, scandium, neodymium, lanthanum, or mixtures thereof. 
     
     
       71. A scroll machine according to  claim 68 , wherein said high performance inoculant is strontium. 
     
     
       72. A scroll machine according to  claim 68 , wherein said high performance inoculant is strontium in an amount of about 6 to about 70 ppm. 
     
     
       73. A scroll machine according to  claim 68 , wherein said high performance inoculant is cerium. 
     
     
       74. A scroll machine according to  claim 68 , wherein said high performance inoculant is yttrium. 
     
     
       75. A scroll machine according to  claim 68 , wherein said high performance inoculant is scandium. 
     
     
       76. A scroll machine according to  claim 68 , wherein said high performance inoculant is neodymium. 
     
     
       77. A scroll machine according to  claim 68 , wherein said high performance inoculant is lanthanum. 
     
     
       78. A scroll machine according to  claim 68 , wherein said high performance inoculant includes an element selected from barium, calcium, titanium, zirconium, or mixtures thereof. 
     
     
       79. A scroll machine according to  claim 68 , wherein said scroll machine is a scroll compressor. 
     
     
       80. A gray cast iron scroll for use in a scroll machine, comprising: 
         a )  a base portion; and    
         b )  a vane portion adjoining said base portion; said base portion and said vane portion being composed of a material comprising:    
         i )  carbon;    
         ii )  silicon;    
         iii )  manganese;    
         iv )  a high performance inoculant including strontium present in an amount of about  3  to about  100  ppm;    
         v )  the balance iron;    
       
         said base portion and said vane portion having a microstructure of type A graphite, a pearlite matrix, and regions that are substantially free of steadite that can be resolved optically at  400  times magnification in an etched state throughout substantially their entire structure;  
       
       
         said base portion and said vane portion being capable of exhibiting said microstructure substantially throughout said scroll; and  
       
       
         wherein said high performance inoculant is effective to promote the formation of the type A graphite and pearlite matrix. 
       
     
     
       81. A gray cast iron scroll according to  claim 80  wherein said high performance inoculant further comprises a lanthanide series rare earth element. 
     
     
       82. A gray cast iron scroll according to  claim 80  wherein said microstructure is substantially free of steadite. 
     
     
       83. A gray cast iron scroll according to  claim 80  wherein the said microstructure is substantially free of type C, type D and type E graphite. 
     
     
       84. A gray cast iron scroll according to  claim 80  wherein the required finished stock on said scroll is less than  1 . 5  millimeter. 
     
     
       85. A scroll machine, comprising: 
         a )  a first scroll;    
         b )  a second scroll in coacting combination with said first scroll, at least one of said scrolls:    
         i )  being composed of a gray cast iron having a high performance inoculant present in an amount of about  3  to about  100  ppm; and    
         ii )  having a microstructure of type A graphite, a pearlite matrix, and regions that are substantially free of steadite that can be resolved optically at  400  times magnification in an etched state and wherein said high performance inoculant is effective to promote the formation of the type A graphite and pearlite matrix.   
     
     
       86. A scroll machine according to  claim 85 , wherein said high performance inoculant is selected from strontium, cerium, yttrium, scandium, neodymium, lanthanum, or mixtures thereof. 
     
     
       87. A scroll machine according to  claim 85 , wherein said high performance inoculant is barium. 
     
     
       88. A scroll machine according to  claim 85 , wherein said high performance inoculant is strontium in an amount of about  6  to about  70  ppm. 
     
     
       89. A scroll machine according to  claim 85 , wherein said high performance inoculant is calcium. 
     
     
       90. A scroll machine according to  claim 85 , wherein said high performance inoculant is titanium. 
     
     
       91. A scroll machine according to  claim 85 , wherein said high performance inoculant is zirconium. 
     
     
       92. A scroll machine according to  claim 7 , wherein said high performance inoculant is barium. 
     
     
       93. A scroll machine according to  claim 7 , wherein said high performance inoculant is calcium. 
     
     
       94. A scroll machine according to  claim 7 , wherein said high performance inoculant is titanium. 
     
     
       95. A scroll machine according to  claim 7 , wherein said high performance inoculant is zirconium. 
     
     
       96. A gray cast iron scroll according to  claim 1  wherein the required finished stock on said scroll is less than  1 . 5  millimeters. 
     
     
       97. A gray cast iron scroll for use in a scroll machine comprising: 
       
         a high performance inoculant present in an amount of about  6  to about  70  ppm; and  
       
       
         having a microstructure of type A graphite and a pearlite matrix and substantially free of steadite that can be resolved optically at  400  times magnification in an etched state wherein said high performance inoculant is effective to promote the formation of the type A graphite and pearlite matrix. 
       
     
     
       98. A gray cast iron scroll according to  claim 97 , wherein said high performance inoculant is selected from strontium, cerium, yttrium, scandium, neodymium, lanthanum, or mixtures thereof. 
     
     
       99. A gray cast iron scroll according to  claim 97 , wherein said high performance inoculant is barium. 
     
     
       100. A gray cast iron scroll according to  claim 97 , wherein said high performance inoculant is calcium. 
     
     
       101. A gray cast iron scroll according to  claim 97 , wherein said high performance inoculant is titanium. 
     
     
       102. A gray cast iron scroll according to  claim 97 , wherein said high performance inoculant is zirconium. 
     
     
       103. A gray cast iron scroll according to  claim 97  wherein the required finished stock on said scroll is less than  1 . 5  millimeters.