AU2004270752A1 - An alloy steel composition - Google Patents
An alloy steel composition Download PDFInfo
- Publication number
- AU2004270752A1 AU2004270752A1 AU2004270752A AU2004270752A AU2004270752A1 AU 2004270752 A1 AU2004270752 A1 AU 2004270752A1 AU 2004270752 A AU2004270752 A AU 2004270752A AU 2004270752 A AU2004270752 A AU 2004270752A AU 2004270752 A1 AU2004270752 A1 AU 2004270752A1
- Authority
- AU
- Australia
- Prior art keywords
- casting
- metal casting
- alloy steel
- metal
- steel composition
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- 239000000203 mixture Substances 0.000 title claims description 30
- 229910000851 Alloy steel Inorganic materials 0.000 title claims description 17
- 238000005058 metal casting Methods 0.000 claims description 47
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 23
- 238000005266 casting Methods 0.000 claims description 19
- 229910045601 alloy Inorganic materials 0.000 claims description 17
- 239000000956 alloy Substances 0.000 claims description 17
- 229910052759 nickel Inorganic materials 0.000 claims description 12
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 11
- 239000010949 copper Substances 0.000 claims description 11
- 229910052802 copper Inorganic materials 0.000 claims description 11
- 229910052804 chromium Inorganic materials 0.000 claims description 8
- 239000011651 chromium Substances 0.000 claims description 8
- 229910052750 molybdenum Inorganic materials 0.000 claims description 8
- 229910052710 silicon Inorganic materials 0.000 claims description 8
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 7
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 claims description 7
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 claims description 7
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 claims description 7
- 229910052799 carbon Inorganic materials 0.000 claims description 7
- 229910052748 manganese Inorganic materials 0.000 claims description 7
- 239000011572 manganese Substances 0.000 claims description 7
- 239000011733 molybdenum Substances 0.000 claims description 7
- 239000010703 silicon Substances 0.000 claims description 7
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 claims description 6
- 239000000470 constituent Substances 0.000 claims description 6
- 238000000034 method Methods 0.000 claims description 6
- 238000001816 cooling Methods 0.000 claims description 4
- 238000005422 blasting Methods 0.000 claims description 2
- 238000005496 tempering Methods 0.000 claims description 2
- 238000012360 testing method Methods 0.000 description 6
- 238000005275 alloying Methods 0.000 description 5
- 238000004458 analytical method Methods 0.000 description 4
- 229910052751 metal Inorganic materials 0.000 description 4
- 239000002184 metal Substances 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 2
- 239000003570 air Substances 0.000 description 2
- 238000004519 manufacturing process Methods 0.000 description 2
- 229910000734 martensite Inorganic materials 0.000 description 2
- 239000010955 niobium Substances 0.000 description 2
- 229910052698 phosphorus Inorganic materials 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000007546 Brinell hardness test Methods 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 229910000831 Steel Inorganic materials 0.000 description 1
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 1
- 239000005864 Sulphur Substances 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000012080 ambient air Substances 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005530 etching Methods 0.000 description 1
- 229910052742 iron Inorganic materials 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 150000001247 metal acetylides Chemical class 0.000 description 1
- 238000005088 metallography Methods 0.000 description 1
- 229910052758 niobium Inorganic materials 0.000 description 1
- GUCVJGMIXFAOAE-UHFFFAOYSA-N niobium atom Chemical compound [Nb] GUCVJGMIXFAOAE-UHFFFAOYSA-N 0.000 description 1
- 230000003287 optical effect Effects 0.000 description 1
- 238000013021 overheating Methods 0.000 description 1
- 229910001562 pearlite Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000012916 structural analysis Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- LEONUFNNVUYDNQ-UHFFFAOYSA-N vanadium atom Chemical compound [V] LEONUFNNVUYDNQ-UHFFFAOYSA-N 0.000 description 1
- 230000000007 visual effect Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
Landscapes
- Manufacture Of Metal Powder And Suspensions Thereof (AREA)
Description
WO 2005/024084 PCT/AU2004/000095 An Alloy Steel Composition The present invention relates to an alloy steel composition and in particular to an alloy steel composition that is suitable for use in the production of metal castings for 5 applications which are subject to highly abrasive wear forces. Background of the Invention Metal castings which are used in applications, such as for example autogenous and semi 10 autogenous grinding mills and ball mills, are subject to a large amount of abrasive wear force, which over time, gradually wears away at the metal casting until replacement is required. As such, it is desirable that the metal castings used in these types of applications can 15 withstand a high degree of abrasive wear and also maintain hardness throughout the entire composition of the metal casting. Previous attempts at producing metal castings with increased abrasive wear resistance have focused on varying the alloying components of steel alloys in order to produce the desired 20 characteristics. In addition, various production techniques, such as air blasting and liquid quenching the metal castings have been used to increase the hardness and thereby abrasive wear resistance of the castings. Surprisingly, it has been found that if an alloy steel composition is produced which 25 includes the alloying components of copper and nickel, then the resulting alloy steel composition has an increased abrasive wear resistance that provides that the composition is very suitable for producing metal castings used in the applications discussed above. Summary of the Invention 30 According to one aspect, the present invention provides an alloy steel composition which includes the following constituents by weight: carbon 0.5 - 3.5% silicon 0.2 - 0.8% WO 2005/024084 PCT/AU2004/000095 -2 manganese 0.5- 1.5% nickel 0.1 - 2.0% chromium 1.0 - 3.0% molybdenum 0.1 - 0.5% 5 copper 0.1 - 2.0%. Preferably, the percentage composition of nickel is 0.10 - 0.45% by weight and the percentage composition of copper is 0.10 - 0.45% by weight. 10 Preferably the alloy steel includes the following composition be weight: carbon 0.75 - 0.90% silicon 0.35 - 0.50% manganese 0.80- 1.00% nickel 0.25 -0.45% 15 chromium 1.90 - 2.30% molybdenum 0.25 - 0.45% copper 0.25 - 0.45%. More preferably the alloy steel includes the following composition be weight: 20 carbon 0.80 - 0.85% silicon 0.42 - 0.48% manganese 0.85 - 0.95 % nickel 0.32- 0.38% chromium 2.05 - 2.25% 25 molybdenum 0.30-0.37% copper 0.32 - 0.38%. According to another aspect, the present invention provides a metal casting produced from an alloy steel composition which includes the following constituents by weight: 30 carbon 0.5 - 3.5% silicon 0.2 - 0.8% WO 2005/024084 PCT/AU2004/000095 -3 manganese 0.5 - 1.5% nickel 0.1 - 2.0% chromium 1.0 - 3.0% molybdenum 0.1 -0.5% 5 copper 0.1 - 2.0%. Preferably the metal casting has a substantially pearlitic microstructure throughout its entirety. Furthermore, the hardness of the casting is greater than 310 HB when measured using the Brinell Hardness Test. Preferably, the hardness of the casting is greater than 335 10 IB and more preferably still greater than 350 HB According to another aspect, the metal casting may be used in applications which are subject to high abrasive wear forces. Preferably, the metal casting may be used as a component in autogenous grinding mills, semi-autogenous grinding mills or ball mills, and 15 more preferably still, the components are lifter bars, liners, pulp lifters and/or grates. Preferably after about 50 to 100 mm of wear has occurred on the metal casting, the hardness of the casting is greater than 310 HB and preferably greater than 330 HB. 20 According to a further aspect the present invention provides a method of producing a metal casting composed of an alloy steel composition, which includes the following constituents by weight: carbon 0.5 - 3.5% silicon 0.2 - 0.8% 25 manganese 0.5 - 1.5% nickel 0.1 - 2.0% chromium 1.0 - 3.0% molybdenum 0.1 - 0.5% copper 0.1 - 2.0%, 30 characterised wherein the method includes the steps of: i. pouring the molten alloy composition into a metal casting mould; WO 2005/024084 PCT/AU2004/000095 -4 ii. cooling the metal casting at ambient temperature; and iii. grind casting and gauge to profile. Brief Description of the Figures 5 The present invention will become better understood from the following detailed description of a preferred but non-limiting embodiment thereof, described in connection with the accompanying drawings, where in: 10 Figure 1 is a photograph of a metal casting produced from an alloy in accordance with one aspect of the present invention; and Figure 2 is a photograph of a commercially available metal casting used in autogenous and semi autogenous grinding mills. 15 Detailed Description of the Invention The alloy steel composition in accordance with one aspect of the present invention includes the following alloying elements: carbon, silicon, manganese, nickel, chromium, molybdenum, copper, with the balance of the composition being principally composed of 20 iron. Other elements which may be present in trace quantities include sulphur, phosphorus, vanadium, aluminium and niobium. With the addition of copper and nickel, in combination with the specific ratios of the other principal alloying constituents, it was found that the resulting alloy provided a surprising 25 through hardness which made it particularly useful for applications such as autogenous and semi-autogenous grinding mills, ball mills and indeed any application that subjects metal castings to highly abrasive wear forces. Furthermore, upon structural analysis of metal castings produced from the alloy composition, it was found that they have a substantially pearlitic microstructure. 30 Metal castings, in accordance with an aspect of the present invention, are produced by WO 2005/024084 PCT/AU2004/000095 -5 preparing the molten alloy composition with the correct proportions of the alloying constituents. The molten alloy is then poured into a mould conforming to the particular shape casting desired. The metal casting is then cooled to ambient air temperature after which the casting is removed from the mould and ground and gauged to the desired profile. 5 If a metal casting is desired which has a thickness of greater than 300mm it may be desirable to air blast the castings, after cooling, in order to increase their hardness. Furthermore, if the metal castings include thicker sections adjacent to thinner sections, then a further step of tempering may be introduced after the normnnalising heat treatment. 10 The present invention will become better understood from the following example of a preferred but non-limiting embodiment thereof. Example 15 A trial was conducted to analyse the effect of abrasive wear force upon various metal castings used in autogenous grinding mills. Three different metal castings made of different alloy steels were tested. Test metal casting A was produced from an alloy according to an aspect of the present invention. The two remaining metal castings B and C 20 are commercially available products. The three test metal castings A, B and C were put into service for a period of four months after which time they were removed and examined. Composition Analysis 25 Samples of the three test metal castings A, B and C were abrasively cut and constantly cooled with water to avoid overheating so they can be used for chemical and metallographic analysis. Chemical analysis results are given in the following table which were provided using an ARL 3460 Optical Emission Spectrometer.
WO 2005/024084 PCT/AU2004/000095 -6 Table: 1 ID C% Si % S% P% Mn% Ni% Cr% Mo% V Cu Al Nb No A 0.85 0.45 0.015 0.015 0.9 0.35 2.15 0.34 0.02 0.35 0.05 0.01 B 0.78 0.05 0.028 0.015 0.92 0.06 2.58 0.31 0.018 0.09 0.07 0.01 C 0.67 0.49 0.018 0.013 0.65 0.07 2.29 0.31 0.017 0.09 0.04 0.01 5 Hardness Each of the worn test metal castings was surface ground to a dept of 3 - 4 mm on the wear face and hardness tested using an Equotip instrument. Hardness results with specification 10 and testing position are given in the following table: Table: 2 Metal Thin Section Thick Section Spec. HB HB A 376 333 B 327 310 C 326 285 15 Metallography A small section was cut from the wear face of each of the three test metal castings. All specimens were wet ground on silicon carbide paper, polished with 6 & 1 pm diamond and 20 etched using 2% Nital. Examination was performed using a metallurgical microscope at x50 to x1000 magnifications. This revealed a slightly different microstructure for each specification. Microstructure of the specimen composed of Alloy A - consisted of a tempered pearlite 25 with a very small amount of spheroidal carbide in some insulated areas.
WO 2005/024084 PCT/AU2004/000095 -7 The microscopic examination of the specimen composed of Alloy B revealed a pearlitic microstructure with a network of boundary carbide and a small amount of spheroidal carbide in some areas. 5 Microstructure of the Alloy C consists of tempered martensite with 0.5% to 1% carbide around the grain boundaries. Also very light etching revealed some micro-cracks in between the grains of the microstructure. 10 Visual examination As it can be seen from the photographs in figures 1 and 2, all pieces are heavily worn with no metal flow on the edges. Some pieces of the castings made from Alloys B and C have been worn to very thin sections of only 40 mm around bolt holes while the most warn part 15 of the casting made from alloy A liner is 80 mm in thickness (See the table below). It has been noticed that areas around boltholes are most affected, so the thickness has been checked and presented in the following table. The thickness results are a good indication of the wear resistance of different metal compositions. 20 Table: 3 Metal Most effected Least effected Spec. area mm area mm A 110 140 A 110 160 A 80 130 B 70 120 B 70 130 C 40 100 C 40 140 25 WO 2005/024084 PCT/AU2004/000095 -8 Conclusion After heat treatment, these grades are expected to achieve a fully pearlitic microstructure with a hardness range on the wear face of 320 HB to 380 HB but some lower hardness can 5 be expected in the middle of very thick section castings as slower cooling occurs in these thick casting sections during heat treatment. The metal casting produced from alloy C has the lowest performance against abrasive wear force as a result of its martensitic microstructure. 10 The casting produced from alloy B shows the presence of a carbide network around the grain boundaries, which increased the hardness but in the same time decreases the toughness of the material. 15 The metal casting produced form alloy A achieved the best performance as a result of its material properties. Through hardness was achieved with a fine pearlitic microstructure with spheroidal carbides in very small-insulated areas. The presence of spheroidal carbide improves wear resistance without decreasing the toughness of the material. 20 Although several preferred embodiments have been described in detail, it should also be understood that various changes, substitutions, and alterations can be made herein by one ordinarily skilled in the art without departing from the spirit or scope of the present invention.
Claims (15)
1. An alloy steel composition which includes the following constituents by weight: carbon 0.5 - 3.5% 5 silicon 0.2 - 0.8% manganese 0.5 - 1.5% nickel 0.1 - 2.0% chromium 1.0 - 3.0% molybdenum 0.1 - 0.5% 10 copper 0.1 - 2.0%.
2. An alloy steel composition according to claim 1 wherein the percentage composition of nickel is 0.10 - 0.45% by weight. 15
3. An alloy steel composition according to claim 1 or 2 wherein the percentage composition of copper is 0.10 - 0.45% by weight.
4. A metal casting produced from the alloy steel composition according to any one of claims 1 to 3. 20
5. A metal casting according to claim 4 which has a substantially pearlitic microstructure throughout its entirety.
6. A metal casting according to claim 4 or 5 wherein the hardness of the casting is 25 greater than 310 HB.
7. A metal casting according to claim 6 wherein the hardness of the casting is greater than 335 HIB. 30
8. A metal casting according to any one of claims 4 to 7 for use in applications which result in high wear upon the casting. WO 2005/024084 PCT/AU2004/000095 -10
9. A metal casting according to any one of claims 4 to 7 for use as components in autogenous grinding mills, semi-autogenous grinding mills or ball mills. 5
10. A metal casting according to claim 9 wherein the component is any component subject to wear.
11. A metal casting according to claim 9 or 10 wherein the components are lifter bars, liners, pulp lifters and/or grates. 10
12. A metal casting according to any one of claims 8 to 10 wherein, after about 50 to 100 mm of wear has occurred on the casting, the hardness of the casting is greater than 310 HB and preferably greater than 330 HB. 15
13. A method of producing a metal casting composed of the alloy steel composition according to any one of claims 1 to 3 characterised by the steps of: i. pouring the molten alloy composition into a metal casting mould; ii. cooling the metal casting at ambient temperature; and iii. grind casting and gauge to profile. 20
14. A method according to claim 13 which includes the step of air blasting when the metal casting is greater than 300 mm in thickness.
15. A method according to claim 13 and 14 which includes the step of tempering at 25 about 580C.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2004270752A AU2004270752A1 (en) | 2003-09-09 | 2004-01-27 | An alloy steel composition |
Applications Claiming Priority (4)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2003904931A AU2003904931A0 (en) | 2003-09-09 | An alloy steel composition | |
| AU2003904931 | 2003-09-09 | ||
| AU2004270752A AU2004270752A1 (en) | 2003-09-09 | 2004-01-27 | An alloy steel composition |
| PCT/AU2004/000095 WO2005024084A1 (en) | 2003-09-09 | 2004-01-27 | An alloy steel composition |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| AU2004270752A1 true AU2004270752A1 (en) | 2005-03-17 |
Family
ID=36251902
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU2004270752A Abandoned AU2004270752A1 (en) | 2003-09-09 | 2004-01-27 | An alloy steel composition |
Country Status (1)
| Country | Link |
|---|---|
| AU (1) | AU2004270752A1 (en) |
-
2004
- 2004-01-27 AU AU2004270752A patent/AU2004270752A1/en not_active Abandoned
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MK5 | Application lapsed section 142(2)(e) - patent request and compl. specification not accepted |