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WO2017132476A1 - Matériaux métalliques traités thermiquement et procédés associés - Google Patents

Matériaux métalliques traités thermiquement et procédés associés Download PDF

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Publication number
WO2017132476A1
WO2017132476A1 PCT/US2017/015283 US2017015283W WO2017132476A1 WO 2017132476 A1 WO2017132476 A1 WO 2017132476A1 US 2017015283 W US2017015283 W US 2017015283W WO 2017132476 A1 WO2017132476 A1 WO 2017132476A1
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WO
WIPO (PCT)
Prior art keywords
article
metallic material
gap
heating
cooling
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.)
Ceased
Application number
PCT/US2017/015283
Other languages
English (en)
Inventor
Dana Craig Bookbinder
Theresa Chang
Jeffrey John Domey
Peter Joseph Lezzi
Richard Orr Maschmeyer
John Christopher Thomas
Kevin Lee Wasson
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Corning Inc
Original Assignee
Corning Inc
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Corning Inc filed Critical Corning Inc
Priority to CN201780008981.6A priority Critical patent/CN108603241A/zh
Priority to US16/073,899 priority patent/US20190040491A1/en
Publication of WO2017132476A1 publication Critical patent/WO2017132476A1/fr
Anticipated expiration legal-status Critical
Ceased legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/52Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
    • C21D9/54Furnaces for treating strips or wire
    • C21D9/56Continuous furnaces for strip or wire
    • C21D9/63Continuous furnaces for strip or wire the strip being supported by a cushion of gas
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/34Methods of heating
    • C21D1/53Heating in fluidised beds
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D1/00General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering
    • C21D1/56General methods or devices for heat treatment, e.g. annealing, hardening, quenching or tempering characterised by the quenching agents
    • C21D1/613Gases; Liquefied or solidified normally gaseous material
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/52Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for wires; for strips ; for rods of unlimited length
    • C21D9/54Furnaces for treating strips or wire
    • C21D9/56Continuous furnaces for strip or wire
    • C21D9/567Continuous furnaces for strip or wire with heating in fluidised beds
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/002Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working by rapid cooling or quenching; cooling agents used therefor
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/004Heat treatment in fluid bed
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/04Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon
    • C22F1/043Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of aluminium or alloys based thereon of alloys with silicon as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/08Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of copper or alloys based thereon
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22FCHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
    • C22F1/00Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
    • C22F1/10Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2201/00Treatment for obtaining particular effects
    • C21D2201/03Amorphous or microcrystalline structure
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2211/00Microstructure comprising significant phases
    • C21D2211/002Bainite
    • CCHEMISTRY; METALLURGY
    • C21METALLURGY OF IRON
    • C21DMODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D2211/00Microstructure comprising significant phases
    • C21D2211/008Martensite
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C19/00Alloys based on nickel or cobalt
    • C22C19/03Alloys based on nickel or cobalt based on nickel
    • C22C19/05Alloys based on nickel or cobalt based on nickel with chromium
    • C22C19/051Alloys based on nickel or cobalt based on nickel with chromium and Mo or W
    • C22C19/055Alloys based on nickel or cobalt based on nickel with chromium and Mo or W with the maximum Cr content being at least 20% but less than 30%
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C19/00Alloys based on nickel or cobalt
    • C22C19/07Alloys based on nickel or cobalt based on cobalt
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/02Alloys based on aluminium with silicon as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/001Ferrous alloys, e.g. steel alloys containing N
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/002Ferrous alloys, e.g. steel alloys containing In, Mg, or other elements not provided for in one single group C22C38/001 - C22C38/60
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/02Ferrous alloys, e.g. steel alloys containing silicon
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/04Ferrous alloys, e.g. steel alloys containing manganese
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/06Ferrous alloys, e.g. steel alloys containing aluminium
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/18Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/44Ferrous alloys, e.g. steel alloys containing chromium with nickel with molybdenum or tungsten
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C38/00Ferrous alloys, e.g. steel alloys
    • C22C38/18Ferrous alloys, e.g. steel alloys containing chromium
    • C22C38/40Ferrous alloys, e.g. steel alloys containing chromium with nickel
    • C22C38/50Ferrous alloys, e.g. steel alloys containing chromium with nickel with titanium or zirconium

Definitions

  • the disclosure relates generally to thermally treated metallic materials and to related methods and systems for the thermal treatment of metals and alloys.
  • thermomechanical processes are used to provide desired combinations of micro structure, mechanical properties, physical properties and/or surface finishes.
  • metallic materials can be thermally treated and/or thermomechanically treated to produce recrystallization of the metallic material's microstructure, stress relief of a metallic material article and/or desired second phase morphology within a host matrix.
  • Such thermal treatments typically include heating of a metallic material article to an elevated temperature, holding the metallic material article at the elevated temperature for a desired length of time and then cooling the metallic material article.
  • a controlled heating rate employed to heat the metallic component article to the elevated temperature and/or cooling a controlled cooling rate to cool the metallic material article is desired.
  • This disclosure relates, in part, to thermally treated metallic material articles, and to methods, processes, and systems that thermally treat metallic material articles.
  • the process and method of the current disclosure heats and/or cools an article formed from a metallic material (article), the article supported with gas during the heating and/or cooling.
  • the article is heated by transferring thermal energy from a heat source to the article across a heating gap between the heat source and the article such that more than 20% of the thermal energy leaving the heat source crosses the heating gap and is received by the article.
  • the article is heated to and held at a desired elevated temperature for a desired amount of time. Thereafter, the article is allowed to cool. In embodiments, the article is allowed to air cool.
  • the article is cooled by transferring thermal energy from the article to a heat sink across a cooling gap between the article and the heat sink such that more than 20% of the thermal energy leaving the heated article crosses the cooling gap and is received by the heat sink.
  • the article is supported with gas during heating and more than half of the thermal energy leaving the heat source crosses the heating gap is received by the article.
  • the article can also be supported with gas during cooling and more than half of the thermal energy leaving the article crosses the cooling gap is received by the heat sink.
  • the heating gap or the cooling gap can have an average thickness between an outer surface of the heat source and the article or the article and an outer surface of the heat sink surface, respectively, that is less than 10 millimeters (mm), 5 mm, 2 mm 1 mm, 800 micrometers ( ⁇ ), 600 ⁇ , 400 ⁇ , or 200 ⁇ .
  • a heat transfer rate from the heat source to the article during heating, or from the article to the heat sink during cooling is greater than 50 kilowatts per square meter (kW/m 2 ), greater than 100 kW/m 2 , greater than 150 kW/m 2 , greater than 200 kW/m 2 , greater than 250 kW/m 2 , greater than 300 kW/m 2 , greater than 350 kW/m 2 , greater than 450 kW/m 2 , greater than 550 kW/m 2 , greater than 650 kW/m 2 , greater than 750 kW/m 2 , greater than 1000 kW/m 2 , or greater than 1200 kW/m 2 for the area of the outer surface of the heat source, or for the area of the outer surface of the article, respectively.
  • kW/m 2 kilowatts per square meter
  • the article can be in the form of a sheet, a cylindrical rod, a hexagonal rod, and the like.
  • the article When the article is in the form of a sheet, the article has a length, a width, and a thickness.
  • the thickness of the sheet is less than 3 mm, less than 2 mm, less than 1.5 mm, less than 1.0 mm, less than 0.5 mm, less than about 0.25 mm, less than about 0.1 mm, less than 0.08 mm, less than 0.06 mm, or less than 0.04 mm. At least one of the width and the length are greater than five times the thickness of the sheet.
  • the rod When the article is in the form of a rod, the rod has an average diameter and a length.
  • the diameter of the rod is less than 10 mm, less than 9 mm, less than 8 mm, less than 7 mm, less than 6 mm, less than 5 mm, less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.8 mm, less than 0.6 mm, less than 0.4 mm, less than 0.2 mm or less than 0.1 mm.
  • the heating gap or cooling gap can be a gas gap with a gap area and a total mass flow rate of gas into the gas gap is greater than 0 and less than 2k/gCp per square meter of gap area where k is the thermal conductivity of a gas within the gas gap evaluated in the direction of heat conduction, g is the distance between the heated article and the heat sink surface, and Cp is the specific heat capacity of the gas within the gas gap.
  • the metallic material can be a pure metal or an alloy and the pure metal or alloy can be polycrystalline, single crystal, or metallic glass.
  • the pure metal can be a commercial pure metal such as commercial pure aluminum (Al), copper (Cu), chromium (Cr), nickel (Ni), niobium (Nb), iron (Fe), magnesium (Mg), molybdenum (Mo), silver (Ag), tantalum (Ta), titanium (Ti), tungsten (W) zirconium (Zr), gold (Au), platinum (Pt) or any other commercially available pure metal.
  • the alloy can be an Al-base alloy, a Cu-base alloy, a Cr- base alloy, a Ni-base alloy, a Nb-base alloy, an Fe-base alloy, a Mg-base alloy, a Mo-base alloy, a Ag-base alloy, a Ta-base alloy, a Ti-base alloy, a W-base alloy, a Zr-base alloy, a Au-base alloy or another known alloy.
  • the article is made from an Al-base alloy and the Al-base alloy article is solution heat treated, quenched and aged in order to provide a precipitation strengthened (also known as precipitation hardened or age hardened) article with reduced residual stresses.
  • the Al-base alloy article can be subjected cold working and then heated by the heat source such that recrystallization of the cold worked Al-base alloy article micro structure occurs.
  • the recrystallized Al-base alloy article can be controllably cooled to prevent undesired grain growth of the recrystallized Al-base alloy article microstructure.
  • the article is made from a Cu-base alloy article and the Cu-base alloy article is solution heat treated, quenched and aged in order to provide a precipitation strengthened article with reduced residual stresses.
  • the Cu-base alloy article can be subjected cold working and then heated by the heat source such that recrystallization of the cold worked Cu-base alloy article microstructure occurs.
  • the recrystallized Cu-base alloy article can be controllably cooled to prevent undesired grain growth of the recrystallized Cu-base alloy article microstructure.
  • the article is made from an Fe-base alloy and the Fe-base alloy article is solution annealed such that the microstructure of the Fe-base alloy is completely austenite and then cooled to provide a microstructure with ferrite and a desired amount of pearlite, including no pearlite.
  • the Fe-base alloy article is solution annealed such that the microstructure of the Fe-base alloy is completely austenite and then cooled to provide a microstructure with ferrite and a desired amount of bainite and/or martensite.
  • the solution annealed Fe-base alloy article can be cooled such retained austenite can be present in the Fe-base alloy article's microstructure.
  • the Fe-base alloy article can be subjected cold working and then heated by the heat source such that recrystallization of the cold worked Fe-base alloy article microstructure occurs.
  • the recrystallized Fe-base alloy article can be controllably cooled to prevent undesired grain growth of the recrystallized Fe-base alloy article microstructure.
  • the article is made from a Ni-base alloy and the Ni-base alloy article is solution annealed such that the microstructure of the Ni-base alloy is completely austenitic (face centered cubic - FCC) and then cooled to provide a microstructure with desired second phase precipitates.
  • Such second phases precipitates can include Ni Al (gamma prime) precipitates, carbide precipitates, nitride precipitates and/or carbonitride precipitates.
  • the Ni-base alloy article can be subjected cold working and then heated by the heat source such that recrystallization of the cold worked Ni-base alloy article microstructure occurs.
  • the recrystallized Ni-base alloy article can be controllably cooled to prevent undesired grain growth of the recrystallized Ni-base alloy article microstructure.
  • the article can be made from other types of alloys and heat treated and cooled to provide a desired article microstructure. It should be appreciated that the microstructure of an alloy article is closely linked to the article's mechanical properties. Accordingly, an alloy article can be heated treated and cooled to provide a desired combination of strength and ductility.
  • the process can include heating of the metallic material article in a heating zone configured to chemically alter a surface region of the article.
  • the heating zone can include chemical vapor deposition (CVD) equipment and/or plasma deposition equipment that can chemically alter the surface region of the article.
  • the surface region of the article can be chemically altered such as by coating with, impregnation and/or diffusion of elements such as nitrogen (nitriding), boron (bonding), carbon (carburizing), and combinations thereof.
  • FIG. 1 is a diagrammatic cross-section of a thin metallic material sheet being cooled by conduction more than by convection using an inventive thermal treatment system according to an exemplary embodiment
  • FIG. 2 is a diagrammatic cross-sectional diagram of metallic material thin sheet being heated and cooled by conduction more than by convection in a continuous manner using an inventive thermal treatment system according to an exemplary embodiment
  • FIG. 3 is a diagrammatic cross-sectional diagram of metallic material thin sheet being heated and cooled by conduction more than by convection in a continuous manner according to an exemplary embodiment
  • FIG. 4 is a graph showing temperature versus time for heating and cooling of metallic material thin sheet according to embodiments disclosed in the present disclosure
  • FIG. 5A is a schematic cross-section of a cold worked metallic material thin sheet before recrystallization
  • FIG. 5B is a schematic cross-section of the metallic material thin sheet of FIG. 4A after recrystallization
  • FIG. 6A is a schematic illustration of an iron alloy having a desired amount of pearlite and produced according to an exemplary embodiment
  • FIG. 6B is a schematic illustration of an iron alloy microstructure with a desired amount of bainite and martensite produced according to an exemplary embodiment
  • FIG. 6C is a schematic illustration of an iron alloy microstructure having no pearlite
  • FIG. 7A is a schematic illustration of an aluminum alloy microstructure having been precipitation strengthened according to an exemplary embodiment
  • FIG. 7B is a schematic illustration of a nickel alloy microstructure having been precipitation strengthened according to an exemplary embodiment
  • FIG. 8 is a schematic cross-section of a metallic glass thin sheet with surface regions having a recrystallized microstructure in an inner region with a glass microstructure produced according to an exemplary embodiment
  • FIG. 9 is a schematic cross-sectional diagram of an apparatus configured to chemically alter a surface region of a metallic material thin sheet article according to an exemplary embodiment.
  • Applicant has recognized a need for improvements in thermal treatment of metallic materials, both in methods and systems for thermally treating metallic materials and the resulting thermally treated metallic materials themselves.
  • thin sheets of metallic materials are useful for a number of applications, including use in heat exchangers, aerospace applications, cookware, cutlery, heat treating equipment, alternative energy components, and building materials.
  • Metallic materials the term herein including pure metals, alloys, intermetallics, and metallic glasses, can be processed to have a wide range of microstructures and mechanical properties.
  • Metallic materials, particularly alloys can provide high strength and excellent ductility compared to ceramics and glasses.
  • metallic materials are typically electrically conductive and are used in electrical applications.
  • Traditional thermal treatment of metallic materials typically includes placing a metallic material article (article) in a furnace at an elevated temperature for a given amount of time and then removing the article form the furnace and cooled.
  • the thermal treatment of the article can result in recrystallization of the article's microstructure.
  • the thermal treatment of the article can also reduce residual stress within the article without recrystallization of the article's microstructure.
  • the article is made from a metal or alloy that has a high temperature phase and a different low temperature phase, e.g.
  • thermal treatment of the article can provide an article micro structure with the ferritic low temperature phase and additional metastable phases.
  • heating and controlled cooling of the article can provide a desired density and spatial location of the one or more metastable phases.
  • traditional thermal treatment of articles typically involves large furnaces that use significant amounts of energy for heating. Additionally, such furnaces may provide a reducing atmosphere for thermal treatment of the articles and this use large amounts of reducing gases such as hydrogen gas.
  • the processes and systems described herein thermally treat an article by heating and/or cooling the article while it is supported with gas.
  • the gas can be a moving and, in further embodiments, capable of moving the article.
  • the article can be heated by transferring thermal energy from a heat source to the article across a heating gap between the heat source and the article such that more than 20% of the thermal energy leaving the heat source crosses the heating gap and can be received by the article.
  • the article can be cooled by transferring thermal energy from the article to a heat sink across a cooling gap between the article and the heat sink such that more than 20% of the thermal energy leaving the article crosses the cooling gap and can be received by the heat sink.
  • more than 50% of the thermal energy leaving the heat source or the article crosses the heating gap or the cooling gap, respectively, and can be received by the article component or the heat sink, respectively.
  • the heating gap or the cooling gap can have an average thickness between an outer surface of the heat source and the article or between the article and an outer surface of the heat sink that can be less than 200 microns, less than 180 microns, less than 160 microns, less than 140 microns, less than 120 microns, less than 100 microns, less than 80 microns, less than 60 microns, less than 40 microns or less than 20 microns.
  • a heat transfer rate from the heat source to the article during heating or from the article to the heat sink during cooling can be greater than 50 kilowatts per square meter (kW/m 2 ), greater than 100 kW/m 2 , greater than 150 kW/m 2 , greater than 200 kW/m 2 , greater than 250 kW/m 2 , greater than 300 kW/m 2 , greater than 350 kW/m 2 , greater than 450 kW/m 2 , greater than 550 kW/m 2 , greater than 650 kW/m 2 , greater than 750 kW/m 2 , greater than 1000 kW/m 2 , or greater than 1200 kW/m 2 for the area of the outer surface of the heat source, or for the area of the outer surface of the article, respectively.
  • the article can be in the form of a sheet, a cylindrical rod, a hexagonal rod, and the like.
  • the article has a length, a width, and a thickness.
  • the thickness of the sheet can be less than 3 mm, less than 2 mm, less than 1.5 mm, less than 1.0 mm, less than 0.5 mm, less than about 0.25 mm, less than about 0.1 mm, less than 0.08 mm, less than 0.06 mm, or less than 0.04 mm.
  • At least one of the width and the length are greater than five times the thickness of the sheet.
  • the rod has an average diameter and a length.
  • the diameter of the rod can be less than 10 mm, less than 9 mm, less than 8 mm, less than 7 mm, less than 6 mm, less than 5 mm, less than 4 mm, less than 3 mm, less than 2 mm, less than 1 mm, less than 0.8 mm, less than 0.6 mm, less than 0.4 mm, less than 0.2 mm or less than 0.1 mm.
  • the heating gap or cooling gap can be a gas gap with a gap area and the total mass flow rate of gas into the gas gap can be greater than zero and less than 2k/gCp per square meter of gap area, where k is the thermal conductivity of a gas within the gas gap evaluated in the direction of heat conduction, g is the distance between the heat source and the article or between the article and the heat sink surface, and Cp is the specific heat capacity of the gas within the gas gap.
  • the metallic material can be a pure metal or an alloy and the pure metal or alloy can be polycrystalline, single crystal, or metallic glass.
  • the pure metal can be a commercial pure metal such as commercial pure aluminum (Al), copper (Cu), chromium (Cr), nickel (Ni), niobium (Nb), iron (Fe), magnesium (Mg), molybdenum (Mo), silver (Ag), tantalum (Ta), titanium (Ti), tungsten (W) zirconium (Zr), gold (Au), platinum (Pt) or any other commercially available pure metal.
  • the alloy can be an Al-base alloy, a Cu-base alloy, a Cr- base alloy, a Ni-base alloy, a Nb-base alloy, an Fe-base alloy, a Mg-base alloy, a Mo-base alloy, a Ag-base alloy, a Ta-base alloy, a Ti-base alloy, a W-base alloy, a Zr-base alloy, a Au-base alloy or another known alloy.
  • the article can be made from an Al-base alloy and the Al-base alloy article can be solution heat treated and quenched in order to provide a precipitation strengthened (also known as precipitation hardened or age hardened) article with reduced residual stresses.
  • the Al-base alloy article can be subjected cold working and then heated by the heat source such that recrystallization of the cold worked Al-base alloy article micro structure occurs.
  • the recrystallized Al-base alloy article can be controllably cooled to prevent undesired grain growth of the recrystallized Al-base alloy article microstructure.
  • the article can be made from a Cu-base alloy article and the Cubase alloy article can be solution heat treated, quenched and aged in order to provide a precipitation strengthened article with reduced residual stresses.
  • the Cu-base alloy article can be subjected cold working and then heated by the heat source such that recrystallization of the cold worked Cu-base alloy article microstructure occurs.
  • the recrystallized Cu-base alloy article can be controllably cooled to prevent undesired grain growth of the recrystallized Cu-base alloy article microstructure.
  • the article can be made from an Fe-base alloy and the Fe-base alloy article can be solution annealed such that the microstructure of the Fe-base alloy can be completely austenite and then cooled to provide a microstructure with ferrite and a desired amount of pearlite, including no pearlite.
  • the Fe-base alloy article can be solution annealed such that the microstructure of the Fe-base alloy can be completely austenite and then cooled to provide a microstructure with ferrite and a desired amount of bainite and/or martensite.
  • the solution annealed Fe-base alloy article can be cooled such retained austenite can be present in the Fe-base alloy article's microstructure.
  • the Fe-base alloy article can be subjected cold working and then heated by the heat source such that recrystallization of the cold worked Fe-base alloy article micro structure occurs.
  • the recrystallized Fe-base alloy article can be controllably cooled to prevent undesired grain growth of the recrystallized Fe-base alloy article microstructure.
  • solution annealed refers to a thermal treatment that produces a solid solution of alloy elements in a high temperature matrix phase.
  • the high temperature matrix phase can be the same phase as a low temperature matrix phase, e.g. face centered cubic (FCC) austenite for Ni-base alloys, or can be a different phase from the low temperature phase, e.g. FCC austenite versus BCC ferrite for Fe-base alloys.
  • FCC face centered cubic
  • the article can be made from a Ni-base alloy and the Ni-base alloy article can be solution annealed such that the microstructure of the Ni-base alloy can be completely austenitic (face centered cubic - FCC) and then cooled to provide a microstructure with desired second phase precipitates.
  • Such second phases precipitates can include Ni 3 Al (gamma prime) precipitates, carbide precipitates, nitride precipitates and/or carbonitride precipitates.
  • the Ni-base alloy article can be subjected cold working and then heated by the heat source such that recrystallization of the cold worked Ni-base alloy article microstructure occurs.
  • the recrystallized Ni-base alloy article can be controllably cooled to prevent undesired grain growth of the recrystallized Ni-base alloy article microstructure.
  • the article can be made from other types of alloys and heat treated and cooled to provide a desired article microstructure. It should be appreciated that the microstructure of an alloy article can be closely linked to the article's mechanical properties. Accordingly, an alloy article can be heated treated and cooled to provide a desired combination of strength and ductility.
  • the process can include heating of the metallic material article in a heating zone configured to chemically alter a surface region of the article.
  • the heating zone can include chemical vapor deposition (CVD) equipment and/or plasma deposition equipment that can chemically alter the surface region of the article.
  • the surface region of the article can be chemically altered such as by coating with, impregnation and/or diffusion of elements such as nitrogen (nitriding), boron (bonding), carbon (carburizing), and combinations thereof.
  • FIG. 1 shows an exemplary embodiment of a metal thermal treatment system 300 according to this disclosure.
  • FIG. 1 shows an exemplary embodiment of a metal thermal treatment system 300 according to this disclosure.
  • FIG. 1 shows a schematic cross- sectional diagram of the system 300, in which an article (sheet) can be heated via conduction of heat from a heat source to the article and cooled via conduction of heat from the article, through a gas into a conductive heat sink.
  • the metal thermal treatment system 300 includes a hot zone 310, a cold zone 330, and a transition gas bearing 320.
  • Transition gas bearing 320 moves or directs the article (e.g., metallic material sheet (sheet) 400a) from the hot zone 310 to the cold zone 330 such that no contact or substantially no contact occurs between the sheet and the bearings.
  • the hot zone 310 has gas bearings 312 each fed from a hot zone plenum 318, and the bearings 312 have heat sources 314 inserted into holes through the bearings 312, which serve to heat the hot zone gas bearings 312 to a desired thermal treatment process temperature.
  • the heat sources 314 can be electrically resistive heat sources or induction heating heat sources.
  • the heat sources 314 may have an outer surfaces 314a that face the channel 316 and the outer surfaces 314a may provide infrared heating.
  • a sheet (hot zone) 400a can be kept between the hot zone gas bearings 312 for a duration long enough to bring it to a desired thermal treatment temperature (e.g., a stress relief temperature, a solution annealing temperature, a high temperature phase annealing temperature, an age hardening temperature, etc.).
  • a desired thermal treatment temperature e.g., a stress relief temperature, a solution annealing temperature, a high temperature phase annealing temperature, an age hardening temperature, etc.
  • heating the article in the hot zone may be done predominantly via conduction of heat from a heat sink through a thin gas barrier.
  • the conductive heating processes used in the hot zone can be similar to, but the reverse of the cooling processes described herein (e.g., pushing heat into the article).
  • the hot zone 310 includes the one or more heat sources 314 disposed adjacent to the channel 316. Where two heat sources are utilized, such heat sources may be disposed on opposite sides of the channel 316, facing each other across a channel gap 316a between the outer surfaces 314a.
  • the heat sources include a plurality of apertures 314b which form part of the gas bearing 312, and the outer surfaces 314a of the hot gas bearings 312 of the hot zone 310 serve as the two heat source surfaces. Due to the low gas flow rate within channel 316 and the small size that can be provided for the channel gap 316a, sheet 400a can be heated within hot zone 310 primarily by conduction of heat from the heat sources 314 across the channel gap 316a and into the sheet 400a, without the sheet 400a touching the heat source outer surfaces 314a.
  • the heat sources and/or the surfaces thereof may be segmented.
  • the heat sources may be porous, and in such embodiments, the apertures through which the gas for gas bearings 312 can be delivered are the pores of the porous heat sinks.
  • the plurality of apertures 314b, a gas source and the channel gap 316a may be in fluid communication.
  • the gas flows through the apertures 314b to form gas cushions, layers or bearings in the channel gap 316a.
  • the gas cushions of some embodiments prevent the sheet 400a from contacting the heat source 314 surfaces.
  • the gas also serves as the gas through which the sheet 400a can be heated by conduction more than by convection.
  • the gas flowed through the apertures 314b heats the heat sources 314.
  • the gas flowed through the apertures both facilitates heat conduction, from the heat source 314, across the gap 316a, into the sheet 400a, and also heats the heat sources 314.
  • a separate gas or liquid may be used to heat the heat sources 314.
  • the heat sources 314 may include passages (not shown), for flowing a heating gas or liquid therethrough to heat the heat sources 314. The passages can be enclosed.
  • one or more gas sources may be used to provide a gas to the channel gap 316a.
  • the gas sources may include the same gas as one another or different gases.
  • the channel gap 316a may, therefore, include one gas, a mixture of gases from different gas sources, or the same gas source.
  • Exemplary gases include air, nitrogen, carbon dioxide, helium or other noble gases, hydrogen and various combinations thereof.
  • the gas may be described by its thermal conductivity when it enters the channel 316 just before it begins to conductively heat the sheet 400a.
  • the gas may have a thermal conductivity of about (e.g., plus or minus 1%) 0.02 W/(m K) or greater, about 0.025 W/(m K) or greater, about 0.03 W/(m K) or greater, about 0.035 W/(m K) or greater, about 0.04 W/(m K) or greater, about 0.045 W/(m K) or greater, about 0.05 W/(m K) or greater, about 0.06 W/(m K) or greater, about 0.07 W/(m K) or greater, about 0.08 W/(m K) or greater, about 0.09 W/(m K) or greater, about 0.1 W/(m K) or greater, about 0.15 W/(m K) or greater, or about 0.2 W/(m K) or greater).
  • a thermal conductivity of about (e.g., plus or minus 1%) 0.02 W/(m K) or greater, about 0.025 W/(m K) or greater, about 0.03 W/(m K) or greater, about 0.0
  • heat transfer rates allow for high heat transfer rates which, as discussed above, allow for rapid and controlled heating within sheet, and allow for rapid, localized and controlled heating of outer surface regions of thin sheet.
  • heat transfer rates as high as 50 kilowatts per square meter (kW/m 2 ), greater than 100 kW/m 2 , greater than 150 kW/m 2 , greater than 200 kW/m 2 , greater than 250 kW/m 2 , greater than 300 kW/m 2 , greater than 350 kW/m 2 , greater than 450 kW/m 2 , greater than 550 kW/m 2 , greater than 650 kW/m 2 , greater than 750 kW/m 2 , greater than 1000 kW/m 2 , or greater than 1200 kW/m 2 or more are possible through conduction alone.
  • the cold zone 330 can provide cooling rates that equate to furnace cooling, air cooling and/or water quenching (1000-4000 kW/m 2 ) of articles thermally treated in the thermal treatment system 300.
  • gaps 316a, between the hot zone gas bearings 312 and the sheet 400a may be relatively large, on the order of 0.05" (1.27 mm) to 0.125" (3.175 mm) or greater, since the sheet 400a may be heated up relatively slowly and thermal radiation from the hot gas bearings 312 into the sheet 400a can be adequate for this purpose.
  • hot zone gap size may be as small as 150 microns per side or 500 microns per side. Smaller gaps may be advantageous, in some embodiments, because they enable the bearings to have better "stiffness" - i.e., ability to centralize the sheet and therefore flatten it while it is in its softened state.
  • the process may re-form the sheets - flattening them - in the initial heating step, for example via the pressure supplied by the gas bearings 312.
  • the top and bottom hot zone bearings may be on actuators, allowing for changing the gap width in a continuous manner or, alternatively, allowing the sheet to be brought into the hot zone when the gap is large and then compressing the gap to flatten the sheet while it is still soft.
  • Process temperatures in the hot and/or cool zone are dependent on a number of factors, including sheet composition, sheet thickness, sheet properties (CTE, etc.), and desired level of thermal treatment (e.g. stress reliving, solution annealing, etc.).
  • the starting process temperature may be any value between the ambient temperature and the melting point of the sheet.
  • system 300 heats the sheet 400a to a temperature between about (e.g., plus or minus 1%) 780 to about 820°C.
  • system 300 heats the sheet to a solution anneal temperature of about 530°C, an annealing temperature of about 410°C and/or an aging precipitation heat treatment temperature of about 175°C.
  • solution strengthened nickel alloys for example, system 300 heats the sheet to a solution anneal temperature of about 1150°C.
  • system 300 heats the sheet to a solution anneal temperature of about 1080°C, to a first age-hardening treatment temperature of about 995°C, to a second age-hardening treatment temperature of about 845°C and to a third age-hardening treatment temperature of about 760°C.
  • the sheet can be cooled at one or more desired cooling rates such that furnace cooling, air cooling, water quenching, or some cooling rate between cooling rates associate with furnace cooling, air cooling or water quenching, can be provided to the sheet. Furthermore, the sheet can be moved back and forth between the hot zone 310 and the cold zone 330 in order to provide desired heating and cooling cycles for the sheet.
  • the sheet 400a can be heated to its desired starting thermal treatment temperature (e.g., a solution anneal temperature), and it can then moved from the hot zone 310 to the cold zone 330 for controlled cooling using any suitable means.
  • moving the sheet 400a from the hot zone 310 to the cold zone 330 may be accomplished by, for example (1) tilting the entire assembly such that gravity acting on the sheet forces it to move to the cold zone, (2) blocking off the gas flow from the leftmost exit of the hot zone 310 (the sides are enclosed in this embodiment), thereby forcing all of the gas emanating from all of the gas bearings to exit from the rightmost exit of the cold zone, causing fluid forces to be exerted on the sheet 400a and causing it to move to the cold zone 330, or (3) by a combination of (1) and (2)).
  • the transition gas bearings 320 may be supplied with gas by transition bearing plenums 328.
  • the solid material thickness behind the surfaces of the transition gas bearings 320 may be thin, of low thermal mass and/or low thermal conductivity, allowing for reduced heat conduction from the hot zone 310 to the cold zone 330.
  • the transition gas bearings 320 may serve as a thermal break or transition between the two zones 310 and 330 and may serve to transition from the larger gaps 316a of the hot zone down to small gaps 336 of the cold zone 330. Further, the low thermal mass and/or low thermal conductivity of transition gas bearings 320 limit(s) the amount of heat transfer and therefore cooling experienced by sheet 400a while passing past transition gas bearings 320.
  • the sheet 400b can be stopped from exiting the right side exit by a mechanical stop or any other suitable blocking mechanism, shown as stop gate 341.
  • stop gate 341 may be moved, unblocking cold zone channel 330a, and then the sheet 400b may be removed from the system 300. If desired, the sheet 400b may be left in the cold zone 330 until somewhere near room temperature or below before removal.
  • sheet 400a can be heated to a desired temperature and the cold zone 330 includes a channel 330a for receiving heated sheet 400a through an opening 330b, conveying the sheet 400a into the cold zone 330, and cooling the sheet 400b in the cold zone 330.
  • the channel 330a includes a conveyance system that may include gas bearings, roller wheels, conveyor belt, or other means to physically transport the sheet through the cold zone.
  • cold zone 330 includes gas bearings 332 which are fed plenums 338 that are separate from hot zone plenums 318 and transition bearing plenums 328.
  • the cold zone 330 includes one or more heat sinks 331 disposed adjacent to the channel 330a. Where two heat sinks are utilized, such heat sinks may be disposed on opposite sides of the channel 330a, facing each other across a channel gap 330a.
  • the heat sinks include a plurality of apertures 331a which form part of the gas bearing 332, and the surfaces of the cold gas bearings 332 of the cold zone 330 serve as the two heat sink surfaces.
  • sheet 400b can be cooled within cold zone 330 primarily by conduction of heat from the sheet 400b across the gap and into the solid heat sinks 331, without the sheet 400b touching the heat sink surfaces.
  • the heat sinks and/or the surfaces thereof may be segmented.
  • the heat sinks may be porous, and in such embodiments, the apertures through which the gas for gas bearings 332 can be delivered are the pores of the porous heat sinks.
  • the plurality of apertures 332b, a gas source and the channel gap 330a may be in fluid communication.
  • the gas flows through the apertures 331a to form gas cushions, layers or bearings in the channel gap 330a.
  • the gas cushions of some embodiments prevent the sheet 400b from contacting the heat sink 331 surfaces.
  • the gas also serves as the gas through which the sheet 400b can be cooled by conduction more than by convection.
  • the gas flowed through the apertures 331a cools the heat sinks.
  • the gas flowed through the apertures both facilitates heat conduction, from the sheet, across the gap, into the heat sinks, and also cools the heat sinks 331.
  • a separate gas or liquid may be used to cool the heat sinks 331.
  • the heat sinks 331 may include passages 334, for flowing a cooling gas or liquid therethrough to cool the heat sinks 331.
  • the passages 334 can be enclosed.
  • one or more gas sources may be used to provide a gas to the channel gap 330a.
  • the gas sources may include the same gas as one another or different gases.
  • the channel gap 330a may, therefore, include one gas, a mixture of gases from different gas sources, or the same gas source.
  • Exemplary gases include air, nitrogen, carbon dioxide, helium or other noble gases, hydrogen and various combinations thereof.
  • the gas can be hydrogen and the thermal treatment system 300 serves as a bright anneal furnace, i.e.
  • a furnace that anneals the sheet in a reducing environment which prevents oxidation of the sheet surface and reduces most oxides present on the sheet surface, thereby providing an annealed sheet with a "bright" surface.
  • the quick transfer of the sheet 400a from the hot zone 310 to the cold zone 330 can provide a rapid cooling rate, e.g. equivalent to water quenching, to the sheet 400b. It should be appreciated that such a "water quench” type of cooling provides cooling rates currently not available for current bright anneal furnaces.
  • the gas may be described by its thermal conductivity when it enters the channel 330a just before it begins to conductively cool the sheet 400b.
  • the gas may have a thermal conductivity of about (e.g., plus or minus 1%) 0.02 W/(m K) or greater, about 0.025 W/(m K) or greater, about 0.03 W/(m K) or greater, about 0.035 W/(m K) or greater, about 0.04 W/(m K) or greater, about 0.045 W/(m K) or greater, about 0.05 W/(m K) or greater, about 0.06 W/(m K) or greater, about 0.07 W/(m K) or greater, about 0.08 W/(m K) or greater, about 0.09 W/(m K) or greater, about 0.1 W/(m K) or greater, about 0.15 W/(m K) or greater, or about 0.2 W/(m K) or greater).
  • the heat sinks 331 of one or more embodiments may be stationary or may be movable to modify the thickness of the channel gap 330a.
  • the thickness of the sheet 400b may be in a range from about 0.4 times the thickness to about 0.6 times the thickness of channel gap 300a, which is defined as the distance between the opposing surfaces of the heat sinks 331 (e.g., upper and lower surface of heat sinks 331 in the arrangement of FIG. 1).
  • the channel gap can be configured to have a thickness sufficient such that the heated sheet can be cooled by conduction more than by convection.
  • the channel gap in the hot zone 310 and/or the cold zone 330 may have a thickness such that when sheet 400a or 400b is being conveyed through or located within the channel 316 a or 330a, the distance between the major surfaces of the sheet 400a or 400b and the heat source surface or heat sink surface (e.g., the gap size discussed above) can be about (e.g., plus or minus 1%) 100 ⁇ or greater (e.g., in the range from about 100 ⁇ to about 200 ⁇ , from about 100 ⁇ to about 190 ⁇ , from about 100 ⁇ to about 180 ⁇ , from about 100 ⁇ to about 170 ⁇ , from about 100 ⁇ to about 160 ⁇ , from about 100 ⁇ to about 150 ⁇ , from about 110 ⁇ to about 200 ⁇ , from about 120 ⁇ to about 200 ⁇ , from about 130 ⁇ to about 200 ⁇ , or from about 140 ⁇ to about 200 ⁇ m).
  • the distance between the major surfaces of the sheet 400a or 400b and the heat source surface or heat sink surface
  • the channel gap may have a thickness such that when sheet 400a or 400b is being conveyed through the channel 316 or 330a, the distance between the sheet and the heat source surface or heat sink surface (the gap or gaps 316a or 330a) can be about (e.g., plus or minus 1%) 100 ⁇ or less (e.g., in the range from about 10 ⁇ to about 100 ⁇ , from about 20 ⁇ to about 100 ⁇ , from about 30 ⁇ to about 100 ⁇ , from about 40 ⁇ to about 100 ⁇ , from about 10 ⁇ to about 90 ⁇ , from about 10 ⁇ to about 80 ⁇ , from about 10 ⁇ to about 70 ⁇ , from about 10 ⁇ to about 60 ⁇ , or from about 10 ⁇ to about 50 ⁇ ).
  • the distance between the sheet and the heat source surface or heat sink surface can be about (e.g., plus or minus 1%) 100 ⁇ or less (e.g., in the range from about 10 ⁇ to about 100 ⁇ , from about 20 ⁇ to about 100 ⁇
  • the total thickness of the channel gap 316a or 330a can be dependent on the thickness of the sheet 400a or 400b, but can be generally characterized as 2 times the distance between the heat source surface or heat sink surface and the sheet, plus the thickness of the sheet. In some embodiments, the distance or gaps 316a or 330a between the sheet and the heat sources or heat sinks may not be equal. In such embodiments, the total thickness of the channel gap 316a or 330a may be characterized as the sum of the distances between the sheet and each heat source surface or the sheet and each heat sink surface, plus the thickness of the sheet.
  • the total thickness of the channel gap 316a or 330a may be less than about (e.g., plus or minus 1%) 2500 ⁇ (e.g., in the range from about 120 ⁇ to about 2500 ⁇ , about 150 ⁇ to about 2500 ⁇ , about 200 ⁇ to about 2500 ⁇ , about 300 ⁇ to about 2500 ⁇ , about 400 ⁇ to about 2500 ⁇ , about 500 ⁇ to about 2500 ⁇ , about 600 ⁇ to about 2500 ⁇ , about 700 ⁇ to about 2500 ⁇ , about 800 ⁇ to about 2500 ⁇ , about 900 ⁇ to about 2500 ⁇ , about 1000 ⁇ to about 2500 ⁇ , about 120 ⁇ to about 2250 ⁇ , about 120 ⁇ to about 2000 ⁇ , about 120 ⁇ to about 1800 ⁇ , about 120 ⁇ to about 1600 ⁇ , about 120 ⁇ to about 1500 ⁇ , about 120 ⁇ to about 1400 ⁇ , about 120 ⁇ to about 1300 ⁇ , about 120 ⁇ to about 1
  • the total thickness of the channel gap may be about 2500 ⁇ or more (e.g., in the range from about 2500 ⁇ to about 10,000 ⁇ , about 2500 ⁇ to about 9,000 ⁇ , about 2500 ⁇ to about 8,000 ⁇ , about 2500 ⁇ to about 7,000 ⁇ , about 2500 ⁇ to about 6,000 ⁇ , about 2500 ⁇ to about 5,000 ⁇ , about 2500 ⁇ to about 4,000 ⁇ , about 2750 ⁇ to about 10,000 ⁇ , about 3000 ⁇ to about 10,000 ⁇ , about 3500 ⁇ to about 10,000 ⁇ , about 4000 ⁇ to about 10,000 ⁇ , about 4500 ⁇ to about 10,000 ⁇ , or about 5000 ⁇ to about 10,000 ⁇ ).
  • the apertures 331a in the heat sink 331 may be positioned to be perpendicular to the heat sink surface or may be positioned at an angle of 20 degrees or less, such as about (e.g., plus or minus 1%) 15 degrees or less, about 10 degrees or less or about 5 degrees or less) from perpendicular to the heat sink surface.
  • the material behind the heat sink (cold gas bearing 332) surfaces can be any suitable material having high heat transfer rates, including metals (e.g., stainless steel, copper, aluminum), ceramics, carbon, etc. This material may be relatively thick compared to the material behind the surfaces of the transition gas bearings 320, as shown in FIG. 1, such that heat sink can easily accept relatively large amounts of thermal energy.
  • the material of the heat sinks 331 can be stainless steel.
  • the metal thermal treatment system 300 shown in FIG. 1 can processes metal sheet in a continuous manner.
  • the thermal treatment system 300 is similar to the thermal treatment system 300 shown in FIG. 1 except a sheet 400 can be continuous processed through the thermal treatment system 300 by supplying a sheet 400 to the thermal treatment system 300 from a feed roll 305 and after exiting the thermal treatment system 300 coiling the thermal treated sheet 400 into an exit roll 335.
  • a sheet 400 can be continuous processed through the thermal treatment system 300 by supplying a sheet 400 to the thermal treatment system 300 from a feed roll 305 and after exiting the thermal treatment system 300 coiling the thermal treated sheet 400 into an exit roll 335.
  • As the sheet 400 enters the hot zone 310 it can be heated as discussed above with respect to sheet 400a.
  • the sheet 400 continues to pass through the transition gas bearing 320 and into the cold zone 330 where it cooled as discussed above with respect to sheet 400b.
  • the speed of the sheet 400 through the thermal treatment system 300, the heating rate of the sheet 400 in the hot zone 310, the thermal treatment temperature of the sheet 400 in the hot zone 310, the cooling rate of the sheet 400 in the cold zone 330 are designed and implemented to provide a thermally treated metallic material sheet with desired a desired micro structure and mechanical properties.
  • FIG. 3 illustrates the use of another treatment system 300 to thermally treat the sheet 400 after it has been thermally treated by the thermal treatment system 300 in FIG. 2.
  • the thermal treatment system 300 in FIG. 2 thermally treats the sheet 400 through a first heating and cooling thermal treatment cycle
  • the thermal treatment system 300 in FIG. 3 thermally treats the sheet 400 through a second heating and cooling thermal treatment cycle.
  • the sheet 400 from feed roll 305 in the thermal treatment system 300 in FIG. 2 can be fed into the heating zone 310 and thermally treated as discussed above in reference to sheet 400a in FIGS. 1-2.
  • the sheet 400 moves from the hot zone 310, through the transition gas bearings 320 and into the cold zone 330 where it can be thermally treated as discussed above in reference to sheet 400b in FIGS. 1-2. As the thermally treated sheet 400 exits the cold zone 330 it can be coiled into the exit roll 335 for the thermal treatment system 300 in FIG. 2. Between the feed roll 305 and the exit roll 335 of the thermal treatment system 300 in FIG. 2, the sheet 400 can be subjected to a first heating and cooling thermal treatment cycle. Exit roll 335 of the thermal treatment system 300 in FIG. 2 can be then used as feed roll 305 for the thermal treatment system 300 in FIG. 3. Similar to the thermal treatment system 300 in FIG. 2, the thermally treated sheet 400 from the thermal treatment system 300 in FIG.
  • thermal treatment system 300 which can be the feed roll 305 for the thermal treatment system 300 in FIG. 3, can be subjected to another (second) heating and cooling thermal treatment cycle.
  • second thermal treatment system as disclosed herein can be used to thermally treat metallic material articles and thus provide more than two heating and cooling thermal treatment cycles.
  • FIG. 4 illustrates a time versus temperature graph for sheet passing through the metal thermal treatment system 300 in FIGS 1 or 2, or passing through one of the thermal treatments systems in FIG. 3.
  • the sheet 400 has a temperature between T1-T2 (e.g., ambient temperature) before entering the hot zone 310 of the thermal treatment system 300, at which time the sheet 400a can be heated to a heat treatment temperature (e.g. a solution anneal temperature) between T3-T4 in the heat zone 310.
  • T1-T2 e.g., ambient temperature
  • a heat treatment temperature e.g. a solution anneal temperature
  • the sheet 400a can be held at the heat treatment temperature between T3-T4 for a predetermined amount of time and then passed through the transition gas bearings 320 into the cold zone 330 where cooling of the sheet 400b to a temperature between T5-T6 at a predetermined and desired cooling rate occurs. Thereafter, the sheet 400b can be removed from the cold zone 330 and allowed to further cool to the temperature between T1-T2 (e.g., ambient temperature). In the alternative, the sheet 400b can be cooled and held at the temperature between T5-T6 in the cold zone 330, and then cooled and held to the temperature between T1-T2 in the cold zone 330, before the sheet 400b exits the cold zone 330.
  • T1-T2 e.g., ambient temperature
  • the cooling rate for the sheet 400b cooled from the temperature between T3-T4 to the temperature between T5-T6 may or may not be the same as the cooling rate for the sheet 400b cooled from the temperature between T5-T6 to the temperature between T1-T2.
  • FIGS. 5A and 5B illustrate recrystallization of an article that has been subjected to work hardening (also known as strain hardening and cold working).
  • work hardening also known as strain hardening and cold working
  • the article has been subjected to plastic deformation and exhibits a work hardened microstructure (e.g. grains elongated in the direction of the plastic deformation process) in FIG. 5 A.
  • a recrystallization temperature in the hot zone 310 for a desired amount of time
  • recrystallization of the microstructure occurs as illustrated ion FIG. 5B.
  • cooling of the article in the cold zone 330 controls grain growth, i.e. prevents excessive grain growth after recrystallization.
  • Such recrystallization of articles can be provided by the thermal treatments system 300 for a variety of metallic materials, including but not limited to commercial pure metals such as commercial pure Al, Cu, Cr, Ni, Nb, Fe, Mg, Mo, Ag, Ta, Ti, W, Zr, Au, Pt or any other commercially available pure metal, and alloys such as Al-base alloys, Cu-base alloys, Cr-base alloys, Ni-base alloys, Nb alloys, Fe-base alloys, Mg alloys, Mo alloys, Ag alloys, Ta alloys, Ti alloys, W alloys, Zr alloys, Au alloys or other known alloys.
  • commercial pure metals such as commercial pure Al, Cu, Cr, Ni, Nb, Fe, Mg, Mo, Ag, Ta alloys, Ti alloys, W alloys, Zr alloys, Au alloys or other known alloys.
  • FIGS. 6A-6C illustrate exemplary microstructures of articles that have been processed through the thermal treatment system 300.
  • steel sheet can be thermally treated in the thermal treatment system 300 such that a ferrite matrix with a desired amount of pearlite can be provided as illustrated in FIG. 5A.
  • steel sheet can be thermally treated such that a ferrite matrix with a desired amount of bainite and/or martensite can be provided as illustrated in FIG. 5B.
  • steel sheet can be thermally treated such that a ferrite matrix free of pearlite and other second phases can be provided as illustrated in FIG. 5C.
  • FIG. 6A an exemplary microstructure of an Al-base alloy having been thermally treated by the metal thermal treatment system 300 is shown.
  • the thermal treatment system 300 has heated and cooled the Al-base alloy such that precipitates known as "GP zones" have been precipitated throughout the alloy microstructure and provided age hardening of the material.
  • FIG. 6B illustrates an exemplary microstructure of a nickel alloy that has been processed through the metal thermal treatment system 300 such that gamma prime precipitates have been precipitated throughout the alloy microstructure and provided precipitation strengthening of the material.
  • a representative microstructure of a metallic glass having been processed through the metal thermal treatment system 300 illustrates surface regions of the metallic glass thin sheet having been recrystallized while an inner region remains with an amorphous or glass morphology.
  • Such thermal treatment provides an article with surfaces that are resistant to crack initiation and propagation and an interior with increased tensile strength and elastic strain limit.
  • the thermal treatment system 300 chemically alters surface regions of articles that pass therethrough.
  • a gaseous atmosphere 500 with one or more chemical elements e.g. Cr, C, B, N, Al, Si, etc.
  • the thermal treatment system 300 can provide the gaseous atmosphere 500 primarily to only one side of the sheet 400a.
  • the one or more chemical elements deposited onto the surface of the sheet 400a can remain at the surface and thereby provide a chemically altered surface.
  • the gaseous atmosphere 500 can be provided or generated using a chemical vapor deposition (CVD) process, a plasma deposition process, etc. In embodiments, the gaseous atmosphere 500 assists in supporting the sheet 400a such that the sheet 400a does not come into physical contact with the heat sources 314.
  • the thermal treatment system 300 with the gaseous atmosphere 500 can chromize a surface region of the sheet 400a (chromizing), carburize a surface region of the sheet 400a (carburizing), boride a surface region of the sheet 400a (bonding), nitride a surface region of the sheet 400a (nitriding), aluminize a surface region of the sheet 400a (aluminizing), siliconize a surface region of the sheet 400a (siliconizing) and combinations thereof.
  • Apparatus setup - As detailed above, the apparatus comprises three zones - a hot zone, a transition zone, and a cold zone. The gaps between the top and bottom thermal bearings in the hot zone and cold zone are set to desired spacings. Gas flow rates in the hot zone, transition zone, and quench zone are set to ensure centering of the article on the gas- bearing.
  • the hot zone can be pre-heated to a desired temperature T 0 where the article will be held a predetermined and desired amount of time before being transferred to the cold zone and cooled.
  • the temperature T 0 is determined by metallic material of the article being thermally treated and the specific thermal treatment being performed on the article.
  • the time to equilibration is dependent at least on the thickness of the article.
  • equilibration occurs in approximately 10 seconds.
  • equilibration occurs in approximately 10 seconds to 30 seconds.
  • the equilibration time may be on the order of 60 seconds.
  • Example 1 A 6061 wrought aluminum sheet having a chemical composition in weight percent of 0.15 Mn, 0.4-0.8 Si, 0.15-0.35 Cr, 0.15-0.4 Cu, 0.7 Fe, 0.25 Zn, 0.8-1.2 Mg, 0.15 Ti, with the remainder being Al and other incidental impurities was provided as thin sheet having a thickness of 1 mm.
  • the thin sheet was annealed in the hot zone at 775°F for 2 hours followed by controlled cooling at 50°F per hour down to 500°F, followed by air cooling.
  • the material was subjected to an age hardening heat treatment at 350°F for 8 hours followed by air cooling in order to produce the T6 temper.
  • Example 2 A cold rolled steel alloy sheet having a thickness of 0.5 mm and a chemical composition within the range and weight percent of 0.085-0.11 C, 1.4-2.0 Mn, 0.09-0.21 Mo, 0.02-0.05 Al, 0.16-0.5 Si, 0.13-0.5 Cr, 0.016 max Ti, 0.06 max Ni, 0.003 max S, 0.015 max P, 0.006 max N, and with the balance being iron and incidental metal impurities can be processed through the metal thermal treatment system 300 and subjected to an intercritical annealing in the hot zone at temperatures between 760-800°C. Thereafter, the intercritically annealed steel alloy sheet can be rapidly cooled to a temperature of less than 450°C in the cold zone.
  • the rapidly cooled sheet has a ferrite-martensite microstructure with less than 6 volume percent bainite, a 0.2% yield strength of at least 330 MPa, a tensile strength of at least 590 MPa, a total elongation to failure of at least 18%, and a uniform elongation of at least 10%.
  • Co-base and Ni-base solid- solution strengthened alloys employ second phase precipitates such as Cr-carbides, W-carbides, etc., to assist in high temperature strengthening of the material
  • the primary strengthening mechanism can be the addition and alloying of various elements within the Co or Ni matrix to provide "solid solution strengthening.”
  • Example 3 One Co-base and two Ni-base solid-solution strengthened alloys having the following nominal chemical compositions (wt%) can be processed through the metal thermal treatment system 300.
  • Cobalt Alloy (CI) 10 Ni, 20 Cr, 15 W, 3 max Fe 1.5 Mn, 0.4 max Si, 0.10 C with the balance Co (approximately 51 et%) and incidental impurities (commercially available as HAYNES® 25 alloy).
  • NI First Nickel Alloy
  • Typical solution annealing temperatures provided by the thermal treatment system 300 for the CI and N1-N2 alloys are shown in Table 1 below.
  • Such solid-solution- strengthened alloys are typically supplied in the solution annealed condition with microstructures of primary carbides dispersed in a single phase matrix.
  • the micro structure can be free of primary carbides at grain boundaries and provides an optimum combination for room temperature fabricability and elevated temperature properties once the material can be put into service.
  • Heat treatments performed at temperatures below the solution heat treating temperature range provided by the thermal treatment system 300 are known as mill annealing or stress relief thermal treatments (see Table 1 below).
  • Mill annealing treatments are employed for restoring formed, partially fabricated, or otherwise as-worked alloy material to a condition where additional deformation or welding of the material can be performed. Such treatments may also be used to produce structures in finished raw materials which are optimum for specific forming operations.
  • mill annealing thermal treatments provided by the thermal treatment system 300 can be used to produce a microstructure with a fine grain size for deep drawing applications. Mill annealing of the solid-solution-strengthened alloys by the thermal treatment system 300 can also be used to relief stress and yet avoid article distortion that can occur at full solution annealing temperatures.
  • the gas bearings of the thermal treatment system 300 support the solid-solution-strengthened alloys during annealing and thus can actually impose and ensure a final shape is maintained during the higher temperature solution annealing thermal treatments.
  • Use of a mill annealing heat treatment typically results in precipitation of secondary carbides on grain boundaries of material originally supplied in the solution-annealed condition, and will not normally restore the material to the as-received condition.
  • Example 4 Two Ni-base age-hardenable (also known as precipitation hardenable or precipitation strengthenable) alloys having the following nominal chemical compositions (wt%) can be processed through the metal thermal treatment system 300.
  • wt% nominal chemical compositions
  • Ni-base age-hardenable alloy 13.5 Co, 2 max Fe, 19 Cr, 4.3 Mo, 1.5 Al, 3 Ti, 0.08 C, 0.1 max Mn, 0.15 max Si, 0.006 B, 0.1 Cu, 0.05 Zr, with balance Ni (approximately 58 wt%) and incidental impurities (commercially available as HAYNES® Waspaloy alloy).
  • Second Ni-base age-hardenable alloy (NiAH2): 16 Cr, 8 Fe, 2.5 Ti, 1 Nb, 0.8 Al, 1 max Co, 0.35 max Mn, 0.35 max Sai, 0.08 max C, with balance Ni (approximately 70 wt%) and incidental impurities (commercially available as INCONEL® X-750 alloy and HAYNES® X-750 alloy).
  • Ni-base age-hardenable alloys derive most of their strength from thermal treatments that result in a range of second phase precipitates in the micro structure.
  • the predominant precipitate is Ni Al (gamma prime).
  • Thermal treatment of such alloys to provide the precipitation hardened microstructure requires a number of heating and cooling steps.
  • a typical heat treatment for the NiAHl alloy to provide the precipitation hardened microstructure includes solution annealing the material at 1080°C for 30 minutes followed by a water quench.
  • the resulting precipitation hardened microstructure for the NiAHl provides excellent mechanical properties up to temperatures approximately 700°C as shown in Table 3 (tensile test properties) and Table 4 (stress-rupture properties) below. Table 3.
  • a typical heat treatment for the NiAH2 alloy to provide the precipitation hardened micro structure includes solution annealing the material at 1040°C followed by a first precipitation thermal treatment at 730°C for 8 hours followed by furnace cooling to a second precipitation thermal treatment at 620°C for 8 hours followed by air cooling to room temperature.
  • the resulting precipitation hardened micro structure for the NiAH2 provides excellent mechanical properties up to temperatures approximately 700°C as shown in Tables 5 and 6 below.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Physics & Mathematics (AREA)
  • Thermal Sciences (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Heat Treatment Of Articles (AREA)

Abstract

L'invention concerne une tôle ou un article en métal traité thermiquement, ainsi que des procédés et des systèmes de fabrication de la tôle ou de l'article traité thermiquement. Le procédé consiste à chauffer et/ou à refroidir la tôle en métal par conduction thermique sans contact pendant suffisamment longtemps pour obtenir une microstructure souhaitée et des propriétés mécaniques souhaitées. Le procédé permet d'obtenir des tôles en métal traitées thermiquement.
PCT/US2017/015283 2016-01-29 2017-01-27 Matériaux métalliques traités thermiquement et procédés associés Ceased WO2017132476A1 (fr)

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CN116356122B (zh) * 2022-12-14 2023-12-12 中建五洲工程装备有限公司 一种正交异性钢结构焊接单元的退火工艺及应用
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