Iron-Base Alloy Containing Chromium-Tungsten Carbide And a Method Of Producing It

Abstract

A method and cast wear resistant component made of an alloy that includes carbon, tungsten, chromium, and cobalt with the balance essentially iron and other alloying components made using waste, surplus or worn-out cemented carbide product, such as cemented carbide cutting tool inserts. In one method, the alloy further includes silicon, manganese, nickel, titanium, and molybdenum. In practicing the method, pieces of waste, surplus or worn-out cemented carbide product having tungsten carbide (WC) are added to a cast iron alloy melt. The melt includes enough chromium to control solubility of the WC. In one method, precipitated carbide structure having chromium and carbon is produced with tungsten in the melt being substitutionally dissolved. In one implementation, tungsten is substitutionally dissolved in a lattice of the precipitated carbide structure. Carbide can be added to the melt via super inoculation. The cast wear resistant component can be a cutting tool.

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       35 . A cast wear resistant component comprised of an alloy made with waste, surplus or worn out cemented carbide product and having an as-cast composition consisting essentially of 2-3.5% weight percent carbon, 5-20% weight percent tungsten, 20-30% weight percent chromium, and 0.5-5% weight percent cobalt, with the balance essentially iron and other alloying components. 
   
   
       36 . The cast wear resistant component of  claim 35  wherein the component is machinable. 
   
   
       37 . The cast wear resistant component of  claim 36  wherein the component is heat treatable. 
   
   
       38 . The cast wear resistant component of  claim 35  wherein the component comprises a tool. 
   
   
       39 . The cast wear resistant component of  claim 38  wherein the component comprises a cutting tool. 
   
   
       40 . The cast wear resistant component of  claim 35  wherein the component has an as-cast composition consisting essentially of 2-3.5% weight percent carbon, 5-20% weight percent tungsten, 20-30% weight percent chromium, 0.8-1.2% weight percent silicon, 0.4-2% weight percent manganese, 0.8-2% weight percent nickel, 0.2-0.5% weight percent titanium, 0-1% weight percent molybdenum. 
   
   
       41 . The cast wear resistant component of  claim 35  wherein the component is comprised of chromium carbide arranged in a lattice structure having tungsten substitutionally dissolved therein. 
   
   
       42 . A method for making a wear resistant component comprising the steps of:
 (a) melting a quantity of metal comprised of cast iron alloy;   (b) adding to the melt, pieces of waste, surplus or worn-out cemented carbide product comprised of tungsten carbide wherein there is chromium in the melt in an amount sufficient to control the solubility of tungsten carbide; and   (c) casting a wear resistant component consisting essentially of 2-3.5% by weight carbon, 5-20% by weight tungsten, 20-30% by weight chromium, and 0.5-5% by weight cobalt, with the balance essentially iron.   
   
   
       43 . The method of  claim 42  wherein the pieces of waste, surplus or worn-out cemented carbide product added to the melt during step (b) comprises cemented carbide cutting tool inserts. 
   
   
       44 . The method of  claim 42  wherein the pieces of waste, surplus or worn-out cemented carbide product added to the melt during step (b) comprise tungsten carbide. 
   
   
       45 . The method of  claim 42  wherein the wear resistant component cast during step (c) comprises a cutting tool. 
   
   
       46 . The method of  claim 42  wherein the wear resistant component formed during step (c) is comprised essentially of 2-3.5% carbon, 5-20% tungsten, 20-30% chromium, 0.8-1.2% silicon, 0.4-2% manganese, 0.8-2% nickel, 0.2-0.5% titanium, 0-1% molybdenum, 0.5-5% cobalt, and the balance essentially iron. 
   
   
       47 . The method of  claim 42  wherein chromium is added in a further step. 
   
   
       48 . The method of  claim 42  wherein the cast iron alloy comprises white cast iron. 
   
   
       49 . The method of  claim 42  comprising a precipitated carbide structure comprised of chromium and carbon and wherein tungsten in the melt substitutionally dissolves in a lattice of the precipitated carbide structure. 
   
   
       50 . The method of  claim 42  wherein before step (c) adding carbide to the melt via super inoculation. 
   
   
       51 . The method of  claim 50  wherein the carbide added to the melt via super inoculation comprises tungsten carbide. 
   
   
       52 . A method for making a wear resistant component comprising the steps of:
 (a) melting a quantity of metal comprised of cast iron alloy;   (b) adding to the melt pieces of waste, surplus or worn-out cemented carbide product comprised of tungsten carbide wherein chromium is provided in the melt in an amount sufficient to control the solubility of tungsten carbide; and   (c) forming a wear resistant component consisting essentially of 2-3.5% carbon, 5-20% tungsten, 20-30% chromium, 0.8-1.2% silicon, 0.4-2% manganese, 0.8-2% nickel, 0.2-0.5% titanium, 0-1% molybdenum, 0.5-5% cobalt, and the balance essentially iron with incidental impurities.   
   
   
       53 . The method of  claim 52  wherein the pieces of waste, surplus or worn-out cemented carbide product added to the melt during step (b) comprises cemented carbide cutting tool inserts. 
   
   
       54 . The method of  claim 52  wherein the pieces of waste, surplus or worn-out cemented carbide product added to the melt during step (b) comprise tungsten carbide. 
   
   
       55 . The method of  claim 52  wherein the wear resistant component cast during step (c) comprises a cutting tool. 
   
   
       56 . The method of  claim 52  wherein chromium is added in a further step before step (c). 
   
   
       57 . The method of  claim 52  wherein the cast iron alloy comprises white cast iron. 
   
   
       58 . The method of  claim 52  comprising a precipitated carbide structure comprised of chromium and carbon and wherein tungsten in the melt substitutionally dissolves in a lattice of the precipitated carbide structure. 
   
   
       59 . The method of  claim 52  wherein before step (c) adding carbide to the melt via super inoculation. 
   
   
       60 . The method of  claim 59  wherein the carbide added to the melt via super inoculation comprises tungsten carbide.