Non-Ferromagnetic Amorphous Steel Alloys Containing Large-Atom Metals

Abstract

The present invention relates to novel non-ferromagnetic amorphous steel alloys represented by the general formula: Fe—Mn-(Q)-B—M, wherein Q represents one or more elements selected from the group consisting of Se, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu, and M represents one or more elements selected from the group consisting of Cr, Co, Mo, C and Si. Typically the atomic percentage of the Q constituent is 10 or less.

1 . An amorphous alloy represented by the formula:
   Fe (100-t) Mn n Cr m Mo p B q M d X r Z s Q g      
       wherein X is an element selected from the group consisting of Ti, Zr, Hf, Nb, V, W and Ta;
 Z is an element selected from the group consisting of C, Co or Ni; 
 Q is an element selected from the group consisting of Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu; 
 M is an element selected from the group consisting of Al, Ga, In, Sn, Si, Ge and Sb; 
 n, m, p, q, d, r, s and g are atomic percentages, wherein
 n is a number selected from 0 to about 29; 
 m and p are independently a number selected from 0 to about 16, 
 wherein n+m is at least 10; 
 q is a number selected from about 6 to about 21; 
 r and d are independently selected from 0 to about 4; 
 s is a number selected from 0 to about 20; 
 g is a number greater than 0 but less than or equal to about 10; and 
 
 t is the sum of n, m, p, q, r, s, d and g, with the proviso that t is a number selected from about 40 to about 60. 
 
     
     
         2 . The alloy of  claim 1 , wherein Q is an element selected from the group consisting of Sc, Y, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu. 
     
     
         3 . The alloy of  claim 1 , wherein said alloy is processable into bulk amorphous samples of at least about 5 mm in thickness in its minimum dimension. 
     
     
         4 . The alloy of  claim 1  or  2  wherein the alloy is represented by the formula:
   Fe (100-t) Mn n Cr m Mo p B q C s Q g    
 
       wherein n is a number selected from 0 to about 29;
 m is a number selected from 0 to about 16, wherein n+m is at least 15; 
 p is a number selected from 0 to about 16; 
 q is a number selected from about 4 to about 8; 
 s is about 13 to about 17; 
 g is a number greater than 0 but less than or equal to about 3; and 
 t is a number selected from about 40 to about 55. 
 
     
     
         5 . The alloy of  claim 4  wherein
 n is a number selected from 0 to about 12, 
 m is a number selected from 0 to about 16, wherein n+m is at least 14, 
 p is a number selected from about 8 to about 16, 
 q is a number selected from about 4 to about 8; 
 s is about 13 to about 17; 
 g is a number selected from about 1 to about 3; and 
 t is a number selected from about 45 to about 55. 
 
     
     
         6 . The alloy of  claim 2  wherein
 Q is an element selected from the group consisting of Sc, Y, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu; 
 n is a number selected from 0 to about 12, 
 m is a number selected from 0 to about 16, wherein n+m is at least 10, 
 p is a number selected from about 8 to about 16, 
 q is at least about 5; 
 r is a number selected from greater than 0 to about 2; 
 d is 0; 
 s is at least about 13; 
 g is a number selected from about 1 to about 3; and 
 t is a number selected from about 38 to about 55. 
 
     
     
         7 . The alloy of  claim 2  wherein
 n is a number selected from 0 to about 12, 
 m is a number selected from 0 to about 16, wherein n+m is at least 10, 
 p is a number selected from about 8 to about 16, 
 q is at least about 5; 
 d is a number selected from greater than 0 to about 2; 
 r is 0; 
 s is at least about 13; 
 g is a number selected from about 1 to about 3; and 
 t is a number selected from about 38 to about 55. 
 
     
     
         8 . The alloy of  claim 1  or  2  wherein the alloy is represented by the formula:
   Fe (100-t) Cr m Mo p B q C s Q g    
 m is a number selected from about 10 to about 20; 
 p is a number selected from about 5 to about 20; 
 q is a number selected from about 5 to about 7; 
 s is a number selected from about 15 to about 16; 
 g is a number selected from about 1 to about 3; and 
 t is the sum of m, p, q, s and g, and is a number selected from about 47 to about 55. 
 
     
     
         9 . The alloy of  claim 1  or  2  wherein the alloy is represented by the formula:
   Fe (100-t) Mn n Cr m Mo p B q Si d X r Ni s Q g    
 
       wherein X is Ta or Nb;
 n is a number selected from about 10 to about 29; 
 m is a number selected from 0 to about 4, wherein n+m is at least 15 but less than 30; 
 p, d and r are numbers independently selected from 0 to about 4; 
 q is a number selected from about 17 to about 21, wherein d+q is less than or equal to 23; 
 g is a number selected from about 4 to about 8; 
 s is a number ranging from 0 to about 20; and 
 t is the sum of n, m, q, d, r, s and g, with the proviso that t is a number ranging from about 35 to about 55. 
 
     
     
         10 . The alloy of  claim 9  wherein the alloy is represented by the formula:
   Fe (100-t) Mn n B q Si d X r Q g    
 
       wherein X is Ta or Nb;
 n is a number selected from about 15 to about 29; 
 q is a number selected from about 17 to about 21; 
 d is a number ranging from 0 to about 2; 
 r is a number selected from about 2 to about 3; 
 g is a number selected from about 4 to about 8; and t is a number selected from about 45 to about 55. 
 
     
     
         11 . The alloy of  claim 10  wherein d and r are both 0. 
     
     
         12 . An iron-based amorphous alloy represented by the formula:
   Fe (100-t) Mn n Cr m B q Si d  Mo r1 Nb r2 Ta r3 Ni s Q g      wherein Q is an element selected from the group consisting of Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu;   n is a number selected from about 15 to about 29;   m is a number selected from 0 to about 4, wherein
 n+m is at least 15; 
   q is a number selected from about 17 to about 21;   d is a number selected from 0 to about 4;   r1, r2 and r3 are numbers independently selected from 0 to about 4;   s is a number selected from 0 to about 20;   g is a number selected from about 4 to about 8; and   t is the sum of n, m, q, r1, r2, r3, d, s and g, with the proviso that t is a number selected from about 40 to about 65.   
     
     
         13 . The alloy of claim12 wherein Q is an element selected from the group consisting of Sc, Y, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu. 
     
     
         14 .- 16 . (canceled) 
     
     
         17 . An alloy comprising an iron-based amorphous alloy represented by the formula:
   Fe (100-t) Mn n Cr m Mo p B q M d X r Z s Q g      
       wherein M represents one or more elements selected from the group consisting of Al, Ga, In, Sn, Si, Ge and Sb;
 X represents one or more elements selected from the group consisting of Ti, Zr, Hf, Nb, V, W and Ta; 
 Z is an element selected from the group consisting of C, Co or Ni; 
 Q represents one or more large-atom metals wherein the sum of the atomic percentage of said large-atom metals is equal to g; 
 n, m, p, q, d, r, s and g are atomic percentages, wherein
 n is a number selected from 0 to 29; 
 in and p are independently a number selected from 0 to 16, 
 wherein n+m is at least 10; 
 q is a number selected from 4 to 21; 
 r and d are independently selected from 0 to 4; 
 s is a number selected from 0 to 20; 
 g is a number greater than 0 but less than or equal to 10; and 
 
 t is the sum of n, m, p, q, r, s, d and g, with the proviso that t is a number selected from 40 to 60. 
 
     
     
         18 . The alloy of  claim 17  wherein
 M is an element selected from the group consisting of Al, Ga, In, Sn, Si, Ge and Sb; 
 X is an element selected from the group consisting of Ti, Zr, Hf, Nb, V, W and Ta; 
 Z is carbon or Co; 
 Q is an element selected from the group consisting of Sc, Y, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu; 
 s is a number selected from 13 to 17; 
 q is a number selected from 4 to 7; 
 d and r are both 0, and the sum of m, p and g is less than 20. 
 
     
     
         19 . The alloy of  claim 17  wherein
 Z is carbon; 
 Q is an element selected from the group consisting of Sc, Y, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu; 
 n is a number selected from 0 to about 15; 
 m is a number selected from 0 to about 16, wherein n+m is at least 15 but less than 30; 
 p is a number selected from about 8 to about 16; 
 s is about 13 to about 17; 
 q is at least about 4 to about 7; 
 d and r are both 0; 
 g is a number selected from about 2 to about 3; and 
 t is a number selected from about 45 to about 55. 
 
     
     
         20 . The alloy of  claim 17  wherein the article of manufacture comprises an iron-based amorphous alloy represented by the formula:
   Fe (100-t) Mn n X r B g Q g    
 
       wherein X is an element selected from the group consisting of Mo, Ta or Nb;
 Q is an element selected from the group consisting of Sc, Y, Gd, Tb, Dy, Ho, Er, Tm, Yb and Lu; 
 n is a number selected from about 15 to about 29; 
 r is a number selected from 2 to 3; 
 q is a number selected from 17 to 21; 
 g is a number selected from 4 to 8; and t is the sum of n, r, q and g, and is a number selected from 45 to 55. 
 
     
     
         21 . A method of preparing homogeneous ingots of an iron-based amorphous alloy comprising large-atom metals, manganese and boron, said method comprising the steps of
 forming an FeB precursor ingot;   forming a Mn-large-atom metal precursor ingot;   melting and mixing the FeB precursor ingot with the remaining elements of the alloy, but excluding the Mn-large-atom metal precursor ingot, to form an alloy mixture;   combining said alloy mixture with the manganese Mn-large-atom metal precursor ingot; and   melting the combination together to form a homogenous ingot.   
     
     
         22 . The method of  claim 21  wherein said manganese is pre-melted in an arc furnace to provide a clean source of manganese prior to combining the manganese with the large-atom metal to form the Mn-large-atom metal precursor ingot. 
     
     
         23 . The method of  claim 21  or  22  wherein boron is alloyed with iron to form near-stochiometric FeB precursor ingot, with the remaining Fe being alloyed with the remaining elements of the alloy prior to said combining step. 
     
     
         24 . The alloy of  claim 1 , wherein said alloy is processable into bulk amorphous samples of less than about 0.1 mm in thickness in its minimum dimension. 
     
     
         25 . The alloy of  claim 1 , wherein said alloy is processable into bulk amorphous samples of at least about 0.1 mm in thickness in its minimum dimension. 
     
     
         26 . The alloy of  claim 1 , wherein said alloy is processable into bulk amorphous samples of at least about 0.5 mm in thickness in its minimum dimension. 
     
     
         27 . The alloy of  claim 1 , wherein said alloy is processable into bulk amorphous samples of at least about 1 mm in thickness in its minimum dimension. 
     
     
         28 . The alloy of  claim 1 , wherein said alloy is processable into bulk amorphous samples of at least about 5 mm in thickness in its minimum dimension. 
     
     
         29 . The alloy of  claim 1 , wherein said alloy is processable into bulk amorphous samples of at least about 10 mm in thickness in its minimum dimension. 
     
     
         30 . The alloy of  claim 1 , wherein said alloy is processable into bulk amorphous samples of at least about 12 mm in thickness in its minimum dimension. 
     
     
         31 . The alloy of  claim 1 , wherein said alloy is processable into an article. 
     
     
         32 . The alloy of  claim 31 , wherein said processed article is provided by at least one of the following processing methods: melt spinning, atomization, spray forming, scanning-beam forming, plastic forming, casting, compaction and commercially available manufacturing methods. 
     
     
         33 . The alloy of  claim 1 , wherein said alloy is processable into a coating. 
     
     
         34 . The alloy of  claim 33 , wherein said processed coating is provided by at least one of the following processing methods: melt spinning, atomization, spray forming, scanning-beam forming, plastic forming, casting, compaction and commercially available coating methods 
     
     
         35 . The alloy of  claim 1 , wherein said coating comprises corrosion resistant type coating and/or wear-resistant type coating. 
     
     
         36 . The alloy of  claim 33 , wherein said coating is disposed on a structure selected from the group consisting of ship frames, submarine frames, vehicle frames, airplane frames, ship parts, submarine parts, vehicle parts, airplane parts, armor penetrators, projectiles, protection armors, rods, train rails, cable armor, power shaft, and actuators, engineering and medical materials and tools, cell phone and PDA casings, housings, and components, electronics and computer casings, housings and components. 
     
     
         37 . The alloy of  claim 1 , wherein said alloy is processable into a structure selected from the group consisting of ship frames, submarine frames, vehicle frames, airplane frames, ship parts, submarine parts, vehicle parts, airplane parts, armor penetrators, projectiles, protection armors, rods, train rails, cable armor, power shaft, and actuators, engineering and medical materials and tools, cell phone and PDA casings, housings, and components, electronics and computer casings, housings and components. 
     
     
         38 . The alloy of  claim 12 , wherein said alloy is processable into bulk amorphous samples of less than about 0.1 mm in thickness in its minimum dimension. 
     
     
         39 . The alloy of  claim 12 , wherein said alloy is processable into bulk amorphous samples of at least about 0.1 mm in thickness in its minimum dimension. 
     
     
         40 . The alloy of  claim 12 , wherein said alloy is processable into bulk amorphous samples of at least about 0.5 mm in thickness in its minimum dimension. 
     
     
         41 . The alloy of  claim 12 , wherein said alloy is processable into bulk amorphous samples of at least about 1 mm in thickness in its minimum dimension. 
     
     
         42 . The alloy of  claim 12 , wherein said alloy is processable into bulk amorphous samples of at least about 5 mm in thickness in its minimum dimension. 
     
     
         43 . The alloy of  claim 12 , wherein said alloy is processable into bulk amorphous samples of at least about 10 mm in thickness in its minimum dimension. 
     
     
         44 . The alloy of  claim 12 , wherein said alloy is processable into bulk amorphous samples of at least about 12 mm in thickness in its minimum dimension. 
     
     
         45 . The alloy of  claim 12 , wherein said alloy is processable into an article. 
     
     
         46 . The alloy of  claim 45 , wherein said processed article is provided by at least one of the following processing methods: melt spinning, atomization, spray forming, scanning-beam forming, plastic forming, casting, compaction, and commercially available manufacturing methods. 
     
     
         47 . The alloy of  claim 12 , wherein said alloy is processable into a coating. 
     
     
         48 . The alloy of  claim 47 , wherein said processed coating is provided by at least one of the following processing methods: melt spinning, atomization, spray forming, scanning-beam forming, plastic forming, casting, compaction, and commercially available coating methods 
     
     
         49 . The alloy of  claim 47 , wherein said coating comprises corrosion resistant type coating and/or wear-resistant type coating. 
     
     
         50 . The alloy of  claim 47 , wherein said coating is disposed on a structure selected from the group consisting of ship frames, submarine frames, vehicle frames, airplane frames, ship parts, submarine parts, vehicle parts, airplane parts, armor penetrators, projectiles, protection armors, rods, train rails, cable armor, power shaft, and actuators, engineering and medical materials and tools, cell phone and PDA casings, housings, and components, electronics and computer casings, housings and components. 
     
     
         51 . The alloy of  claim 12 , wherein said alloy is processable into a structure selected from the group consisting of ship frames, submarine frames, vehicle frames, airplane frames, ship parts, submarine parts, vehicle parts, airplane parts, armor penetrators, projectiles, protection armors, rods, train rails, cable armor, power shaft, and actuators, engineering and medical materials and tools, cell phone and PDA casings, housings, and components, electronics and computer casings, housings and components. 
     
     
         52 .- 65 . (canceled) 
     
     
         66 . The alloy of  claim 17 , wherein said alloy is processable into bulk amorphous samples of less than about 0.1 mm in thickness in its minimum dimension. 
     
     
         67 . The alloy of  claim 17 , wherein said alloy is processable into bulk amorphous samples of at least about 0.1 mm in thickness in its minimum dimension. 
     
     
         68 . The alloy of  claim 17 , wherein said alloy is processable into bulk amorphous samples of at least about 0.5 mm in thickness in its minimum dimension. 
     
     
         69 . The alloy of  claim 17 , wherein said alloy is processable into bulk amorphous samples of at least about 1 mm in thickness in its minimum dimension. 
     
     
         70 . The alloy of  claim 17 , wherein said alloy is processable into bulk amorphous samples of at least about 5 mm in thickness in its minimum dimension. 
     
     
         71 . The alloy of  claim 17 , wherein said alloy is processable into bulk amorphous samples of at least about 10 mm in thickness in its minimum dimension. 
     
     
         72 . The alloy of  claim 17 , wherein said alloy is processable into bulk amorphous samples of at least about 12 mm in thickness in its minimum dimension. 
     
     
         73 . The alloy of  claim 17 , wherein said alloy is processable into an article. 
     
     
         74 . The alloy of  claim 73 , wherein said processed article is provided by at least one of the following processing methods: melt spinning, atomization, spray forming, scanning-beam forming, plastic forming, casting, compaction, and commercially available manufacturing methods. 
     
     
         75 . The alloy of  claim 17 , wherein said alloy is processable into a coating. 
     
     
         76 . The alloy of  claim 75 , wherein said processed coating is provided by at least one of the following processing methods: melt spinning, atomization, spray forming, scanning-beam forming, plastic forming, casting, compaction, and commercially available coating methods 
     
     
         77 . The alloy of  claim 75 , wherein said coating comprises corrosion resistant type coating and/or wear-resistant type coating. 
     
     
         78 . The alloy of  claim 75 , wherein said coating is disposed on a structure selected from the group consisting of ship frames, submarine frames, vehicle frames, airplane frames, ship parts, submarine parts, vehicle parts, airplane parts, armor penetrators, projectiles, protection armors, rods, train rails, cable armor, power shaft, and actuators, engineering and medical materials and tools, cell phone and PDA casings, housings, and components, electronics and computer casings, housings and components. 
     
     
         79 . The alloy of  claim 17 , wherein said alloy is processable into a structure selected from the group consisting of ship frames, submarine frames, vehicle frames, airplane frames, ship parts, submarine parts, vehicle parts, airplane parts, armor penetrators, projectiles, protection armors, rods, train rails, cable armor, power shaft, and actuators, engineering and medical materials and tools, cell phone and PDA casings, housings, and components, electronics and computer casings, housings and components. 
     
     
         80 . The method of  claim 21 , further comprising processing said alloy into bulk amorphous samples of less than about 0.1 mm in thickness in its minimum dimension. 
     
     
         81 . The method of  claim 21 , further comprising processing said alloy into bulk amorphous samples of at least about 0.1 mm in thickness in its minimum dimension. 
     
     
         82 . The method of  claim 21 , further comprising processing said alloy into bulk amorphous samples of at least about 0 5 mm in thickness in its minimum dimension. 
     
     
         83 . The method of  claim 21 , further comprising processing said alloy into bulk amorphous samples of at least about 1 mm in thickness in its minimum dimension. 
     
     
         84 . The method of  claim 21 , further comprising processing said alloy into bulk amorphous samples of at least about 5 mm in thickness in its minimum dimension. 
     
     
         85 . The method of  claim 21 , further comprising processing said alloy into bulk amorphous samples of at least about 10 mm in thickness in its minimum dimension. 
     
     
         86 . The method of  claim 21 , further comprising processing said alloy into bulk amorphous samples of at least about 12 mm in thickness in its minimum dimension. 
     
     
         87 . The method of  claim 21 , further comprising processing said alloy into an article. 
     
     
         88 . The method of  claim 87 , wherein said processed article is provided by at least one of the following processing methods: melt spinning, atomization, spray forming, scanning-beam foaming, plastic forming, casting, compaction and commercially available manufacturing methods. 
     
     
         89 . The method of  claim 21 , further comprising processing said alloy into a coating. 
     
     
         90 . The method of  claim 89 , wherein said processed coating is provided by at least one of the following processing methods: melt spinning, atomization, spray forming, scanning-beam forming, plastic forming, casting, compaction, and commercially available coating methods 
     
     
         91 . The method of  claim 89 , wherein said coating comprises corrosion resistant type coating and/or wear-resistant type coating. 
     
     
         92 . The method of  claim 89 , wherein said coating is disposed on a structure selected from the group consisting of ship frames, submarine frames, vehicle frames, airplane frames, ship parts, submarine parts, vehicle parts, airplane parts, armor penetrators, projectiles, protection armors, rods, train rails, cable armor, power shaft, and actuators, engineering and medical materials and tools, cell phone and PDA casings, housings, and components, electronics and computer casings, housings and components. 
     
     
         93 . The method of  claim 21 , further comprising processing said alloy into a structure selected from the group consisting of ship frames, submarine frames, vehicle frames, airplane parts, ship parts, submarine parts, vehicle parts, airplane parts, armor penetrators, projectiles, protection armors, rods, train rails, cable armor, power shaft, and actuators, engineering and medical materials and tools, cell phone and PDA casings, housings, and components, electronics and computer casings, housings and components. 
     
     
         94 . An amorphous steel alloy having the composition:
   Fe (100-t) Mn n Cr m Mo p B q C s Y g ,   
       where n is from about 7 to about 12,
 m is from about 4 to about 6, 
 p is from about 8 to about 15, 
 g is from about 1 to about 3, 
 p+g equals from about 11 to about 15, 
 s+q equals at least 18, and 
 t is from about 47 to about 53. 
 
     
     
         95 . An amorphous steel alloy having the composition:
   Fe 50 Mn 10 Cr 4 Mo 14 Y 1 C 15 B 6 .