Metal Steel Production by Slab Casting

Abstract

The present disclosure is directed at metal alloys and methods of processing with application to slab casting methods and post-processing steps towards sheet production. The metals provide unique structure and exhibit advanced property combinations of high strength and/or high ductility.

What is claimed is: 
     
         1 . A method comprising:
 a. supplying a metal alloy comprising Fe at a level of 61.0 to 88.0 atomic percent, Si at a level of 0.5 to 9.0 atomic percent, Mn at a level of 0.90 to 19.0 atomic percent and optionally B at a level of up to 8.0 atomic percent;   b. melting said alloy and cooling and solidifying and forming an alloy having a thickness according to one of the following:
 i. cooling at a rate of ≦250 K/s; or 
 ii. solidifying to a thickness of ≧2.0 mm 
   c. wherein said solidified alloy has a melting point (Tm) and heating said alloy to a temperature of 700° C. to below said alloy Tm and reducing said thickness of said alloy.   
     
     
         2 . The method of  claim 1  wherein said alloy in step (c) is reduced in thickness at an applied strain rate of 10 −6  to 10 4 . 
     
     
         3 . The method of  claim 1  wherein said alloy after step (c) is heat treated at a temperature of 700° C. to 1200° C. to form an alloy having a yield strength of 200 MPa to 1000 MPa. 
     
     
         4 . The method of  claim 1  wherein said alloy having a yield strength of 200 MPa to 1000 MPa has:
 a. grains of 50 nm to 50000 nm 
 b. boride grains, if present, of 20 nm to 10000 nm 
 c. precipitation grains of 1 nm to 200 nm 
 
     
     
         5 . The method of  claim 1  wherein said alloy in step (c) is repeatedly heat treated to said temperature of 700° C. to below said alloy Tm and said alloy thickness is reduced during each of said heat treatments. 
     
     
         6 . The method of  claim 1  wherein said solidified alloy in step (c) indicates a yield strength and stressing said alloy and exceeding said yield strength and providing a resulting alloy that indicates a yield strength of 200 MPa to 1650 MPa, tensile strength of 400 MPa to 1825 MPa and an elongation of 2.4% to 78.1%. 
     
     
         7 . The method of  claim 6  wherein said resulting alloy has one or more of the following:
 a. grains of 25 nm to 25000 nm 
 b. boride grains, if present, of 20 nm to 10000 nm, 
 c. precipitation grains of 1 nm to 200 nm. 
 
     
     
         8 . The method of  claim 1  wherein said solidified alloy in step (b) has a thickness of greater than or equal to 2.0 mm up to 500 mm. 
     
     
         9 . The method of  claim 6  wherein said resulting alloy has a thickness of 0.1 mm to 25.0 mm. 
     
     
         10 . The method of  claim 1  further including one or more of the following:
 Ni at a level of 0.1 to 9.0 atomic percent; 
 Cr at a level of 0.1 to 19.0 atomic percent; 
 Cu at a level of 0.1 to 4.0 atomic percent; and 
 C at a level of 0.1 to 4.0 atomic percent. 
 
     
     
         11 . The method of  claim 6  wherein said resulting alloy is positioned in a vehicle. 
     
     
         12 . The method of  claim 7  wherein said resulting alloy is positioned in a vehicle. 
     
     
         13 . The method of  claim 6  wherein said alloy is positioned in one of a drill collar, drill pipe, pipe casing, tool joint, wellhead, compressed gas storage tank or liquefied natural gas canister. 
     
     
         14 . The method of  claim 7  wherein said alloy is positioned in one of a drill collar, drill pipe, pipe casing, tool joint, wellhead, compressed gas storage tank or liquefied natural gas canister. 
     
     
         15 . A method comprising:
 a. supplying a metal alloy comprising Fe at a level of 61.0 to 88.0 atomic percent, Si at a level of 0.5 to 9.0 atomic percent, Mn at a level of 0.90 to 19.0 atomic percent, and optionally B up to 8.0 at. %;   b. melting said alloy and cooling and solidifying and forming an alloy having a thickness according to one of the following:
 i. cooling at a rate of ≦250 K/s; or 
 ii. solidifying to a thickness of ≧2.0 mm 
   c. wherein said solidified alloy has a melting point (Tm) and heating said alloy to a temperature of 700° C. to below said alloy Tm and reducing said thickness of said alloy wherein said alloy has a yield strength and stressing said alloy and exceeding said yield strength and providing a resulting alloy that indicates a yield strength of 200 MPa to 1650 MPa, tensile strength of 400 MPa to 1825 MPa and an elongation of 2.4% to 78.1%.   
     
     
         16 . The method of  claim 15  wherein said alloy formed in step b has a thickness of greater than 2.0 mm up to 500 mm. 
     
     
         17 . The method of  claim 15  wherein said resulting alloy has a thickness of 0.1 mm to 25.0 mm. 
     
     
         18 . A method comprising:
 a. supplying a metal alloy comprising Fe at a level of 61.0 to 88.0 atomic percent, Si at a level of 0.5 to 9.0 atomic percent, Mn at a level of 0.90 to 19.0 atomic percent, and optionally B up to 8.0 at. %;   b. melting said alloy and cooling and solidifying and forming an alloy having a thickness of ≧2.0 mm up to 500 mm;   c. wherein said solidified alloy has a melting point (Tm) and heating said alloy to a temperature of 700° C. to below said alloy Tm and reducing said thickness of said alloy to a thickness of 0.1 mm to 25.0 mm wherein said alloy has a yield strength and stressing said alloy and exceeding said yield strength and providing a resulting alloy that indicates a yield strength of 200 MPa to 1650 MPa, tensile strength of 400 MPa to 1825 MPa and an elongation of 2.4% to 78.1%.   
     
     
         19 . The method of  claim 18  wherein said resulting alloy is positioned in a vehicle. 
     
     
         20 . The method of  claim 18  wherein said resulting alloy is positioned in one of a drill collar, drill pipe, pipe casing, tool joint, wellhead, compressed gas storage tank or liquefied natural gas canister.