Molten aluminum resistant alloys

Abstract

Embodiments of methods for protection a material from a reaction from molten aluminum. In some embodiments, a coating can be applied over a substrate which has significantly less of a reaction rate with molten aluminum, thus preventing damage or chemical changes to the substrate. The coating alloy can be formed from cast iron in combination with niobium in some embodiments.

What is claimed is: 
     
         1 . A method of protecting a component from molten aluminum reaction, the method comprising:
 coating a component formed from a base material with an alloy;   wherein the alloy has a reaction level to molten aluminum of less than 38 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K; and   wherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.   
     
     
         2 . The method of  claim 1 , wherein the alloy is a Nb—Zr alloy with 30-60 wt. % Zr. 
     
     
         3 . The method of  claim 1 , wherein the alloy has a reaction rate to molten aluminum less than 50% than that of the base material. 
     
     
         4 . The method of  claim 1 , wherein the alloy is a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron) 100-x Nb x  with x ranging from 10 to 30 wt. %. 
     
     
         5 . The method of  claim 1 , wherein the alloy is a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron) 100-x Nb x  with x ranging from 0 to 10 wt. %. 
     
     
         6 . The method of  claim 1 , wherein the alloy has a reaction rate less than 10% than that of the base material. 
     
     
         7 . The method of  claim 1 , wherein the alloy has a reaction rate less than 5% than that of the base material. 
     
     
         8 . An alloy resistant to molten aluminum, the alloy comprising:
 two or more elements;   a reaction level of less than 38 atom %, wherein the reaction level is calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K; and   a minimum concentration of highly resistant secondary phases of 5 mole %.   
     
     
         9 . The alloy of  claim 8 , wherein the reaction level is 10 atom % or less. 
     
     
         10 . The alloy of  claim 8 , wherein the reaction level is 5 atom % or less. 
     
     
         11 . The alloy of  claim 8 , wherein the alloy is a Nb—Zr alloy with 30-60 wt. % Zr. 
     
     
         12 . The alloy of  claim 8 , wherein the alloy is a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron) 100-x Nb x  with x ranging from 10 to 30 wt. %. 
     
     
         13 . The alloy of  claim 8 , wherein the alloy is a pseudo alloy of grey cast iron and niobium according to the formula: (grey cast  iron ) 100-x Nb x  with x ranging from 0 to 10 wt. %. 
     
     
         14 . The alloy of  claim 8 , wherein the alloy has a minimum concentration of highly resistant secondary phases of 10 mole %. 
     
     
         15 . The alloy of  claim 8 , wherein the alloy has a minimum concentration of highly resistant secondary phases of 20 mole %. 
     
     
         16 . The alloy of  claim 8 , wherein the alloy comprises Fe and the following in weight percent:
 Nb: about 10;   Si: 0 to about 2;   Mn: 0 to about 2; and   C: 0 to about 2.5.   
     
     
         17 . The alloy of  claim 8 , wherein the alloy comprises Fe and one of the following in weight percent:
 Nb: about 10, Si: about 1.6, Mn: about 0.5, C: about 2.5;   Nb: about 10, Si: about 1.6, Mn: about 0.5, C: about 2.0;   Nb: about 10, Si: about 1.6, Mn: about 0.5, C: about 1.5; or   Nb: about 10, Si: about 1.6, Mn: about 0.5, C: about 1.0.   
     
     
         18 . The alloy of  claim 8 , wherein the alloy is a coating on a base substrate. 
     
     
         19 . The alloy of  claim 8 , wherein the alloy is a casting component for casting molten aluminum. 
     
     
         20 . An article of manufacture for use in an aluminum casting process, the article comprising:
 an alloy forming at least a portion of the article;   wherein the alloy has a reaction level to molten aluminum of less than 38 atomic %, the reaction level being calculated by determining a minimum alloy content in a pseudo binary alloy/aluminum phase diagram where the liquidus temperature is at or above 1500K; and   wherein the alloy has a minimum concentration of highly resistant secondary phases of 5 mole %.   
     
     
         21 . The article of manufacture of  claim 20 , wherein the alloy is a grey cast iron. 
     
     
         22 . The article of manufacture of  claim 20 , wherein the alloy has a reaction rate in molten aluminum of less than or equal to ½ the rate of H13 steel. 
     
     
         23 . The article of manufacture of  claim 20 , wherein the alloy is pseudo alloy of grey cast iron and niobium according to the formula: (grey cast iron) 100-x Nb x  with x ranging from 0 to 10 wt. %. 
     
     
         24 . The article of manufacture of  claim 20 , wherein the alloy has a reaction rate less than 10% than that of the H13 steel. 
     
     
         25 . The article of manufacture of  claim 20 , wherein the alloy has a reaction rate less than 5% than that of the H13 steel. 
     
     
         26 . A casting component for casting aluminum, wherein the casting component is either clad with or is comprised of a metal alloy composition, the metal alloy composition having a reaction level of about 38 atom % or less, wherein the reaction level is defined as the minimum alloy content of the metal alloy composition in the phase diagram between aluminum and the metal alloy composition where the liquidus curve is at or above 1500 K. 
     
     
         27 . The casting component of  claim 26 , wherein the alloy has a reaction rate in molten aluminum of less than or equal to ½ the rate of H13 steel. 
     
     
         28 . The casting component of  claim 26 , wherein a % loss of an alloy rod, based on area loss and diameter loss, formed the metal alloy composition is less than 5% after undergoing a molten aluminum flow rate of 0.2 meters/second. 
     
     
         29 . A method of casting aluminum, comprising:
 providing molten aluminum into contact with a surface of a casting component, wherein the casting component is either clad with or is comprised of a metal alloy composition, the metal alloy composition having a reaction level of about 38 atom % or less, wherein the reaction level is defined as the minimum alloy content of the metal alloy composition in the phase diagram between aluminum and the metal alloy composition where the liquidus curve is at or above 1500 K; and   casting the molten aluminum.