Method of producing corrosion resistant metal alloys with improved strength and ductility

Abstract

Nickel and chromium as the exclusive components of an alloy is formed by mixing under cover of nitrogen gas and spray casting thereof wherein a molten outflow stream of such alloy components is atomized by exposure to jets of the nitrogen gas after pressurization, resulting in formation of molten alloy metal droplets deposited on to a surface.

1. In a method of casting a ductile alloy having a base metal by heating thereof to produce a molten stream that is atomized into a spray of droplets directed onto a moving substrate surface; the improvement residing in: selecting a corrosion resisting material as a component of the alloy undergoing said heating; exclusively limiting said alloy to the base metal and the corrosion resisting material; and utilizing an inert cover gas to atomize the molten stream into said spray of droplets for deposit onto said surface to increase in strength the ductile alloy from a yield strength of less than 145 ksi. 
   
   
     2. The method as defined in  claim 1 , wherein said base metal is nickel, the corrosion resisting material is chromium and the inert cover gas is nitrogen selected to effect said increase in strength of the ductile alloy with ductility improved from less than 25% tensile elongation. 
   
   
     3. In a method of coating a surface with a ductile alloy; the improvement residing in: casting onto said surface a molten stream exclusively limited to: a corrosion-resisting material constituting between 48% and 52% of the ductile alloy undergoing heating during said casting for increase in strength thereof and a base metal; and selecting an inert cover gas to atomize the molten stream into a spray of droplets for deposit onto the surface thereby effecting said increase in strength of the ductile alloy during said casting from a yield strength of less than 145 ksi.