Fe-base in-situ composite alloys comprising amorphous phase

Abstract

An Fe-base in-situ composite alloy, castable into 3-dimensional bulk objects is provided, where the alloy includes a matrix having one or both of a nano-crystalline phase and an amorphous phase, and a face-centered cubic crystalline phase. The alloy has an Fe content of more than 60 atomic percent.

What is claimed is: 
     
       1. An Fe-base in-situ composite alloy, castable into 3-dimensional bulk objects, wherein the alloy when cast comprises:
 a matrix comprising one or both of a nano-crystalline phase and an amorphous phase; 
 a face-centered cubic crystalline phase; and 
 an Fe content more than 60 atomic percent; 
 an Mn content in the range of from about 5 to about 25 atomic percent;  
 wherein the face-centered cubic crystalline phase is in the form of dendrites, and 
 wherein the alloy contains at least one of C, Si, B, P, and Al in the range from about 8 to about 20 atomic percent and the total content of the at least one C, Si, B, P, or Al is higher in the matrix than in the face-centered cubic crystalline phase. 
 
     
     
       2. The alloy as in  claim 1 , wherein the matrix is substantially amorphous phase. 
     
     
       3. The alloy as in  claim 1 , wherein the matrix is substantially nano-crystalline phase. 
     
     
       4. The alloy as in  claim 1 , wherein the volume percentage of the amorphous phase is in the range of from 5% up to 70%. 
     
     
       5. The alloy as in  claim 1 , wherein the volume percentage of the matrix is in the range of from 20% up to 60%. 
     
     
       6. The alloy as in  claim 1 , wherein the alloy is substantially formed by Fe, (Mn, Co, Ni, Cu) (C, Si, B, P, Al), wherein the Fe content is from more than 60 to 75 atomic percentage, the total of (Mn, Ca Co, Ni, Cu) is in the range of from 5 to 25 atomic percentage, and the total of (C, Si, B, P, Al) is in the range of from 8 to 20 atomic percentage. 
     
     
       7. The alloy as in  claim 6 , wherein the content of (C, Si, B, P, Al) is higher in the matrix than in the face-centered cubic crystalline phase. 
     
     
       8. The alloy as in  claim 6 , wherein the alloy is substantially formed by Fe (Mn, Co, Ni, Cu) (C, Si), wherein the Fe content is from more than 60 to 75 atomic percentage, the total of (Mn, Co, Ni, Cu) is in the range of from 5 to 25 atomic percentage, and the total of (C, Si) is in the range of from 8 to 20 atomic percentage, and the Si to C ratio is less than 0.5. 
     
     
       9. The alloy as in  claim 6 , wherein the alloy is substantially formed by Fe (Mn, Co, Ni, Cu) (C), wherein the Fe content is from more than 60 to 75 atomic percentage, the total of (Mn, Co, Ni, Cu) is in the range of from 5 to 25 atomic percentage, and the content of C, is in the range of from 8 to 20 atomic percentage. 
     
     
       10. The alloy as in  claim 9 , An Fe-base in-situ composite alloy, castable into 3-dimensional bulk objects, wherein the alloy when cast comprises:
 a matrix comprising one or both of a nano-crystalline phase and an amorphous phase; 
 a face-centered cubic crystalline phase; and 
 an Fe content more than 60 atomic percent; 
 an Mn content wherein the range of Fe and Mn is from about 80 to about 86 atomic percent of the total alloy composition; 
 wherein the face-centered cubic crystalline phase is in the form of dendrites, wherein the alloy contains (C) and wherein the content of C is higher in the matrix than in the face-centered cubic crystalline phase. 
 
     
     
       11. The alloy as in  claim 6 , further comprising a total of (Cr, Mo) content up to 8 atomic percent. 
     
     
       12. The alloy as in  claim 6 , further comprising a Y content up to 3 atomic percent. 
     
     
       13. The alloy as in  claim 1 , further comprising a Cr content up to 8 atomic percent. 
     
     
       14. The alloy as in  claim 1 , further comprising a Y content up to 3 atomic percent. 
     
     
       15. The in-situ composite alloy as in  claim 1 , wherein the particle size of the face-centered cubic crystalline phase is in the range of 3 to 30 microns. 
     
     
       16. An article formed of an Fe-base in-situ composite alloy comprising:
 a matrix comprising one or both of a nano-crystalline phase and an amorphous phase; 
 a face-centered cubic crystalline phase; 
 an Fe content in the range of 65% to 70%; 
 at least one of Mn, Co, Ni, and Cu in the range of from about 5 to about 25 atomic percent;  
 a three dimensional shape having a measurement of at least 0.5 mm in each dimension; and 
 a flow-stress level of at least about 2.0 GPa; 
 wherein the face-centered cubic crystalline phase is in the form of dendrites, and 
 wherein the alloy contains C, and the total content of C is higher in the matrix than in the face-centered cubic crystalline phase. 
 
     
     
       17. The article formed from the in-situ composite alloy as in  claim 16 , wherein the particle size of the face-centered cubic crystalline phase is in the range of 1 to 100 microns. 
     
     
       18. A bulk solidifying amorphous alloy comprising a Fe-base in-situ composite alloy comprising a matrix and a face-centered cubic crystalline phase; wherein the matrix comprises one or both of a nano-crystalline phase and an amorphous phase, and wherein the face-centered cubic crystalline phase comprises dendrites, wherein the alloy contains Mn and (C) and the content of C is higher in the matrix than in the face-centered cubic crystalline phase. 
     
     
       19. An object comprising the bulk solidifying amorphous alloy of claim 18, the article comprises at least one dimension having a size of at least 0.5 mm. 
     
     
       20. A 3-dimensional bulk object comprising an Fe-base in-situ composite alloy comprising a matrix and a face-centered cubic crystalline phase; wherein the matrix comprises one or both of a nano-crystalline phase and an amorphous phase, and wherein the face-centered cubic crystalline phase comprises dendrites, wherein the alloy contains (Mn, Co, Ni, Cu) (C, Si, B, P, Al) and the content of (C, Si, B, P, Al) is higher in the matrix than in the face-centered cubic crystalline phase. 
     
     
       21. An object comprising the bulk solidifying amorphous alloy of claim 20, the 3-dimensional bulk object comprises at least one dimension having a size of at least 0.5 mm. 
     
     
       22. An article formed of an Fe-base in-situ composite alloy comprising:
 a matrix comprising one or both of a nano-crystalline phase and an amorphous phase;   a face-centered cubic crystalline phase;   an Fe content in the range of 65% to 70%;   at least one of Mn, Co, Ni, and Cu in the range of from about 5 to about 25 atomic percent;   a three dimensional shape having a measurement of at least 0.5 mm in each dimension; and   a flow-stress level of at least about 2.0 GPa;   wherein the face-centered cubic crystalline phase is in the form of dendrites, wherein the alloy contains (C, Si, B, P, Al) and the content of (C, Si, B, P, Al) is higher in the matrix than in the face-centered cubic crystalline phase.   
     
     
       23. An Fe-base in-situ composite comprising:
 a matrix comprising one or both of a nano-crystalline phase and an amorphous phase;   a face-centered cubic crystalline phase; and   an Fe content more than 65% to 70% atomic percent;   at least one of Mn, Co, Ni, and Cu in the range of from 5 to 25 atomic percent;   wherein the face-centered cubic crystalline phase is in the form of dendrites, and   wherein the alloy contains at least one of C, Si, B, P, and Al in the range of from 8 to 20 atomic percent and the total content of the at least one C, Si, B, P, or Al is higher in the matrix than in the face-centered cubic crystalline phase.