# Patent

## Title
Cast parts with enhanced wear resistance

## Abstract

A wear part made in a foundry is provided having a structure reinforced with at least one type of metallic carbide, and/or of metallic nitride, and/or of boride, and/or of metallic oxides, and/or of intermetallic compounds, hereafter called components. The raw materials acting as reagents for the components are put into a mold before casting in the form of inserts or preformed shapes of compacted powders or in the form of barbitones. The reaction of the powders is triggered in situ by the molten metal casting, forming a porous conglomerate in situ. The metal infiltrates the porous conglomerate, thereby making a reinforced structure so as to result in inclusion of the components in the structure of the metal used for the casting, thus creating a reinforcing structure on the wear part.

## Background
This application is a division of U.S. application Ser. No. 10/860,546, filed Jun. 4, 2004, which is a continuation of application No. PCT/BE02/00150, filed on Sep. 30, 2002.


FIELD OF THE INVENTION
The present invention relates to the production of cast parts with enhanced wear resistance by an improvement in the resistance to abrasion whilst retaining acceptable resistance to impact in the reinforced areas.
TECHNOLOGICAL BACKGROUND AT THE BASIS OF THE INVENTION
Installations for extracting and breaking up minerals, and in particular crushing and grinding material, are subjected to numerous constraints of performance and costs.
As an example, one might cite in the area of the treatment of aggregates, of cement and of minerals, wear parts such as ejectors and anvils of grinding machines with vertical shafts, hammers and breakers of grinding machines with horizontal shafts, cones for crushers, tables and rollers for vertical crushers, armoured plating and elevators for ball mills or rod mills. With regard to mining extraction installations, one might mention, among others, pumps for bituminous sands or drilling machines, pumps for mines and dredging teeth.
The suppliers of wear parts for these machines are faced with increased demands for wear parts which meet the constraints of resistance to impact and resistance to abrasion at the same time.
Traditional materials generally meet one or the other of these types of requirement but are very rarely resistant to both impact and abrasion. Indeed, ductile materials offer enhanced resistance to impact but have very little resistance to abrasion. On the other hand, hard abrasion-resistant materials have very little resistance to violent impact.
Historically, the first reflections on this problem led to an exclusively metallurgical approach which consisted in suggesting steels with manganese that are very resistant to impacts and nevertheless achieve intermediate hardness levels of the order of 650 to 700 Hv (Vickers hardness).
Other alternatives such as castings with chrome have also been suggested. These allow to achieve hardness levels of the order of 700 to 850 Hv after suitable thermal treatment. These values are achieved for alloys containing a percentage of carbide up to 35%.
Currently, bimetallic castings have also been used, but these nevertheless have the disadvantage of being limited to parts of simple shape, which drastically reduces their opportunities for industrial application.
Wear parts are generally considered as consumables, which means that apart from purely technical constraints, there is also a financial constraint which limits the opportunities for solutions that have an average cost of US$4/Kg. It is generally estimated that this price level, which is twice as high as that of traditional wear parts, is the threshold of financial acceptability for customers.
DESCRIPTION OF THE SOLUTIONS ACCORDING TO STATE OF THE ART
Achieving a wear part that is resistant to abrasion and impact has already been the subject of studies of various types.
In this context, one has naturally turned to composite parts based on ceramics and, in this area, the Applicant already discloses in document WO 99/47264 an alloy based on iron and ceramics which is very resistant to wear and impact.
In document WO 98/15373, the Applicant proposes to insert into a mould, before casting, a wafer of porous ceramic which is infiltrated by the metal during casting. The opportunities for application of this invention are nevertheless limited to parts of strong cross-section and to alloys with high fluidity in casting. Moreover, the positioning of these ceramic wafers is rather conditioned by the requirements of infiltration by the cast metal than by the actual requirements of the part's use.
Without aiming at the same objectives, Merzhanov discloses in document WO 90/07013 a fireproof porous material obtained by cold compression of the raw material, of an exothermic mixture of powders under vacuum, followed by starting the combustion of the mixture. Here, we are dealing with a chain reaction. With this method, he obtains extremely hard materials but without any resistance to impact. This is essentially due to the high porosity of the products.
Moreover, in document WO 90/11154, the same inventor proposes a similar method where, in this case, the mixture of powders, after having reacted, is subjected to pressures as high as 1000 bars. This invention results in the production of layers that are extremely resistant to abrasion but with insufficient resistance to impact. The aim here is above all to produce surfaces for abrasive tools that are greatly solicited in this sense.
In general, the use of very pure powders such as titanium, boron, tungsten, aluminum, nickel, molybdenum, silicon, carbon, etc. powders results in extremely porous pieces after the reaction with porosity rates close to 50%. These therefore require compression after the reaction involving compaction and thus an increase in density, which is indispensable for industrial use.
The implementation complexity of such a method, the control of the reactions and the cost of the raw materials nevertheless considerably limit the introduction of these technologies into industry.
The invention avoids the pitfalls of the state of the art by producing wear parts of original structure and produced by an original and simple method, which is thus inexpensive.
AIMS OF THE INVENTION
The present invention aims to provide wear parts resistant both to abrasion and to impact at a financially acceptable price as well as a method for their production. It aims in particular to solve the problems associated with the solutions according to the state of the art.
SUMMARY OF THE INVENTION
The present invention relates to a wear part, produced by a foundry, with a structure reinforced by at least one type of metallic carbide, and/or metallic nitrides, and/or metallic oxides, and/or metallic borides, as well as intermetallic compounds, hereafter called the components, characterized in that the raw materials acting as reagents for said components have been put into a mould, before casting, in the form of inserts or pre-shaped compacted powders or in the form of barbitones, in that the reaction of said powders is triggered in situ by the casting of a metal forming a porous conglomerate in situ and in that said metal infiltrates the porous conglomerate, thus forming a reinforced structure, so as to achieve the inclusion of said components in the structure of the metal used for the casting of the part, and thereby to create a reinforcing structure in the wear part.
One of the key aspects of the present invention shows that the porous conglomerate, created in situ and infiltrated by the molten metal has a Vickers hardness of over 1000 Hv20 whilst providing an impact resistance higher than that of the considered pure ceramics and at least equal to 10 MPa√m.
According to one of the features of the invention, the reaction in situ between the raw materials, i.e. the reagents for said components, is a chain reaction and it is triggered by the heat of the molten metal by forming a very porous conglomerate capable of being simultaneously infiltrated by the molten metal without significant alteration of the inforcing structure.
According to one particularly advantageous embodiment of the invention, the reaction between the raw materials takes place at atmospheric pressure and without any particular protective gaseous atmosphere and without the need for compression after the reaction.
The raw materials intended to produce the component belong to the group of ferrous alloys, preferably of FerroTi, FerroCr, FerrbNb, FerroW, FerroMo, FerroB, FerroSi, FerroZr or FerroV, or belong to the group of oxides, preferably TiO2, FeO, Fe2O3, SiO2, ZrO2, CrO3, Cr2O3, B2O3, MoO3, V2O5, CuO, MgO and NiO or even to the group of metals or their alloys, preferably iron, nickel, titanium or aluminium and also carbon, boron or nitride compounds.



BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a barbitone 4 spread over the areas where the cast part 2 in the mould 1 is to be reinforced.
FIG. 2 shows the invention in the form of reinforcing inserts 3 in the part to be cast 2 in the mould 1.
FIGS. 3, 4 and 5 show hardness impressions for a casting with chrome (FIG. 3), a pure ceramic (FIG. 4) and an alloy (FIG. 5) reinforced with ceramic as in the present invention.
FIG. 6 shows particles of TiC in an iron alloy, resulting from a reaction in situ of FeTi with carbon to produce TiC in an iron-based matrix. The size of the TiC particles is of the order of a few microns.



DETAILED DESCRIPTION OF THE INVENTION
The present invention proposes cast parts whose wear surfaces are reinforced by putting in the mould, before casting, materials comprising powders that are able to react in in situ and under the sole action of the heat of the casting.
To this end, reagents in compacted powders are used and placed in the mould in the form of wafers or inserts 3 in the required shape, or alternatively in the form of a coating 4 covering the mould 1 where the part 2 is to be reinforced.
The materials that can react in situ produce hard compounds of carbides, borides, oxides, nitrides or intermetallic compounds. These, once formed, combine with any possible carbides already present in the casting alloy so as to further increase the proportion of hard particles with a hardness of Hv>1300 that contribute to the wear resistance. The latter are “infiltrated” at about 1500° C. by the molten metal and form an addition of particles resistant to abrasion incorporated into the structure of the metal used for the casting (FIG. 6).
Moreover, in contrast to the methods of the state of the art, it is not necessary to use pure metallic powders to obtain this reaction in situ. The method proposed advantageously allows to use inexpensive ferrous alloys or oxides in order to obtain extremely hard particles embedded in the matrix formed by the casting metal where reinforcement of the wear resistance is required.
Not only does the invention require no subsequent compaction, that is compression, of the areas with reinforced structure, but it benefits from the porosity thus created in said areas to allow the infiltration of the molten metal into the gaps at high temperature (FIG. 6).
This requires no particular protective atmosphere and takes place at atmospheric pressure with the heat provided by casting, which clearly has a particularly positive consequence on the cost of the method. A structure with very favorable features in terms of the simultaneous resistance to impact and abrasion is thus obtained.
The hardness values achieved by the particles thus embedded into the reinforced surfaces are in the range of 1300 to 3000 Hv. Following the infiltration by the casting metal, the compound obtained has a hardness higher than 1000 Hv20 whilst retaining an impact resistance higher than 10 MPa√{square root over (m)}. The impact resistance is measured by indentation, which means that a dent is made by means of a diamond piercing tool of pyramidal shape at a calibrated load.
As a result of the load, the material is bent and may develop cracks at the corners of the dent. The length measurement of the cracks allows the impact resistance to be calculated (FIGS. 1, 2 and 3).
The raw materials intended to produce the component belong to the group of ferrous alloys, preferably of FerroTi, FerroCr, FerroNb, FerroW, FerroMo, FerroB, FerroSi, FerroZr or FerroV, or they belong to the group of oxides, preferably TiO2, FeO, Fe2O3, SiO2, ZrO2, CrO3 Cr2O3, B2O3, MoO3, V2O5, CuO, MgO and NiO or to the group of metals or their alloys, preferably iron, nickel, titanium or aluminium and also carbon, boron or nitride compounds.
By way of an example, the reactions used in the present invention are generally of the type:

FeTi+C->TiC+Fe

TiO2+Al+C->TiC+Al2O3 

Fe2O3+Al->Al2O3+Fe

Ti+C−>TiC

Al+C+B2O3->B4C+Al2O3 

MoO3+Al+Si->MoSi2+Al2O3 

These reactions may also be combined.

The reaction speed may also be controlled by the addition of different metals, alloys or particles which do not take part in the reaction. These additions may moreover advantageously be used in order to modify the impact resistance or other properties of the composite created in-situ in situ according to requirements. This is shown by the following illustrative reactions:

Fe2O3+2Al+xAl2O3+→(1+x)Al2O3+2Fe

Ti+C+Ni→TiC+Ni

DESCRIPTION OF A PREFERRED EMBODIMENT OF THE INVENTION
The first preferred embodiment of the invention consists in compacting the chosen reactive powders by simple cold pressure. This takes place in a compression mould bearing the desired shape of the insert or the preformed shape 3, possibly in the presence of a binding agent, for the reinforcement of the cast part 2. This insert or preformed shape will then be placed into the casting mould 1 in the desired place.
For the powders, a particle size distribution is chosen with a D50 between 1 and 1000 microns, preferably lower than 100μ. Practical experience has shown that this particle size was the ideal compromise between the handling of the raw materials, the ability of the porous product to be infiltrated and the control of the reaction.
During casting, the hot metal triggers the reaction of the preformed shape or of the insert which transforms into a conglomerate with a porous structure of hard particles. This conglomerate, still at high temperature, is itself infiltrated and embedded in the casting metal making up the part. This step is carried out between 1400 and 1700° C. depending on the casting temperature of the alloy chosen to make the part.
A second preferred embodiment is the use of a barbitone (paste) 4 containing the various reagents so as to coat certain areas of the mould 1 or of the cores. The application of one or more layers is possible depending on the thickness desired. These different layers are then allowed to dry before the metal is poured into the mould 1. This molten metal also serves to trigger the reaction in order to create a porous layer which is infiltrated immediately after its reaction to form a structure that is particularly resistant both to impact and wear.

## Claims

1. A method for the production of a cast metal wear part with a structure reinforced by a conglomerate of particles of one or more components selected from the group consisting of metallic carbides, borides, and intermetallic compounds, the particulate conglomerate having pores with cast metal therein, the method comprising:
placing two or more powdered raw materials into a casting mold, the powdered raw materials having a shape in the mold;
adding a molten casting metal to the casting mold with the raw material therein; and
chemically reacting the two or more powdered raw materials in situ in the casting mold to provide the particulate porous conglomerate comprising one or more components, the molten casting metal triggering the in situ chemical reaction of the two or more powdered raw materials to provide the particulate porous conglomerate, the molten casting metal infiltrating the particulate porous conglomerate formed by the in situ chemical reaction and resulting in inclusion of casting metal in the conglomerate, each of the two or more powdered materials of a type and an amount which is effective for providing the reaction which provides the conglomerate of one or more of the components, the conglomerate with the cast metal therein in the structure of the cast metal wear part,
the components selected from the group consisting of metallic carbides, borides, intermetallic compounds and mixtures thereof,
the powdered raw materials selected from the group consisting of ferro-alloys, oxides, nickel, nickel alloys, iron, iron alloys, titanium, titanium alloys, carbon, carbon compounds, boron, boron compounds and mixtures thereof,
the ferro-alloys selected from the group consisting of FerroTi, FerroCr, FerroNb, FerroW, FerroMo, FerroB, FerroSi, FerroZr, FerroV and mixtures thereof,
the oxides selected from the group consisting of TiO2, FeO, Fe2O3, CrO3, Cr2O3, B2O3, MoO3, V2O5, CuO, MgO, NiO and mixtures thereof.

2. The method of claim 1 wherein the reaction of the raw materials takes place at atmospheric pressure without the method requiring any compression after reaction of the raw materials.

3. The method of claim 1, wherein the reaction of the raw materials does not require any specific gaseous protective atmosphere.

4. The method of claim 1, wherein the particles of the conglomerate have a Vickers hardness between 1300 and 3000 Hv.

5. The method of claim 4 wherein the method results in the particulate porous conglomerate in an iron based matrix.

6. The method of claim 1 wherein the method results in the particulate porous conglomerate in an iron based matrix.

7. A method for the production of a cast metal wear part with a structure reinforced by a reinforced conglomerate of titanium carbide particles, the reinforced particulate conglomerate having pores with cast metal therein, the method comprising:
placing two or more powdered raw materials into a casting mold, the powdered raw materials having a shape in the casting mold and selected from the group consisting of FerroTi, carbon, carbon compounds, titanium, titanium alloys, TiO2, iron, iron alloys, nickel, and nickel alloys and mixtures thereof;
adding a molten casting metal to the casting mold; and
chemically reacting the powdered raw materials in situ in the casting mold to provide a particulate porous conglomerate, the molten metal triggering an in situ chemical reaction of the powdered raw materials to provide the particulate porous conglomerate, the molten casting metal infiltrating the particulate porous conglomerate formed by the in situ chemical reaction and resulting in inclusion of casting metal in the conglomerate, each of the two or more powdered materials of a type and an amount for providing a reaction which provides the conglomerate of titanium carbide, the conglomerate having titanium carbide with the cast metal therein in the structure of the cast metal wear part.

8. The method of claim 7 wherein the method results in the particulate porous conglomerate in an iron based matrix.

9. The method of claim 8 wherein the powdered raw materials having a shape in the casting mold are selected from the group consisting of FerroTi, carbon, carbon compounds, titanium, titanium alloys, TiO2, iron, iron alloys and mixtures thereof.

10. The method of claim 7 wherein the powdered raw materials having a shape in the casting mold are selected from the group consisting of FerroTi, carbon, carbon compounds, titanium, titanium alloys, TiO2, iron, iron alloys and mixtures thereof.

11. A method for the production of a cast metal wear part with a structure reinforced by a conglomerate of particles of one or more components selected from the group consisting of metallic carbides, borides, and intermetallic compounds, the particulate conglomerate having pores with cast metal therein, the method comprising:
placing two or more powdered raw materials into a casting mold, the powdered raw materials having a shape in the mold;
adding a molten casting metal to the casting mold with the raw material therein; and
chemically reacting the two or more powdered raw materials in situ in the casting mold to provide the particulate porous conglomerate comprising one or more components, the molten casting metal triggering the in situ chemical reaction of the two or more powdered raw materials to provide the particulate porous conglomerate, the molten casting metal infiltrating the particulate porous conglomerate formed by the in situ chemical reaction and resulting in inclusion of casting metal in the conglomerate and resulting in the particulate porous conglomerate in an iron based matrix,
each of the two or more powdered materials of a type and an amount which is effective for providing the in situ chemical reaction which provides the conglomerate of one or more components and which provides particles of the conglomerate of the one or more of the components with a Vickers hardness of higher than 1000 Hv20, the conglomerate with the cast metal therein in the structure of the cast metal wear part,
the components selected from the group consisting of metallic carbides, borides, intermetallic compounds and mixtures thereof,
the powdered raw materials selected from the group consisting of ferro-alloys, oxides, nickel, nickel alloys, iron, iron alloys, titanium, titanium alloys, carbon, carbon compounds, boron, boron compounds and mixtures thereof,
the ferro-alloys selected from the group consisting of FerroTi, FerroCr, FerroNb, FerroW, FerroMo, FerroB, FerroSi, FerroZr, FerroV and mixtures thereof,
the oxides selected from the group consisting of TiO2, FeO, Fe2O3, CrO3, Cr2O3, B2O3, MoO3, V2O5, CuO, MgO, NiO and mixtures thereof.

12. The method of claim 11 wherein the powdered raw materials having a shape in the casting mold are selected from the group consisting of FerroTi, carbon, carbon compounds, titanium, titanium alloys, TiO2, iron, iron alloys and mixtures thereof.