An iron based powder composition

Abstract: An iron or copper based metal powder useful for plasma deposition of a coating that has a dry coefficient of friction .75 or less and readily conducts heat through the coating. The powder comprises (a) H 2 O atomised and annealed particles consisting essentially of (by weight) carbon .15-.85%, oxygen .1-.45%, an air hardening agent selected from manganese and nickel of .1-6.5%, and the remainder iron or copper, with at least 90% of the particles having oxygen and iron or copper combined in the lowest atomic oxygen form for an oxide of such metal. A method of making anti-friction iron powder that is economical, selectively produces FeO and promotes fine flowable particles. The method comprises (a) steam atomisation of a molten steel that excludes other oxygen, the steel containing carbon up to .4% by weight to produce a collection of comminuted particles, and (b) annealing the particles in an air atmosphere for a period of time of .25-2.0 hours in a temperature range of 427-760°C (800°-1400°F) to reduce carbon in the particles to about .2% or sponge iron by reducing Fe 3 O 4 or Fe 2 O 3 in CO and (H 2 O steam) to attain nearly all iron with nearly all FeO and 0.1 to 0.85 C.

Description: This invention relates to an iron based powder that is plasma sprayable and functions as a heat transferring solid lubricant when deposited as a thin coating on surfaces exposed to high temperatures. Automotive engines present a wide variety of interengaging components that generate friction as a result of interengagement. For example, sliding contact between pistons or piston rings with the cylinder bore walls of an internal combustion engine, account for a significant portion of total engine friction. It is desirable to significantly reduce such friction, by use of durable anti-friction coatings, particularly on the cylinder bore walls, to thereby improve engine efficiency and fuel economy, while allowing heat to be transmitted across such coatings to facilitate the operation of the engine cooling system. Nickel plating on pistons and cylinder bore walls has been used for some time to provide corrosion resistance to iron substrates while offering only limited reduction of friction because of the softness and inadequate formation of nickel oxide (see U.S. Patent 991,404). Chromium or chromium oxide coatings have been selectively used in the 1980's to enhance wear resistance of engine surfaces, but such coatings are difficult to apply, are unstable, very costly, and fail to significantly reduce friction because of their lack of holding an oil film, have high hardness, and often are incompatible with piston ring materials. In the same time period, iron and molybdenum powders also have been jointly applied to aluminium cylinder bore walls in very thin films to promote abrasion resistance. Such system offers only a limited advantage. Molybdenum particles and the many oxide forms of iron that result from the conventional application processes, do not possess a low coefficient of friction that will allow for appreciable gains in engine efficiency and fuel economy. In a first aspect, it is an object of this invention to provide an iron-based low cost metal powder useful for plasma deposition of a coating that (i) will possess an ultra-low dry coefficient of friction (i.e. about .2) and (ii) will readily conduct heat through the coating. To this end, the invention is a low alloy steel powder composition for thermal spraying comprising (a) H 2 O atomised and annealed iron alloy particles comprising by weight carbon 0.15-0.85%, oxygen 0.1-0.45%, an air hardening agent selected from manganese and nickel of 0.1-6.5%, and the remainder iron and impurities and, (b) at least 90% by volume of the particles having iron and oxygen combined as FeO only. In a second aspect, it is an object of this invention to provide a method of making anti-friction iron-based powder that (i) is highly economical, (ii) selectively produces FeO and (iii) promotes fine flowable particles. To this end, the invention is a method of making anti-friction iron-based powder suitable for plasma deposition, comprising the steps of (a) H 2 O (steam) atomisation of a molten stream of low alloy steel containing, by weight, carbon up to 0.9%, an air hardening agent selected from Mn and Ni of 0.1-6.5% and the remainder iron and impurities to produce a collection of comminuted particles; the steam atomisation is carried out to exclude the presence of oxygen other than in said H 2 O, thereby restricting reaction of Fe to only the oxygen in the water-based steam thereby to produce a powder having at least 90% by volume of the particles having oxygen and iron combined as FeO only, and (b) annealing the particles in an air atmosphere for preferably a period of time of 0.25-10.0 hours in a temperature range of 427°C-871°C (800°-1600°F) to reduce carbon in the particles to a level of 0.15% to 0.45%. The invention will now be described further, by way of example, with reference to the accompanying drawings, in which: Figure 1 is an enlarged schematic cross sectional illustration of iron based particles fused in a plasma deposited coating; Figure 2 is a graphical illustration comparing friction data of the powder of this invention with other powders; Figure 3 is a schematic illustration of the method steps of this invention including steam atomisation of iron and subsequent annealing; and Figure 4 is a flow diagram of the steps used to fabricate a coated cylinder bore wall using the powder of this invention. The unique powder of this invention, depositable by plasma spraying, exhibits a low coefficient of dry friction in the deposited form, and readily permits thermal transfer of heat through the coating. As shown in Figure 1, each powder particle 10 consists essentially of a steel grain having a composition comprising, by weight of the material, carbon .15-.85%, an air hardening agent selected from manganese and nickel in an amount of .1-6.5%, oxygen in an amount of .1-.45%, and the remainder iron and impurities. Each grain has a controlled size and fused shape which is flattened as a result of impact upon deposition leaving desirable micropores 12. The honed surface 13 of the coating 11 of such particles 10 exposes such micropores. The critical aspect of the steel grains is that at least 90% by volume of the iron, that is combined with oxygen, is combined in the FeO form only. The steel particles have a hardness of about Rc 20 to 40, a particle size of about 10 to 110 microns and a shape generally of irregular granular configuration. The combination of size and shape provide high flowability during plasma spraying, that is essential for smooth flow and a uniform deposition rate and high deposition efficiently. As comparatively shown in Figure 2, the coefficient of friction for the FeO form of iron oxide is about 0.2. This compares to a dry coefficient of friction of 0.4 for Fe 3 O 4 of about 0.45 to 0.6 for Fe 2 O 3 , 0.3 for nickel, 0.6 of NiAlSi, 0.3-0.4 for Cr 2 O 3 , and 0.3-0.4 for chromium. To produce such steel powder, a molten stream 15 of sponge iron to which has been added some manganese or nickel and carbon (composition comprising up to 0.9% carbon, 0.1-6.5% manganese or nickel, and the remainder iron except for impurities of about 0.3-0.6%) is introduced to a closed chamber 16 having an inert atmosphere 17 therein. A jet 18 of steam (or water) is impacted at an included angle of less than 90° to the molten stream to chill and comminute the stream 15 into atomised particles 19. Due to the exclusion of air or other oxygen contaminates, the only source of oxygen to unite with the iron in the molten stream is in the steam or water jet itself which is reduced. This limited access to oxygen forces the iron to combine as FeO and not as Fe 2 O 3 or Fe 3 O 4 because of the favourable temperature and the presence of carbon, which reacts with higher oxides to reduce them to FeO. The reduction of water releases H 2 ; the hydrogen adds to the nonoxidising atmosphere in the atomisation chamber. The presence of manganese or nickel allows the powder to be air hardenable when heated back up to a temperature of 649-760°C (1200°-1400°F) which will be experienced during plasma spraying. The particles 19 are collected in the bottom 20 of the chamber and thence transferred to a conveyor 21 of an annealing furnace 22 whereupon, for a period of 0.25-2.0 hours, the particles are subjected to a temperature of about 649-760°C (1200°-1400°F) which forces carbon to combine with oxygen in the furnace atmosphere to form CO or CO 2 and thereby decarburise the particles to a level of about 0.2% to 0.6% carbon, whichever is desirable. To plasma coat an aluminium cylinder bore wall of an internal combustion engine, with such atomised and annealed particles (see the flow diagram of Figure 4), the surfaces of the cylinder bore walls are prepared by first washing and degreasing; degreasing can be carried out by hot vapour and the washed walls can be dried by use of oil-free jets of air. Secondly, the clean surfaces are then operated upon to expose fresh metal devoid of aluminium oxide. This can be accomplished by either machining shallow serrations in the bore wall surfaces, electric discharge erosion of the surfaces, or by grit (shot) blasting or hydroblasting (which is very high water blasting) of such surfaces. An alternate process is thermochemical etching using a reactive halogenated gas such as Freon onto heated surface. If a thin coating (i.e. 110-180 microns) is to be applied, the cylinder bore wall surfaces are centred with respect to the true cylinder axis by machining as part of the surface preparation prior to plasma spraying. This operation is carried out in the conventional way (the cylinder bore centres are truly spaced/centred with respect to the crankshaft bearing axis. If the coating is to be relatively thick (i.e. 300-500 microns), the bore surfaces need not be centred prior to coating; rather, a rough honing operation is effective to centre the coated surface relative to the true cylinder bore axis. Plasma coating is carried out by the procedures adapting the spray parameters and equipment, disclosed in co-pending European patent application no. 95308825.9 which disclosure is incorporated herein by reference. Finished honing is carried out in plateaus to remove approximately 150 to 200 microns (taken on a radius of the cylinder bore) to flush the surface to a smoothness of 10-30 micro inches* . This honing operation is carried out following a certain specified step of grinding using 80/100 grit, 200/300 grit, 400 grit, followed by 600 grit honing stones. This is important to provide a good oil layer retention. Such honing is preferably carried out with silicon carbide or diamond abrasive grit honing stones which provide material removal without oxidising the iron substrate or the conventional coolant (i.e. a phosphate or stearate detergent oil/water emulsion). Variations of less than 10-15 microns in surface asperities and freedom from distortion to a maximum 10 to 50 microns throughout the length of the cylinder bore, are considered part of this treatment.

Claims: A low alloy steel powder composition, for thermal spraying comprising: (a) H 2 O atomised and annealed iron alloy particles comprising, by weight, 0.15-0.85% C, an air hardening agent selected from Mn and Ni of 0.1-6.5%, oxygen of 0.1-0.45%, and the remainder iron and impurities; and (b) at least 90% by volume of said particles having oxygen and iron combined as FeO only. A composition as claimed in claim 1, in which said particles exhibit a coefficient of dry friction of 0.25 or less. A composition as claimed in claim 1 or claim 2, in which said particles have a size in the range of 20-60 microns, and a particle shape characterised by spherical or semi-spherical or free flowing granular configuration. A composition as claimed in any one of the preceding claims, in which the particles have a hardness in the range of Rc 15 to 60. A composition as claimed in any one of the preceding claims, in which said powder exhibits a flowability of at least 100 gms/min. through an orifice of 5mm diameter by 100mm long. A composition as claimed in any one of the preceding claims, in which said powder has a thermal conductivity of at least 1/3 of that aluminium. A method of making anti-friction iron-based powder for plasma deposition, comprising: (a) H 2 O atomisation of a molten stream of low alloy steel to produce a collection of comminuted particles, said alloy containing, by weight, carbon up to 0.9%, an air hardening agent selected from Mn and Ni of 0.1-6.5%. and the remainder iron and impurities, said atomisation excluding the presence of oxygen other than in said H 2 O thereby restricting reaction of Fe to only the oxygen in said stream thereby to produce a powder having at least 90% by volume of the particles having oxygen and iron combined as FeO only; and (b) annealing said particles in an air atmosphere at a temperature range of 427-871°C (800°-1600°F) for a period of time to reduce carbon in said alloy to a level of 0.15-0.45%. A method as claimed in claim 7, in which said annealing time period is in the range of 0.25-10.0 hours.

Inventors: FUCINARI CARLO A, RAO V DURGA NAGESWAR, ROSE ROBERT A, YEAGER DAVID A, FUCINARI, CARLO A., RAO, V. DURGA NAGESWAR, ROSE, ROBERT A., YEAGER, DAVID A.
Applicants: FORD MOTOR CO, FORD WERKE AG, FORD MOTOR COMPANY, FORD MOTOR COMPANY LIMITED, FORD-WERKE AKTIENGESELLSCHAFT
Application year: 1995
Main classification: B22F9
IPC codes: C23C4, C22C32, B22F1