Iron aluminum based engine intake valves and method of making thereof

An intake valve for an internal combustion engine made by the steps comprising:

• (a) providing a coil or bar stock of an iron aluminum alloy having the composition comprising:
• ______________________________________ Ingredient Weight Percent ______________________________________ Aluminum 9 to 13.3 Carbon 0.05 to 0.35 Refractory metal 0.5 to 3 and/or Titanium 0.3 to 1.5 Zirconium 0 to 1 Manganese 0 to 1 Silicon 0 to 0.8 Chromium 0 to 3 the balance being iron ______________________________________
• (b) extruding said coil or bar stock to a poppet valve preform configuration at a temperature in the range of 800.degree. to 2,000.degree. F. and a true strain of about 0.5 to 2.2;
• (c) heading said preform to a pre-machined configuration while maintaining the head of said preform at an effective heading temperature up to 2,200.degree. F., said heading being carried out at a true strain of about 1.4 to 2.3;
• and
• (d) grinding said headed preform, without intermediate heat treatment, to a machined configuration.

A method for making an intake valve for an internal combustion engine comprising the steps of:

• (a) providing a coil or bar stock of an iron aluminum alloy having the composition comprising:
• (i) 76.05-90.15 weight percent iron
• (ii) 9-13.3 weight percent aluminum,
• (iii) 0.05-0.35 weight percent carbon,
• (iv) 0.5-3 weight percent of a refractory metal and/or 0.3-1.5 weight percent titanium.
• (b) extruding said coil or bar to a poppet valve preform configuration at a temperature in the range of 800.degree. to 2,000.degree. F. and a true strain of about 0.5 to 2.2;
• (c) heading said preform to pre-machined configuration while maintaining the head of said preform at an effective heading temperature up to 2,200.degree. F., said heading being carried out at a true strain of about 1.4 to 2.3;
• and
• (d) grinding said headed preform, without intermediate heat treatment, to a machined configuration.

A method for making an intake valve for an internal combustion engine comprising the steps of

• (a) providing a coil or bar stock of an iron aluminum alloy having the composition comprising:
• ______________________________________ Ingredient Weight Percent ______________________________________ Aluminum 9 to 13.3 Carbon 0.05 to 0.35 Refractory metal 0.5 to 3 and/or Titanium 0.3 to 1.5 Zirconium 0 to 1 Manganese 0 to 1 Silicon 0 to 0.8 Chromium 0 to 3 the balance being iron ______________________________________
• (b) extruding said coil or bar stock to a poppet valve preform configuration at a temperature in the range of 800.degree. to 2,000.degree. F. and a true strain of about 0.5 to 2.2;
• (c) heading said preform to a pre-machined configuration while maintaining the head of said preform at an effective heading temperature up to 2,200.degree. F., said heading being carried out at a true strain of 1.4 to 2.3;
• and
• (d) grinding said headed preform, without intermediate heat treatment, to a machined configuration.

A light weight iron aluminum alloy comprising on a weight basis:

• (i) 76.05-90.15 weight percent iron,
• (ii) 9-13.3 weight percent aluminum,
• (iii) 0.05-0.35 weight percent carbon,
• (iv) 0.3-1.5 weight percent titanium,
• (v) 0.5-1% zirconium,
• said alloy having a disordered structure and improved ductility and high temperature yield strength.

A light weight iron aluminum alloy comprising on a weight basis;

• (i) 76.05-90.15 weight percent iron,
• (ii) 9-13.3 weight percent aluminum,
• (iii) 0.05-0.35 weight percent carbon,
• (iv) 0.5-3 weight percent of refractory metal selected from the group consisting of molybdenum, vanadium, niobium, tungsten and tantalum;
• 0-1% zirconium,
• (vi) 0-1% manganese,
• (vii) 0-0.8% silicon, and
• (viii) 0-3% chromium,
• said alloy having a disordered structure without heat treatment and improved high temperature yield strength.

An internal combustion engine valve having an iron aluminide composition,

• a) 76.05-90.15 weight percent iron;
• b) 9-13.3 weight percent aluminum;
• c) 0.05-0.35 weight percent carbon;
• d) 0.05-3 weight percent of a refractory metal and/or 0.3-1.5 weight percent titanium.
• and a disordered structure for improved high temperature properties.