Fe-based alloy powder adapted for sintering, Fe-based sintered alloy having wear resistance, and process for producing the same

An Fe-based sintered alloy having superb wear resistance consisting, percent by weight, essentially of, as a whole:

• Co in an amount of 1.3 to 15%;
• Mo in an amount of 1.3 to 10%;
• Cr in an amount of 0.80 to 18%;
• W in an amount of 0.050 to 2.4%;
• C in an amount of 0.20 to 3.2%;
• Ni in an amount of 0.50 to 17%;
• and
• the balance of Fe and inevitable impurities;
• and
• said Fe-based sintered alloy including a matrix and hard particles dispersed in the matrix in an amount of 2.0 to 30% by weight;
• said matrix consisting, percent by weight, essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• C in an amount of 0.20 to 2.0%;
• Ni in an amount of 10% or less;
• and
• the balance of Fe and inevitable impurities;
• and
• said hard particles consisting, percent by weight, essentially of:
• Cr in an amount of 40 to 75%;
• W in an amount of 3.0 to 12.5%;
• C in an amount of 1.0 to 5.0%;
• and
• the balance of Ni and inevitable impurities.

An Fe-based sintered alloy having superb wear resistance consisting, percent by weight, essentially of, as a whole:

• Co in an amount of 1.3 to 15%
• Mo in an amount of 1.5 to 16%;
• Cr in an amount of 0.40 to 12%;
• W in an amount of 0.20 to 6.0%;
• C in an amount of 0.40 to 3.2%;
• Ni in an amount of 0.20 to 9.0%;
• and
• the balance of Fe and inevitable impurities;
• and
• said Fe-based sintered alloy including a matrix and hard particles dispersed in the matrix in an amount of 2.0 to 30% by weight;
• said matrix consisting, percent by weight, essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• C in an amount of 0.20 to 2.0%;
• Ni in an amount of 10% or less;
• and
• the balance of Fe and inevitable impurities;
• and
• said hard particles consisting, percent by weight, essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• C in an amount of 0.50 to 5.0%;
• Fe in an amount of 5.0 to 30%;
• and
• the balance of Ni and inevitable impurities.

An Fe-based sintered alloy having superb wear resistance consisting, percent by weight, essentially of, as a whole:

• Co in an amount of 1.3 to 15%;
• Mo in an amount of 1.5 to 16%;
• Cr in an amount of 0.40 to 12%;
• W in an amount of 0.20 to 6.0%;
• C in an amount of 0.20 to 3.2%;
• Ni in an amount of 0.60 to 15%;
• and
• the balance of Fe and inevitable impurities;
• and
• said Fe-based sintered alloy including a matrix and hard particles dispersed in the matrix in an amount of 2.0 to 30% by weight;
• said matrix consisting, percent by weight, essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• C in an amount of 0.20 to 2.0%;
• Ni in an amount of 10% or less;
• and
• the balance of Fe and inevitable impurities;
• and
• said hard particles consisting, percent by weight, essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• C in an amount of 0.50 to 4.0%;
• and
• the balance of Ni and inevitable impurities.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comparing an Fe-based alloy powder, an Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to a melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder consisting, percent by weight, essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance of Fe and inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and consisting, percent by weight, essentially of:
• Cr in an amount of 20 to 75%;
• W in an amount of 3.0 to 20%;
• and
• the balance of Ni and inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, an Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to a melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder consisting, percent by weight, essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance of Fe and inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and consisting, percent by weight, essentially of:
• Cr in an amount of 40 to 60%;
• W in an amount of 3.0 to 10%;
• C in an amount of 1.0 to 4.0%;
• and
• the balance of Ni and inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

An Fe-based sintered alloy having superb wear resistance, on a weight percent basis, consisting essentially of, as a whole:

• Co in an amount of 1.3 to 15%;
• Mo in an amount of 1.3 to 16%;
• Cr in an amount of 0.40 to 18%;
• W in an amount of 0.050 to 6.0%;
• C in an amount of 0.20 to 3.2%;
• Ni in an amount of 0.20 to 17%;
• at least one element selected from Si in an amount of 0.006 to 0.75%, Nb in an amount of 0.02 to 1.5% and Ti in an amount of 0.01 to 0.93%;
• and
• the balance of Fe and inevitable impurities;
• and
• said Fe-based sintered alloy including a matrix and hard particles dispersed in the matrix in an amount of 2.0 to 30% by weight;
• said matrix, on a weight percent basis, consisting essentially of:
• Co in amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• C in an amount of 0.20 to 2.0%;
• Ni in an amount of 10% or less;
• and
• the balance of Fe and inevitable impurities;
• and
• said hard particles, on a weight percent basis, consisting essentially of:
• Cr in an amount of 20 to 75%;
• W in an amount of 3.0 to 20%;
• C in an amount of 0.50 to 5.0%;
• at least one element selected form the group consisting of Si in an amount of 0.30 to 2.5%, Nb in an amount of 1.0 to 5.0% and Ti in an amount of 0.50 to 3.1%;
• and
• the balance of Ni and inevitable impurities.

An Fe-based sintered alloy having superb wear resistance, on a weight percent basis, consisting essentially of, as a whole:

• Co in an amount of 1.3 to 15%;
• Mo in an amount of 1.3 to 16%;
• Cr in an amount of 0.40 to 18%;
• W in an amount of 0.050 to 6.0%;
• C in an amount of 0.20 to 3.2%;
• Ni in an amount of 0.20 to 17%;
• and
• the balance Fe and the inevitable impurities;
• and
• said Fe-based sintered alloy including a matrix and hard particles dispersed in the matrix in an amount of 2.0 to 30% by weight;
• said matrix, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• C in an amount of 0.20 to 2.0%;
• Ni in an amount of 10% or less;
• and the balance Fe and the inevitable impurities;
• and
• said hard particles, on a weight percent basis, consisting essentially of:
• Cr in an amount of 20 to 75%;
• W in an amount of 3.0 to 20%;
• C in an amount of 0.50 to 5.0%;
• Mo in an amount of 5.0 to 20%;
• and
• the balance Ni and the inevitable impurities.

An Fe-based sintered alloy having superb wear resistance, on a weight percent basis, consisting essentially of, as a whole:

• Co in an amount of 1.3 to 15%;
• Mo in an amount of 1.3 to 16%;
• Cr in an amount of 0.40 to 18%;
• W in an amount of 0.050 to 6.0%;
• C in an amount of 0.20 to 3.2%;
• Ni in an amount of 0.20 to 17%;
• and
• the balance Fe and the inevitable impurities;
• and
• said Fe-based sintered alloy including a matrix and hard particles dispersed in the matrix in an amount of 2.0 to 30% by weight;
• said matrix, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• C in an amount of 0.20 to 2.0%;
• Ni in an amount of 10% or less;
• and
• the balance Fe and the inevitable impurities;
• and
• said hard particles, on a weight percent basis, consisting essentially of:
• Cr in an amount of 20 to 75%;
• W in an amount of 3.0 to 20%;
• C in an amount of 0.50 to 5.0%;
• Fe in an amount of 5.0 to 30%;
• and
• the balance Ni and the inevitable impurities.

An Fe-based sintered alloy having superb wear resistance, on a weight percent basis, consisting essentially of, as a whole:

• Co in an amount of 1.3 to 15%;
• Mo in an amount of 1.5 to 16%;
• Cr in an amount of 0.40 to 12%;
• W in an amount of 0.20 to 6.0%;
• C in an amount of 0.40 to 3.2%;
• Ni in an amount of 0.20 to 9.0%;
• Si in an amount of 0.6% or less;
• and
• the balance Fe and the inevitable impurities;
• and
• said Fe-based sintered alloy including a matrix and hard particles dispersed in the matrix in an amount of 2.0 to 30% by weight;
• said matrix, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• C in an amount of 0.20 to 2.0%;
• Ni in an amount of 10% or less;
• and
• the balance Fe and the inevitable impurities;
• and
• said hard particles, on a weight percent basis, consisting essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• C in an amount of 0.50 to 4.0%;
• Fe in an amount of 5.0 to 30%;
• Si in an amount of 2.0% or less;
• and the balance Ni and the inevitable impurities.

An Fe-based sintered alloy having superb wear resistance, on a weight percent basis, consisting essentially of, as a whole:

• Co in an amount of 1.3 to 15%;
• Mo in an amount of 2.0 to 10%;
• Cr in an amount of 0.40 to 12%;
• W in an amount of 0.20 to 6.0%;
• C in an amount of 0.40 to 3.2%;
• Ni in an amount of 0.20 to 9.0%;
• Si in an amount of 0.6% or less;
• and
• the balance Fe and the inevitable impurities;
• and
• said Fe-based sintered alloy including a matrix and hard particles dispersed in the matrix in an amount of 2.0 to 30% by weight;
• said matrix, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of more than 3.0% (note inclusive) and up to 10%;
• C in an amount of 0.20 to 2.0%;
• Ni in an amount of 10% or less;
• and
• the balance Fe and the inevitable impurities;
• and
• said hard particles, on a weight percent basis, consisting essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• C in an amount of 0.50 to 4.0%;
• Fe in an amount of 5.0 to 30%;
• Si in an amount of 2.0% or less;
• and
• the balance Ni and the inevitable impurities.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, an Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and, on a weight percent basis, consisting essentially of:
• Cr in an amount of 20 to 75%;
• W in an amount of 3.0 to 20%:
• C in an amount of 0.50 to 4.0%;
• and
• the balance Ni and the inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, a Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and, on a weight percent basis, consisting essentially of:
• Cr in an amount of 20 to 75%;
• W in an amount of 3.0 to 20%:
• Mo in an amount of 5.0 to 20%;
• and
• the balance Ni and the inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, a Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder:
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, on a weight percent basis, and consisting essentially of:
• Cr in an amount of 20 to 75%;
• W in an amount of 3.0 to 20%;
• Fe in an amount of 10 to 30%;
• and the balance Ni and the inevitable impurities;
• and said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, a Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, on a weight percent basis, and consisting essentially of:
• Cr in an amount of 20 to 75%;
• W in an amount of 3.0 to 20%;
• at least one element selected from the group consisting of Si in an amount of 0.30 to 2.0%, Nb in an amount of 1.0 to 4.0% and Ti in an amount of 0.50 to 2.5%;
• and
• the balance Ni and the inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, a Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• CO in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and, on a weight percent basis, consisting essentially of:
• Cr in an amount of 40 to 60%;
• W in an amount of 3.0 to 10%;
• C in an amount of 1.0 to 4.0%;
• at least one element selected from the group consisting of Si in an amount of 0.30 to 2.0%, Nb in an amount of 1.0 to 4.0% and Ti in an amount of 0.50 to 2.5%;
• and
• the balance Ni and the inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, a Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of more than 3.0% (not inclusive) and up to 10%;
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and, on a weight percent basis, consisting essentially of:
• Cr in an amount of 40 to 60%;
• W in an amount of 3.0 to 10%;
• C in an amount of 1.0 to 4.0%;
• at least one element selected from the group consisting of Si in an amount of 0.30 to 2.0%, Nb in an amount of 1.0 to 4.0% and Ti in an amount of 0.50 to 2.5%;
• and
• the balance Ni and the inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, a Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• MO in an amount of 2.0 to 100;
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and consisting, percent by weight, essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• Fe in an amount of 10 to 30%;
• C in an amount of 0.50 to 4.0%;
• Si in an amount of 2.0% or less;
• and
• the balance Ni and the inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, an Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and, on a weight percent basis, consisting essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• C in an amount of 1.0 to 4.0%;
• and
• the balance Ni and the inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, a Ni-based alloy powder, a graphite powder, a freemachining additive and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to the melting point or less of said Ni-based alloy powder:
• said Fe-based alloy powder, on a weight percent basis, consisting essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%:
• and
• the balance Fe and the inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and, on a weight percent basis, consisting essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• C in an amount of 4.0% or less;
• and
• the balance Ni and the inevitable impurities;
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight;
• and
• said free-machining additive being at least one member selected from the group consisting of CaF.sub.2, MnS and MoS.sub.2, and mixed in an amount of 0.20 to 2.0% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, an Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to a melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder consisting, percent by weight, essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance of Fe and inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and consisting, percent by weight, essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• Fe in an amount of 10 to 30%;
• and
• the balance of Ni and inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.

A process for producing an Fe-based sintered alloy having superb wear resistance, comprising the steps of:

• forming a powder mixture comprising an Fe-based alloy powder, an Ni-based alloy powder, a graphite powder and a forming lubricant, thereby preparing a green compact;
• and
• sintering said green compact at a temperature of from 1,323 K. to a melting point or less of said Ni-based alloy powder;
• said Fe-based alloy powder consisting, percent by weight, essentially of:
• Co in an amount of 2.0 to 15%;
• Mo in an amount of 2.0 to 10%;
• and
• the balance of Fe and inevitable impurities;
• said Ni-based alloy powder mixed in an amount of 2.0 to 30% by weight, and consisting, percent by weight, essentially of:
• Mo in an amount of 5.0 to 20%;
• Cr in an amount of 20 to 40%;
• W in an amount of 10 to 20%;
• and
• the balance of Ni and inevitable impurities;
• and
• said graphite powder mixed in an amount of 0.20 to 2.1% by weight.