Arcanum Alloy Design Inc.

Public Joint Stock Company “Severstal”

Daniel E Bullard

Joseph E McDermott

Martin Janousek

Zachary M Detweiler

Adam G Thomas

The present disclosure provides systems and methods for depositing a metal layer adjacent to or on a substrate. Substrates may comprise, for example, one or more of iron, chromium, nickel, silicon, vanadium, titanium, boron, tungsten, aluminum, molybdenum, cobalt, manganese, zirconium, and niobium, oxides thereof, nitrides thereof, sulfides thereof, or any combination thereof. A substrate may be a steel substrate. A metal layer may be deposited via, for example, roll coating, vapor deposition, slurry deposition, or electrochemical deposition.

Methods and systems for coating a steel substrate

A steel manufacturing process can include forming an iron oxide layer on a hot band during hot rolling; reducing the iron oxide layer on the hot band to form a sponge iron layer that includes pores; the sponge-iron layer having a thickness in a range of about 0.05 &#x3bc;m to about 1000 &#x3bc;m, about 0.1 &#x3bc;m to about 100 &#x3bc;m, or about 5 &#x3bc;m to about 25 &#x3bc;m; and depositing an alloying element into the pores of the sponge iron layer to form an impregnated sponge-iron layer. The process can further include annealing the impregnated sponge-iron layer to produce an iron alloy layer carried by the substrate.

Sponge-iron alloying

A steel wire having a stainless steel exterior; the steel wire includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 &#x3bc;m to about 250 &#x3bc;m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 &#x3bc;m and less than the thickness of the stainless steel region, and has a bonding composition. The bonding composition includes an admixture of iron and chromium, with a chromium concentration proximal to the stainless steel region that is approximately equal to the chromium concentration of the stainless steel region and has a chromium concentration proximal to the core region that has less than about 5 wt. % chromium.

Metallurgically bonded stainless steel

Herein are disclosed steel forms having stainless steel exteriors that pass a 0T-bend Advanced T-bend Test. One steel form has a stainless steel exterior; the steel form includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 &#x3bc;m to about 250 &#x3bc;m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition can include an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 &#x3bc;m and less than the thickness of the stainless steel region, and has a bonding composition. The bonding composition can include an admixture of iron and chromium, with a chromium concentration proximal to the stainless steel region that is approximately equal to the chromium concentration of the stainless steel region and has a chromium concentration proximal to the core region that has less than about 5 wt. % chromium.

A steel form having a stainless steel exterior; the steel form includes a core region that comprises at least 55 wt. % iron which is metallurgically bonded to a stainless steel coating that consists of a stainless steel region and a bonding region. The stainless steel region can have a thickness of about 1 &#x3bc;m to about 250 &#x3bc;m, and a stainless steel composition that is approximately consistent across the thickness of the stainless steel region. The stainless steel composition includes an admixture of iron and about 10 wt. % to about 30 wt. % chromium. The bonding region is positioned between the stainless steel region and the core region, has a thickness that is greater than 1 &#x3bc;m and less than the thickness of the stainless steel region, and has a bonding composition. The bonding composition includes an admixture of iron and chromium, with a chromium concentration proximal to the stainless steel region that is approximately equal to the chromium concentration of the stainless steel region and has a chromium concentration proximal to the core region that has less than about 5 wt. % chromium.

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Cupertino, CA, United States of America

Daniel E Bullard