Low energy forming of metals

Claim 2

In a method of forming metallic articles, the improved process comprising the steps of: providing a die having a surface formed complementary to the shape desired to be formed, providing a molten solution of an alloy conditionable to exhibit enhanced plasticity, dispersing said molten solution into discrete droplets, quenching said droplets at a rate effective to produce pellets having a nonequilibrium, uniform cast structure, severely mechanically working said pellets, whereby said pellets bond together and undergo recrystallization thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, and forcing said mass into said die by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress.

Claim 3

In a method of forming metallic articles, the improved process comprising the steps of: providing a die having a surface formed complementary to the shape desired to be formed, providing metal pellets of an alloy conditionable to exhibit enhanced plasticity made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, severely mechanically working said pellets, whereby said pellets bond together and undergo recrystallization thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, and forcing said mass into said die by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress.

Claim 4

In a method of forming metallic articles, the improved process comprising the steps of: providing a die having a surface formed complementary to the shape desired to be formed, providing metal pellets of an alloy conditionable to exhibit enhanced plasticity made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, severely mechanically working said pellets, whereby said pellets bond together and undergo recrystallization thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, and forcing said mass into said die by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress.

Claim 5

In a method of forming metallic articles, the improved process comprising the steps of: providing a forming apparatus comprising a cylinder having pressure means operable therein, a die cavity formed complementary to the shape desired to be formed, and a restricted orifice communicating between said cylinder and said die cavity, providing metal pellets of an alloy conditionable to exhibit enhanced plasticity made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, forcing said pellets through said orifice by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress, whereby said pellets undergo severe mechanical working and thereby bond together and undergo recrystallization in said orifice thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, said mass flowing into and filling said cavity under the application of said stress.

Claim 6

In a method of forming metallic articles, the improved process comprising the steps of: providing a forming apparatus comprising a cylinder having pressure means operable therein, a die cavity formed complementary to the shape desired to be formed, and a restricted orifice communicating between said cylinder and said die cavity, providing metal pellets of an alloy conditionable to exhibit enhanced plasticity made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, forcing said pellets through said orifice by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress, whereby said pellets undergo severe mechanical working and thereby bond together and undergo recrystallization in said orifice thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, said mass flowing into and filling said cavity under the application of said stress.

Claim 7

In a method of forming metallic articles, the improved process comprising the steps of: providing a first forming apparatus comprising a cylinder having pressure means operable therein, a tubular die and a restricted orifice communicating between said cylinder and said die, providing a second forming apparatus comprising a cylinder having pressure means operable therein and a die cavity communicating with said cylinder and having a surface formed complementary to the shape desired to be formed, providing metal pellets of an alloy conditionable to exhibit enhanced plasticity made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, forcing said pellets through said orifice by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress, whereby said pellets undergo severe mechanical working and thereby bond together and undergo recrystallization in said orifice thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, said mass flowing into said tubular die under the application of said stress thereby forming a rod, transferring said rod to said cylinder of said second forming apparatus, and forcing said rod into said die cavity by applying a second compressive stress thereto, for a period of time inversely related to said second compressive stress.

Claim 8

In a method of forming metallic articles, the improved process comprising the steps of: providing a first forming apparatus comprising a cylinder having pressure means operable therein, a tubular die and a restricted orifice communicating between said cylinder and said die, providing a second forming apparatus comprising a cylinder having pressure means operable therein and a die cavity communicating with said cylinder and having a surface formed complementary to the shape desired to be formed, providing metal pellets of an alloy conditionable to exhibit enhanced plasticity made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, forcing said pellets through said orifice by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress, whereby said pellets undergo severe mechanical working and thereby bond together and undergo recrystallization in said orifice thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, said mass flowing into said tubular die under the application of said stress thereby forming a rod, transferring said rod to said cylinder of said second forming apparatus, and forcing said rod into said die cavity by applying a second compressive stress thereto, for a period of time inversely related to said second compressive stress.

Claim 9

The method of claim 4 wherein said die of said first forming apparatus comprises said cylinder of said second forming apparatus and wherein means are provided for moving said die out of communication with said orifice of said first apparatus and into communication with said die cavity of said second apparatus.

Claim 10

In a method of forming metallic articles, the improved process comprising the steps of: providing a die having a surface formed complementary to the shape desired to be formed, providing metal pellets of an alloy conditionable to exhibit enhanced plasticity, said alloy exhibiting increased plasticity with increasing temperature up to its phase transformation temperature, made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, heating said pellets to an elevated temperature at which said alloy exhibits substantially its greatest plasticity, but not above said phase transformation temperature, severely mechanically working said pellets, whereby said pellets bond together and undergo recrystallization thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, and forcing said mass heated to a temperature in the vicinity of said elevated temperature but not above said phase transformation temperature into said die by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress.

Claim 11

In a method of forming metallic articles, the improved process comprising the steps of: providing a die having a surface formed complementary to the shape desired to be formed, providing metal pellets of an alloy conditionable to exhibit enhanced plasticity, said alloy exhibiting increased plasticity with increasing temperature up to its phase transformation temperature, made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, heating said pellets to an elevated temperature at which said alloy exhibits substantially its greatest plasticity, but not above said phase transformation temperature, severely mechanically working said pellets, whereby said pellets bond together and undergo recrystallization thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, and forcing said mass heated to a temperature in the vicinity of said elevated temperature but not above said phase transformation temperature into said die by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress.

Claim 12

In a method of forming metallic articles, the improved process comprising the steps of: providing a die having a surface formed complementary to the shape desired to be formed, providing metal pellets of an alloy of a composition of, by weight, approximately 78 percent zinc and 22 percent aluminum, made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, heating said pellets to a temperature of about 525* F., severely mechanically working said pellets, whereby said pellets bond together and undergo recrystallization thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, and forcing said mass heated to a temperature in the vicinity of 525* F. but not above 527* F. into said die by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress.

Claim 13

In a method of forming metallic articles, the improved process comprising the steps of: providing a die having a surface formed complementary to the shape desired to be formed, providing metal pellets of an alloy of a composition of, by weight, approximately 78 percent zinc and 22 percent aluminum, made by dispersing a molten solution of said alloy into discrete droplets and quenching said droplets at a rate effective to produce said pellets having a nonequilibrium, uniform cast structure, heating said pellets to a temperature of about 525* F., severely mechanically working said pellets, whereby said pellets bond together and undergo recrystallization thereby forming a homogeneous mass having a fine grain structure and exhibiting enhanced plasticity, and forcing said mass heated to a temperature in the vicinity of 525* F. but not above 527* F. into said die by applying a compressive stress thereto, for a period of time inversely related to said applied compressive stress.