US4594104A
Expired / Lapsed
US
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Consolidated articles produced from heat treated amorphous bulk parts
Assignee: Honeywell International Inc
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Filing: 1985-04-26
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Granted: 1986-06-10
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Expires: 2005-04-26
Abstract
Abstract The present invention provides a method for producing a consolidated article composed of a transition metal alloy. The method includes the step of selecting a rapidly solidified alloy which is at least about 50% glassy. The alloy is formed into a plurality of alloy bodies, and these alloy bodies are compacted at a pressing temperature of not more than about 0.6 Ts (solidus temperature in DEG C.) to consolidate and bond the alloy bodies together into a glassy metal compact having a density of at least about 90% T.D. (theoretical density). The compacted glassy alloy bodies are then heat treated at a temperature generally ranging from about 0.55-0.85 Ts, but, in any case, above the alloy crystallization temperature, for a time sufficient to produce a fine grain crystalline alloy structure in the compacted article.
Inventors
- 👤 Derek Reybould
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 18:26
CPC Classifications
C; C22; C22C; C22C45/00; B; B22; B22F; B22F9/00; B22F9/002; B22F9/008; C22C26/00; C22C2026/005
Claims Analysis
Total Claims: 31
Claim 1
Independent Claim
107 words
A method for producing a consolidated metal article, comprising the steps of: (a) selecting a rapidly solidified alloy, which is at least 50% glassy; (b) forming said alloy into a plurality of alloy bodies; (c) compacting said alloy bodies at a pressing temperature of not more than about 0.6 Ts (solidus temperature measured in °C.) and at a pressure sufficient to bond said alloy bodies together into a glassy metal compact having at least about 90% T.D.; and (d) heat treating said compacted alloy bodies at a heat treatment temperature ranging from about 0.55-0.85 Ts for a time period sufficient to provide a crystalline alloy consolidated article.
Claim 2
Independent Claim
107 words
A method for producing a consolidated metal article, comprising the steps of: (a) selecting a rapidly solidified alloy, which is at least 50% glassy; (b) forming said alloy into a plurality of alloy bodies; (c) compacting said alloy bodies at a pressing temperature of not more than about 0.6 Ts (solidus temperature measured in °C.) and at a pressure sufficient to bond said alloy bodies together into a glassy metal compact having at least about 90% T.D.; and (d) heat treating said compacted alloy bodies at a heat treatment temperature ranging from about 0.55-0.85 Ts for a time period sufficient to provide a crystalline alloy consolidated article.
Claim 3
Dependent Claim
20 words
The method of claim 1, wherein said rapidly solidified alloy has a structure that is at least about 80% glassy.
Claim 4
Dependent Claim
14 words
The method of claim 1, wherein said rapidly solidified alloy is substantially 100% glassy.
Claim 5
Dependent Claim
98 words
The method of claim 1, wherein said glassy alloy consists essentially of the formula M a T b X c , wherein "M" is one or more elements selected from the group consisting of Fe, Co, Ni, W, Mo, Nb, V, Ta and Cr, "T" is one or more elements selected from the group consisting of Al and Ti, "X" is one or elements selected from the group consisting of B, C, Si and P, "a" ranges from about 50-95 at. %, "b" ranges from about 0-40 at. %, "c" ranges from about 5-30 at. % and a+b+c=100.
Claim 6
Dependent Claim
74 words
The method of claim 1, wherein said selected, rapidly solidified alloy consists essentially of the formula M' bal B f X' g , wherein M' is one or more elements selected from the group consisting of Fe, Ni, Mo and W, B is boron, X' is one or more elements selected from the group consisting of C and Si, "f" ranges from about 5-25 at. % and "g" ranges from about 0-20 at. %.
Claim 7
Dependent Claim
13 words
The method of claim 1, wherein said compacting step includes a dynamic compaction.
Claim 8
Dependent Claim
25 words
The method of claim 6, wherein said dynamic compaction is provided by a high speed punch moving at a speed ranging from about 100-2000 m/sec.
Claim 9
Dependent Claim
19 words
The method of claim 7, wherein said dynamic compaction is performed at a speed ranging from about 600-2000 m/sec.
Claim 10
Dependent Claim
21 words
The method of claim 1, further comprising the step of hot forming said compacted alloy during said heat treating step (d).
Claim 11
Dependent Claim
13 words
The method of claim 9, wherein said hot forming is provided by extrusion.
Claim 12
Dependent Claim
13 words
The method of claim 9, wherein said hot forming is provided by forging.
Claim 13
Dependent Claim
18 words
The method of claim 1 wherein the consolidation temperature, measured in °C., is between 0.6 and 1.1 Tx.
Claim 14
Dependent Claim
15 words
The method of claim 12 wherein the consolidation temperature is between 0.6 and 0.95 Tx.
Claim 15
Dependent Claim
15 words
The method of claim 12 wherein the consolidation temperature is between 0.8 and 0.95 Tx.
Claim 16
Dependent Claim
136 words
A consolidated article comprising a crystalline alloy consisting essentially of the formula M a T b X c , wherein "M" is one or more elements selected from the group consisting of Fe, Co, Ni, W, Mo, Nb, V, Ta and Cr, "T" is one or more elements selected from the group consisting of Al and Ti, "X" is one or more elements selected from the group consisting of B, C, Si and P, "a" ranges from about 50-95 at. %, "b" ranges from about 0-40 at. %, "c" ranges from about 5-30 at. % and a+b+c=100, said alloy comprising a crystalline matrix that has an average grain size of less than about 2 micrometers and has substantially all of its constituent amounts of boron, carbon, silicon, and phosphorous held unprecipitated in a solid solution phase.
Claim 17
Dependent Claim
136 words
A consolidated article comprising a crystalline alloy consisting essentially of the formula M a T b X c , wherein "M" is one or more elements selected from the group consisting of Fe, Co, Ni, W, Mo, Nb, V, Ta and Cr, "T" is one or more elements selected from the group consisting of Al and Ti, "X" is one or more elements selected from the group consisting of B, C, Si and P, "a" ranges from about 50-95 at. %, "b" ranges from about 0-40 at. %, "c" ranges from about 5-30 at. % and a+b+c=100, said alloy comprising a crystalline matrix that has an average grain size of less than about 2 micrometers and has substantially all of its constituent amounts of boron, carbon, silicon, and phosphorous held unprecipitated in a solid solution phase.
Claim 18
Dependent Claim
40 words
The article of claim 15, further comprising, admixed and consolidated in the article, at least one additional crystalline alloy consisting essentially of the formula M a T b X c , but different in composition from the first crystalline alloy.
Claim 19
Dependent Claim
166 words
A consolidated article comprising a crystalline alloy consisting essentially of the formula M a T b X c , wherein "M" is one or more elements selected from the group consisting of Fe, Co, Ni, W, Mo, Nb, V, Ta and Cr, "T" is one or more elements selected from the group consisting of Al and Ti, "X" is one or more elements selected from the group consisting of B, C, Si and P, "a" ranges from about 50-90 at. %, "b" ranges from about 0-40 at. %, "c" ranges from about 5-30 at. % and a+b+c=100, said alloy alloy comprising a substantially uniform dispersion of substantially spherical precipitates in a crystalline matrix that has an average grain size of less than about 2 micrometers, said precipitates composed of at least one metalloid selected from the group consisting of carbides, borides, silicides, and phosphides and having a maximum precipitate diameter of less than about 4 micrometers, said article further comprising diamond powder admixed and consolidated therein.
Claim 20
Dependent Claim
166 words
A consolidated article comprising a crystalline alloy consisting essentially of the formula M a T b X c , wherein "M" is one or more elements selected from the group consisting of Fe, Co, Ni, W, Mo, Nb, V, Ta and Cr, "T" is one or more elements selected from the group consisting of Al and Ti, "X" is one or more elements selected from the group consisting of B, C, Si and P, "a" ranges from about 50-90 at. %, "b" ranges from about 0-40 at. %, "c" ranges from about 5-30 at. % and a+b+c=100, said alloy alloy comprising a substantially uniform dispersion of substantially spherical precipitates in a crystalline matrix that has an average grain size of less than about 2 micrometers, said precipitates composed of at least one metalloid selected from the group consisting of carbides, borides, silicides, and phosphides and having a maximum precipitate diameter of less than about 4 micrometers, said article further comprising diamond powder admixed and consolidated therein.
Claim 21
Dependent Claim
59 words
The article of claim 17, wherein "M" is one or more elements selected from the group consisting of Fe, Co, Ni, W, Mo, V, and Cr; "X" is one or more elements selected from the group consisting of B, C, and Si; "a" ranges from 70-95 at. %; "b" is 0; and "c" ranges from about 5-30 at. %.
Claim 22
Dependent Claim
20 words
The article of claim 17, wherein said metalloid compounds have a maximum particle diameter of less than about 1 micrometer.
Claim 23
Dependent Claim
20 words
The article of claim 18, wherein said metalloid compounds have a maximum particle diameter of less than about 1 micrometer.
Claim 24
Dependent Claim
29 words
The article of claim 17, wherein said alloy contains at least two metal components and said metalloid compounds have a maximum particle diameter of less than about 0.5 micrometer.
Claim 25
Dependent Claim
29 words
The article of claim 18, wherein said alloy contains at least two metal components and said metalloid compounds have a maximum particle diameter of less than about 0.5 micrometer.
Claim 26
Dependent Claim
40 words
The article of claim 17, further comprising, admixed and consolidated in the article, at least one additional crystalline alloy consisting essentially of the formula M a T b X c , but different in composition from the first crystalline alloy.
Claim 27
Independent Claim
79 words
A method for producing a consolidated metal article, comprising the steps of: (a) selecting a rapidly solidified alloy which is at least about 50% glassy; (b) depositing said alloy onto a substrate to form glassy alloy layer bonded thereto; and (c) heat treating said glassy alloy at a temperature ranging from about 0.55-0.85 Ts for a time sufficient to form a crystalline phase of said alloy having a hardness that is greater than the hardness of said glassy alloy.
Claim 28
Independent Claim
79 words
A method for producing a consolidated metal article, comprising the steps of: (a) selecting a rapidly solidified alloy which is at least about 50% glassy; (b) depositing said alloy onto a substrate to form glassy alloy layer bonded thereto; and (c) heat treating said glassy alloy at a temperature ranging from about 0.55-0.85 Ts for a time sufficient to form a crystalline phase of said alloy having a hardness that is greater than the hardness of said glassy alloy.
Claim 29
Dependent Claim
21 words
The method of claim 24, wherein said crystalline alloy phase has a maximum grain size of less than about 2 micrometers.
Claim 30
Independent Claim
117 words
A method for producing a consolidated metal article, comprising the steps of: (a) selecting a rapidly solidified alloy, which is at least 50% glassy; (b) forming said alloy into a plurality of alloy bodies; (c) compacting said alloy bodies together with diamond powder at a pressing temperature of not more than about 0.6 Ts (solidus temperature measured in °C.) and at a pressure sufficient to bond said alloy bodies together and to form with the diamond powder a compact having at least about 90% T.D.; and (d) heat treating said compact at a heat treatment temperature ranging from about 0.55-0.85 Ts for a time period sufficient to provide a crystalline alloy consolidated article without graphitizing the diamond.
Claim 31
Independent Claim
117 words
A method for producing a consolidated metal article, comprising the steps of: (a) selecting a rapidly solidified alloy, which is at least 50% glassy; (b) forming said alloy into a plurality of alloy bodies; (c) compacting said alloy bodies together with diamond powder at a pressing temperature of not more than about 0.6 Ts (solidus temperature measured in °C.) and at a pressure sufficient to bond said alloy bodies together and to form with the diamond powder a compact having at least about 90% T.D.; and (d) heat treating said compact at a heat treatment temperature ranging from about 0.55-0.85 Ts for a time period sufficient to provide a crystalline alloy consolidated article without graphitizing the diamond.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
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| 3.5 Years (Year 4) | 1989-06-09 | 1989-12-09 | 1990-06-10 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-06-09 | 1993-12-09 | 1994-06-10 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-06-09 | 1997-12-09 | 1998-06-10 | $7700.00 | Window Closed / Lapsed |