US4605440A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Boron-carbide-aluminum and boron-carbide-reactive metal cermets
Assignee: United States Department of Energy
•
Filing: 1985-05-06
•
Granted: 1986-08-12
•
Expires: 2005-05-06
Abstract
Abstract Hard, tough, lightweight boron-carbide-reactive metal composites, particularly boron-carbide-aluminum composites, are produced. These composites have compositions with a plurality of phases. A method is provided, including the steps of wetting and reacting the starting materials, by which the microstructures in the resulting composites can be controllably selected. Starting compositions, reaction temperatures, reaction times, and reaction atmospheres are parameters for controlling the process and resulting compositions. The ceramic phases are homogeneously distributed in the metal phases and adhesive forces at ceramic-metal interfaces are maximized. An initial consolidation step is used to achieve fully dense composites. Microstructures of boron-carbide-aluminum cermets have been produced with modulus of rupture exceeding 110 ksi and fracture toughness exceeding 12 ksi 2ROOT in. These composites and methods can be used to form a variety of structural elements.
Inventors
- 👤 Danny C. Halverson
- 👤 Aleksander J. Pyzik
- 👤 Ilhan A. Aksay
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-23 23:54
CPC Classifications
C; C22; C22C; C22C29/00; C22C29/02; C22C29/06; C22C29/062; C04; C04B; C04B35/00; C04B35/515; C04B35/56; C04B35/563; C04B35/622; C04B35/64; C04B35/65; C22C1/00; C22C1/04; C22C1/05; C22C1/051; C22C29/14
Claims Analysis
Total Claims: 47
Claim 1
Independent Claim
88 words
A composition of matter, comprising a boron-carbide-aluminum composite with a tailored microstructure having at least four of any of the following phases: (a) AlB 2 , (b) α-AlB 12 , (c) AlB 12 C 2 , (d) Al 4 C 3 , (e) AlB 24 C 4 , (f) Al 4 B 1-3 C 4 , (g) a phase containing boron, carbon and aluminum and exhibiting an X-ray diffraction pattern shown in Table I, (h) B 4 C, and (i) an aluminum phase, homogeneously distributed in the composite.
Claim 2
Dependent Claim
88 words
A composition of matter, comprising a boron-carbide-aluminum composite with a tailored microstructure having at least four of any of the following phases: (a) AlB 2 , (b) α-AlB 12 , (c) AlB 12 C 2 , (d) Al 4 C 3 , (e) AlB 24 C 4 , (f) Al 4 B 1-3 C 4 , (g) a phase containing boron, carbon and aluminum and exhibiting an X-ray diffraction pattern shown in Table I, (h) B 4 C, and (i) an aluminum phase, homogeneously distributed in the composite.
Claim 3
Dependent Claim
17 words
The composition of claim 1 wherein adhesive forces at ceramic-metal interfaces in the composite are substantially maximized.
Claim 4
Dependent Claim
23 words
The composition of claim 1 including a phase containing boron, carbon, and aluminum, and exhibiting a X-ray diffraction pattern shown in Table I.
Claim 5
Dependent Claim
46 words
The composition of claim 1 including at least the following five phases: AlB 2 , α-AlB 12 , AlB 12 C 2 , Al 4 C 3 , and a phase containing boron, carbon and aluminum and exhibiting an X-ray diffraction pattern shown in Table I.
Claim 6
Dependent Claim
12 words
The composition of claim 1 wherein the composite is substantially fully dense.
Claim 7
Dependent Claim
12 words
The composition of claim 2 wherein the composite is substantially fully dense.
Claim 8
Dependent Claim
12 words
The composition of claim 3 wherein the composite is substantially fully dense.
Claim 9
Dependent Claim
12 words
The composition of claim 4 wherein the composite is substantially fully dense.
Claim 10
Dependent Claim
17 words
A composition containing boron, carbon, and aluminum, and exhibiting a X-ray diffraction pattern shown in Table I.
Claim 11
Dependent Claim
17 words
A composition containing boron, carbon, and aluminum, and exhibiting a X-ray diffraction pattern shown in Table I.
Claim 12
Dependent Claim
89 words
A composition of matter comprising a composite of boron-carbide and a metal reactive with boron-carbide, and having a plurality of ceramic phases homogeneously distributed in metal phases, said metal being selected from the group consisting of Al, As, Ba, Be, Ca, Co, Cr, Fe, Hf, Ir, La, Li, Mg, Mn, Mo, Na, Nb, Ni, Os, Pd, Pt, Pu, Re, Rh, Ru, Sc, Si, Sr, Ta, Tc, Th, Ti, U, V, W, Y, and Zr, and alloys thereof, and compounds thereof which are reduced to the metallic form during processing.
Claim 13
Dependent Claim
89 words
A composition of matter comprising a composite of boron-carbide and a metal reactive with boron-carbide, and having a plurality of ceramic phases homogeneously distributed in metal phases, said metal being selected from the group consisting of Al, As, Ba, Be, Ca, Co, Cr, Fe, Hf, Ir, La, Li, Mg, Mn, Mo, Na, Nb, Ni, Os, Pd, Pt, Pu, Re, Rh, Ru, Sc, Si, Sr, Ta, Tc, Th, Ti, U, V, W, Y, and Zr, and alloys thereof, and compounds thereof which are reduced to the metallic form during processing.
Claim 14
Dependent Claim
17 words
The composition of claim 10 wherein adhesive forces at ceramic-metal interfaces in the composite are substantially maximized.
Claim 15
Dependent Claim
12 words
The composition of claim 10 wherein the composite is substantially fully dense.
Claim 16
Dependent Claim
16 words
An article of manufacture comprising a structural element formed of a composition according to claim 1.
Claim 17
Dependent Claim
16 words
An article of manufacture comprising a structural element formed of a composition according to claim 4.
Claim 18
Dependent Claim
16 words
An article of manufacture comprising a structural element formed of a composition according to claim 8.
Claim 19
Dependent Claim
16 words
An article of manufacture comprising a structural element formed of a composition according to claim 12.
Claim 20
Independent Claim
67 words
A method for producing a boron-carbide-reactive metal composite, comprising: wetting boron-carbide with a metal reactive with boron-carbide, or with an alloy thereof, or with a compound thereof which is reduced to the metallic form during processing; reacting the boron-carbide and metal to produce a multiphase microstructure wherein ceramic phases are homogeneously distributed in metallic phases and adhesive forces at ceramic-metal interfaces in the composite are substantially maximized.
Claim 21
Independent Claim
67 words
A method for producing a boron-carbide-reactive metal composite, comprising: wetting boron-carbide with a metal reactive with boron-carbide, or with an alloy thereof, or with a compound thereof which is reduced to the metallic form during processing; reacting the boron-carbide and metal to produce a multiphase microstructure wherein ceramic phases are homogeneously distributed in metallic phases and adhesive forces at ceramic-metal interfaces in the composite are substantially maximized.
Claim 22
Dependent Claim
53 words
The method of claim 17 wherein the metal is selected from the group consisting of Al, As, Ba, Be, Ca, Co, Cr, Fe, Hf, Ir, La, Li, Mg, Mn, Mo, Na, Nb, Ni, Os, Pd, Pt, Pu, Re, Rh, Ru, Sc, Si, Sr, Ta, Tc, Th, Ti, U, V, W, Y, and Zr.
Claim 23
Dependent Claim
10 words
The method of claim 18 wherein the metal is Al.
Claim 24
Dependent Claim
22 words
The method of claim 19 wherein the step of wetting is performed by heating to a temperature of about 1050° C.-1250° C.
Claim 25
Dependent Claim
11 words
The method of claim 20 comprising heating for about 2-10 minutes.
Claim 26
Dependent Claim
22 words
The method of claim 19 wherein the step of reacting is performed by heating to a temperature of about 800° C.-1400° C.
Claim 27
Dependent Claim
13 words
The method of claim 22 comprising heating for at least about 10 minutes.
Claim 28
Dependent Claim
20 words
The method of claim 17 further comprising: consolidating the boron-carbide and reactive metal substantially homogeneously prior to wetting and reacting.
Claim 29
Dependent Claim
30 words
The method of claim 24 wherein the step of consolidating is performed by: forming the boron-carbide and metal into particles of preselected sizes; codispersing the particles; consolidating the codispersed particles.
Claim 30
Dependent Claim
23 words
The method of claim 25 wherein the particles are formed in a size range of about 50 microns to less than 1 micron.
Claim 31
Dependent Claim
16 words
The method of claim 26 including forming the particles into at least two substantially different sizes.
Claim 32
Dependent Claim
19 words
The method of claim 25 wherein the step of codispersing is performed by placing the particles in a solvent.
Claim 33
Dependent Claim
13 words
The method of claim 28 further including adding a surfactant to the solvent.
Claim 34
Dependent Claim
18 words
The method of claim 28 for aluminum wherein the solvent is methyl alcohol, benzene, toluene, or carbon tetrachloride.
Claim 35
Dependent Claim
18 words
The method of claim 25 wherein the step of consolidating the codispersed particles is performed by slip casting.
Claim 36
Dependent Claim
18 words
The method of claim 25 wherein the step of consolidating the codispersed particles is performed by centrifugal casting.
Claim 37
Independent Claim
26 words
A method for consolidating boron-carbide and aluminum particles, comprising: forming the boron-carbide and aluminum into particles of preselected sizes; codispersing the particles; consolidating the codispersed particles.
Claim 38
Independent Claim
26 words
A method for consolidating boron-carbide and aluminum particles, comprising: forming the boron-carbide and aluminum into particles of preselected sizes; codispersing the particles; consolidating the codispersed particles.
Claim 39
Dependent Claim
19 words
The method of claim 33 wherein the step of codispersing is performed by placing the particles in a solvent.
Claim 40
Dependent Claim
13 words
The method of claim 34 further including adding a sufactant to the solvent.
Claim 41
Dependent Claim
17 words
The method of claim 33 wherein the step of consolidating the particles is performed by slip casting.
Claim 42
Dependent Claim
17 words
The method of claim 33 wherein the step of consolidating the particles is performed by centrifugal casting.
Claim 43
Dependent Claim
28 words
The composition of claim 1 wherein the aluminum phase is selected from aluminum, aluminum alloys, or aluminum compounds which are reduced to aluminum during formation of the composite.
Claim 44
Dependent Claim
18 words
The composition of claim 4 further including at least one of the following: B 4 C and Al.
Claim 45
Dependent Claim
15 words
The composition of claim 1 having a fracture toughness of at least about 12 ksi√in.
Claim 46
Dependent Claim
16 words
The composition of claim 1 having a modulus of rupture of at least about 110 ksi.
Claim 47
Dependent Claim
28 words
The composition of claim 1 wherein the relative proportions of the phases is selectable as a function of reaction temperature and reaction time during formation of the composite.
References Cited (Backward Citations)
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1989-08-11 | 1990-02-10 | 1990-08-12 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1993-08-11 | 1994-02-10 | 1994-08-12 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1997-08-11 | 1998-02-10 | 1998-08-12 | $7700.00 | Window Closed / Lapsed |