US4605599A — High density tungsten alloy sheet

Claim 1

Independent Claim 149 words

A process for the manufacture of high density tungsten (W) alloy sheet comprising the steps of: selecting at least first and second alloy constituents, wherein each of said constituents have a melting point below that of tungsten and wherein the first constituent has a higher melting point than said second constituent; forming a substrate in sheet or foil form containing as a major portion said first alloy constituent; loading said substrate with a metal powder mixture containing predetermined amounts of tungsten powder admixed with powder particles of at least said second alloy constituent; heating said powder mixture and said substrate to form a partially consolidated tungsten alloy skeleton partially bonded to the substrate; further heating said partially consolidated tungsten alloy skeleton and said substrate to a temperature above the melting point of said substrate, whereby said substrate melts and infiltrates the tungsten alloy skeleton to complete the densification thereof.

Claim 2

Dependent Claim 149 words

A process for the manufacture of high density tungsten (W) alloy sheet comprising the steps of: selecting at least first and second alloy constituents, wherein each of said constituents have a melting point below that of tungsten and wherein the first constituent has a higher melting point than said second constituent; forming a substrate in sheet or foil form containing as a major portion said first alloy constituent; loading said substrate with a metal powder mixture containing predetermined amounts of tungsten powder admixed with powder particles of at least said second alloy constituent; heating said powder mixture and said substrate to form a partially consolidated tungsten alloy skeleton partially bonded to the substrate; further heating said partially consolidated tungsten alloy skeleton and said substrate to a temperature above the melting point of said substrate, whereby said substrate melts and infiltrates the tungsten alloy skeleton to complete the densification thereof.

Claim 3

Dependent Claim 21 words

The process of claim 1 wherein the first alloy constituent is iron (Fe) and the second alloy constituent is nickel (Ni).

Claim 4

Dependent Claim 12 words

The process of claim 2 wherein the substrate comprises substantially pure iron.

Claim 5

Dependent Claim 16 words

The process of claim 2 wherein the substrate comprises an alloy substantially of iron and nickel.

Claim 6

Dependent Claim 51 words

The process of claim 1 wherein the first alloy constituent is iron (Fe), the second alloy constituent is nickel (Ni) and the admixture of tungsten and nickel powders also contains a predetermined amount of metal powders selected from at least one of the group consisting of cobalt (Co) and molybdenum (Mo).

Claim 7

Dependent Claim 39 words

The process of claim 1 including the steps of cooling said partially consolidated tungsten alloy skeleton and substrate after said first heating step and cutting said cooled skeleton and substrate into premeasured lengths prior to said further heating step.

Claim 8

Dependent Claim 24 words

The process of claim 6 wherein the first heating step, the further heating step and the cooling step are conducted in a protective atmosphere.

Claim 9

Dependent Claim 14 words

The process of claim 7 wherein the protective atmosphere is hydrogen (H 2 ).

Claim 10

Dependent Claim 38 words

The process of claim 2 wherein the first heating step is conducted at a temperature of about 1200° C. and said further heating step is conducted at gradually increasing temperatures between about 1200° C. to about 1550° C.

Claim 11

Dependent Claim 56 words

The process of claim 9 wherein the residence time within the first heating step is about one hour commencing when the powder mixture has reached a temperature of about 1200° C., and the residence time within the further heating step is about one hour commencing when the substrate has reached a temperature of about 1550° C.

Claim 12

Dependent Claim 14 words

The high density tungsten alloy sheet product produced by the process of claim 1.

Claim 13

Dependent Claim 150 words

A process for the manufacture of high density tungsten alloy sheet comprising the steps of: forming a substrate in sheet or foil form and containing iron (Fe) as a major portion of its composition; loading said substrate with a metal powder mixture containing predetermined amounts of tungsten (W) powder admixed with powder particles of at least nickel (Ni); heating said powder mixture and said substrate in a protective atmosphere at a temperature of about 1200° C. to form a partially consolidated tungsten-nickel skeleton partially bonded to the substrate; further heating said tungsten-nickel skeleton and said substrate in a protective atmosphere and gradually increasing the temperature within a range of from about 1200° C. up to about 1550° C., whereby said tungsten and nickel particles further consolidate and said substrate melts and infiltrates said tungsten-nickel skeleton to complete the densification thereof; and cooling said densified tungsten-nickel-iron sheet in a protective atmosphere.

Claim 14

Dependent Claim 150 words

A process for the manufacture of high density tungsten alloy sheet comprising the steps of: forming a substrate in sheet or foil form and containing iron (Fe) as a major portion of its composition; loading said substrate with a metal powder mixture containing predetermined amounts of tungsten (W) powder admixed with powder particles of at least nickel (Ni); heating said powder mixture and said substrate in a protective atmosphere at a temperature of about 1200° C. to form a partially consolidated tungsten-nickel skeleton partially bonded to the substrate; further heating said tungsten-nickel skeleton and said substrate in a protective atmosphere and gradually increasing the temperature within a range of from about 1200° C. up to about 1550° C., whereby said tungsten and nickel particles further consolidate and said substrate melts and infiltrates said tungsten-nickel skeleton to complete the densification thereof; and cooling said densified tungsten-nickel-iron sheet in a protective atmosphere.

Claim 15

Dependent Claim 42 words

The process of claim 12 including the steps of cooling said partially consolidated tungsten-nickel skeleton and substrate in a protective atmosphere after said first heating step and cutting said cooled skeleton and substrate into premeasured lengths prior to said further heating step.

Claim 16

Dependent Claim 13 words

The process of claim 12 wherein the substrate consists substantially of pure iron.

Claim 17

Dependent Claim 17 words

The process of claim 12 wherein the substrate consists substantially of an alloy of iron and nickel.

Claim 18

Dependent Claim 36 words

The process of claim 12 wherein the admixture of tungsten and nickel powders also contains a predetermined amount of metal powders selected from at least one of the group consisting of colbalt (Co) and molybdenum (Mo).

Claim 19

Dependent Claim 14 words

The high density tungsten alloy sheet product produced by the process of claim 12.

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

High density tungsten alloy sheet

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