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US4732778A
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Method for forming composite layer by laser irradiation upon aluminum alloy substrate surface of powder mixture containing metal carbide ceramic particles, silicon, and metal element forming inter metallic compound with silicon
Assignee: Toyota Motor Corp
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Filing: 1986-09-02
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Granted: 1988-03-22
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Expires: 2006-09-02
Abstract
Abstract In a method for forming a covering composite layer on the surface of an aluminum alloy substrate, a powder mixture containing ceramic carbide of a metal, silicon and a metal element which forms with silicon an inter metallic compound having a specific gravity comparable with that of the ceramic carbide is disposed upon the surface of the aluminum alloy substrate, and then the powder mixture so disposed is irradiated with a laser, so that the silicon and the metal element which forms the inter metallic compound with silicon in the powder mixture and a surface portion of the aluminum alloy substrate are melted and fused together. The silicon expedites uniform distribution of the ceramic carbide particles in a molten surface layer of the aluminum alloy substrate by producing a melt of the inter metallic compound having a specific gravity comparable with the ceramic carbide, thereby preventing segregation of the ceramic carbide particles due to specific gravity difference, while highly uniformly dispersing the ceramic carbide particles are carried by the inter metallic compound having affinity toward the aluminum alloy due to silicon component.
Inventors
- 👤 Minoru Kawasaki
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 20:48
CPC Classifications
B; B23; B23K; B23K35/00; B23K35/22; B23K35/24; B23K35/32; B23K35/327; B23K26/00; B23K26/20; B23K26/32; B23K26/34; B23K35/28; B23K35/286; C; C23; C23C; C23C26/00; C23C26/02; B23K2103/00; B23K2103/08; B23K2103/10; B23K2103/15; B23K2103/18
Claims Analysis
Total Claims: 21
Claim 1
Independent Claim
129 words
A method for forming a composite layer on the surface of an aluminum alloy substrate, comprising the steps of: (a) disposing a powder mixture containing a ceramic carbide of a metal, silicon and a metal element which forms with silicon an inter metallic compound having a specific gravity ratio of about 0.7 to about 2.0 relative to said ceramic carbide of a metal upon the surface of said aluminum alloy substrate; and: (b) irradiating with a laser said power mixture as disposed upon said surface of said aluminum alloy substrate, so as to melt said silicon and said metal element which forms said inter metallic compound with said silicon in said powder mixture and a surface portion of said aluminum alloy substrate and so as to fuse them together.
Claim 2
Independent Claim
129 words
A method for forming a composite layer on the surface of an aluminum alloy substrate, comprising the steps of: (a) disposing a powder mixture containing a ceramic carbide of a metal, silicon and a metal element which forms with silicon an inter metallic compound having a specific gravity ratio of about 0.7 to about 2.0 relative to said ceramic carbide of a metal upon the surface of said aluminum alloy substrate; and: (b) irradiating with a laser said power mixture as disposed upon said surface of said aluminum alloy substrate, so as to melt said silicon and said metal element which forms said inter metallic compound with said silicon in said powder mixture and a surface portion of said aluminum alloy substrate and so as to fuse them together.
Claim 3
Dependent Claim
49 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein said silicon and said metal element which forms an inter metallic compound with silicon are provided as a powder of an alloy of said silicon and said metal element.
Claim 4
Dependent Claim
33 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 2, wherein said metal element which forms an inter metallic compound with silicon is copper.
Claim 5
Dependent Claim
58 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein the content of said ceramic carbide of a metal included in said powder mixture is between about 0.1% and about 20%, and the content of silicon included in said powder mixture is between about 5% and about 95%.
Claim 6
Dependent Claim
58 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein the content of said ceramic carbide of a metal included in said powder mixture is between about 0.5% and about 15%, and the content of silicon included in said powder mixture is between about 7% and about 90%.
Claim 7
Dependent Claim
51 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein said powder mixture is disposed upon said surface of said aluminum alloy substrate by being supplied in loose powder form thereonto into the path of the beam produced by said laser.
Claim 8
Dependent Claim
55 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein the ratio of the specific gravity of said inter metallic compound formed by silicon and a metal to the specific gravity of said ceramic carbide of a metal is between about 0.8 and about 1.5.
Claim 9
Independent Claim
34 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to any one of claims 1 through 7, wherein said ceramic carbide of a metal is titanium carbide.
Claim 10
Dependent Claim
33 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 2, wherein said metal element which forms an inter metallic compound with silicon is molybdenum.
Claim 11
Dependent Claim
58 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 9, wherein the content of said ceramic carbide of a metal included in said powder mixture is between about 0.1% and about 20%, and the content of silicon included in said powder mixture is between about 5% and about 95%.
Claim 12
Dependent Claim
58 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 9, wherein the content of said ceramic carbide of a metal included in said powder mixture is between about 0.5% and about 15%, and the content of silicon included in said powder mixture is between about 7% and about 90%.
Claim 13
Dependent Claim
36 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 6, wherein a carrier inert gas is fed into said loose powder form supply of said powder mixture.
Claim 14
Dependent Claim
54 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 9, wherein the ratio of the specific gravity of said inter metallic compound formed by silicon and molybdenum to the specific gravity of said ceramic carbide of a metal is between about 0.8 and about 1.5.
Claim 15
Independent Claim
37 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to any one of claims 1, 2, or 9 through 13, wherein said ceramic carbide of a metal is molybdenum carbide.
Claim 16
Dependent Claim
40 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein said silicon and a said metal element which forms an inter metallic compound with silicon are provided as respective powders.
Claim 17
Dependent Claim
33 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 2, wherein said metal element which forms an inter metallic compound with silicon is Ta.
Claim 18
Dependent Claim
33 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 2, wherein said metal element which forms an inter metallic compound with silicon is W.
Claim 19
Dependent Claim
59 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein a mixture of said powder mixture and said surface portion of said aluminum alloy substrate, as fused and melted by said laser, is cooled and solidified principally by heat conduction to the main body of said aluminum alloy substrate.
Claim 20
Dependent Claim
45 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein said irradiation of said powder mixture as disposed upon said surface of said aluminum alloy substrate by said laser is performed in an inert atmosphere.
Claim 21
Dependent Claim
43 words
A method for forming a composite layer on the surface of an aluminum alloy substrate according to claim 1, wherein said powder mixture is disposed upon said surface of said aluminum alloy substrate by being applied thereon as a paste including a binder.
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) | 1991-03-22 | 1991-09-21 | 1992-03-22 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1995-03-22 | 1995-09-21 | 1996-03-22 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 1999-03-22 | 1999-09-21 | 2000-03-22 | $7700.00 | Window Closed / Lapsed |