US4836982A — Rapid solidification of metal-second phase compos…

Claim 1

Independent Claim 147 words

A method for the production of metalsecond phase composition materials containing a second phase, said method comprising precipitating at least one second phase material in a metal matrix by contacting reactive second phase forming constituents, in the presence of a substantially non-reactive solvent matrix metal in which the second phase forming constituents are more soluble that the second phase, at a temperature at which sufficient diffusion of said constituents into the solvent matrix metal occurs, to cause reaction of the reactive second phase forming constituents to increase the temperature to a temperature exceeding the melting temperature of the matrix metal, to precipitate the second phase in the solvent matrix metal, rapidly quenching the metal-second phase composite material at a rate in the range of approximately 10 4 ° C. per second to 10 8 ° C. per second and recovering a rapidly solidified metal-second phase composite material.

Claim 2

Independent Claim 147 words

A method for the production of metalsecond phase composition materials containing a second phase, said method comprising precipitating at least one second phase material in a metal matrix by contacting reactive second phase forming constituents, in the presence of a substantially non-reactive solvent matrix metal in which the second phase forming constituents are more soluble that the second phase, at a temperature at which sufficient diffusion of said constituents into the solvent matrix metal occurs, to cause reaction of the reactive second phase forming constituents to increase the temperature to a temperature exceeding the melting temperature of the matrix metal, to precipitate the second phase in the solvent matrix metal, rapidly quenching the metal-second phase composite material at a rate in the range of approximately 10 4 ° C. per second to 10 8 ° C. per second and recovering a rapidly solidified metal-second phase composite material.

Claim 3

Dependent Claim 23 words

The method of claim 1, wherein the rapid quenching is accomplished by depositing the metal-second phase material against a rapidly moving quench surface.

Claim 4

Dependent Claim 20 words

The method of claim 1, wherein the rapid quenching is accomplished by atomizing the metal-second phase material to form droplets.

Claim 5

Dependent Claim 14 words

The method of claim 3, wherein said droplets are subjected to a coolant shower.

Claim 6

Dependent Claim 14 words

The method of claim 3, wherein said droplets are deposited in a cooling bath.

Claim 7

Dependent Claim 11 words

The method of claim 1, wherein the reaction is substantially complete.

Claim 8

Dependent Claim 22 words

The method of claim 1, wherein the reactive second phase forming constituents and the solvent metal are each provided as individual elements.

Claim 9

Dependent Claim 22 words

The method as set forth in claim 1, wherein the second phase forming constituents and the solvent metal are provided as powders.

Claim 10

Dependent Claim 24 words

The method of claim 1, wherein the second phase forming constituents and the solvent metal are provided as powders that are premixed and compacted.

Claim 11

Dependent Claim 11 words

The method of claim 1, wherein the second phase is particulate.

Claim 12

Dependent Claim 22 words

The method of claim 10, wherein the particulate second phase is titanium diboride, zirconium diboride, zirconium disilicide, titanium oxide, or titanium nitride.

Claim 13

Dependent Claim 13 words

The method of claim 11, wherein the second phase is submicron in size.

Claim 14

Dependent Claim 21 words

The method of claim 1, wherein the second phase forming constituents are each provided as an alloy of said solvent metal.

Claim 15

Dependent Claim 21 words

The method of claim 13, wherein the second phase forming constituents in the solvent matrix metal are contacted in stoichiometric proportions.

Claim 16

Dependent Claim 34 words

The method of claim 1, wherein at least one second phase forming constituent is provided as an alloy of the solvent metal, and the other second phase forming constituents are provided as individual elements.

Claim 17

Dependent Claim 23 words

The method of claim 1, wherein an additional alloying material is added to dioxidize the solvent metal matrix prior to the rapid quenching.

Claim 18

Dependent Claim 21 words

The method of claim 1, wherein additional alloying material is introduced to the solvent matrix metal prior to the rapid quenching.

Claim 19

Dependent Claim 23 words

The method of claim 17, wherein the concentration of the second phase is from about 0.1 to less than about 30 volume percent.

Claim 20

Dependent Claim 30 words

The method of claim 17, wherein the solvent metal matrix and the second phase forming constituents are added incrementally to the solvent matrix metal or alloy prior to rapid quenching.

Claim 21

Dependent Claim 27 words

The method of claim 17, wherein the solvent metal matrix with the second phase precipitated therein is added to a metal or alloy prior to rapid quenching.

Claim 22

Dependent Claim 27 words

The method of claim 1, wherein the solvent matrix metal with the second phase precipitated therein is added to a metal or alloy prior to rapid quenching.

Claim 23

Dependent Claim 21 words

The method of claim 21, wherein additional alloying material is introduced to the second phase containing material prior to rapid quenching.

Claim 24

Dependent Claim 30 words

The method of claim 1, wherein the solvent metal matrix and the second phase forming constituents are added incrementally to the solvent matrix metal or alloy prior to rapid quenching.

Claim 25

Dependent Claim 21 words

The method of claim 23, wherein additional alloying material is introduced to the second phase containing material prior to rapid quenching.

Claim 26

Dependent Claim 12 words

The method of claim 1, wherein the second phase is a ceramic.

Claim 27

Dependent Claim 12 words

The method of claim 1, wherein the second phase is an intermetallic.

Claim 28

Dependent Claim 15 words

The method of claim 1, wherein the composite contains additional particles precipitated during rapid quenching.

Claim 29

Dependent Claim 15 words

The method of claim 1, wherein the composite contains additional precipitate developed by scavenging interstitials.

Claim 30

Independent Claim 130 words

A method for precipitation of a second phase in a metallic matrix, the method comprising steps of: (a) preparing a mixture of reactive second phase forming constituents and a substantially nonreactive solvent matrix metal in which the second phase forming constituents are more soluble than the second phase; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent matrix metal to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture consuming the second phase forming constituents, and to form a uniform distribution of second phase particles; (d) rapidly quenching the mixture at a rate in the range of approximately 10 4 ° C. per second to 10 8 ° C. per second; and (e) recovering a rapidly solidified product.

Claim 31

Independent Claim 130 words

A method for precipitation of a second phase in a metallic matrix, the method comprising steps of: (a) preparing a mixture of reactive second phase forming constituents and a substantially nonreactive solvent matrix metal in which the second phase forming constituents are more soluble than the second phase; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent matrix metal to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture consuming the second phase forming constituents, and to form a uniform distribution of second phase particles; (d) rapidly quenching the mixture at a rate in the range of approximately 10 4 ° C. per second to 10 8 ° C. per second; and (e) recovering a rapidly solidified product.

Claim 32

Dependent Claim 27 words

The method of claim 29, wherein at least one second phase forming constituent is a transition metal of the third to sixth groups of the Periodic Table.

Claim 33

Dependent Claim 20 words

The method of claim 29, wherein the second phase is an oxide, nitride, boride, carbide, silicide, oxynitride, sulfide or oxysulfide.

Claim 34

Dependent Claim 52 words

The method of claim 29, wherein at least one second phase forming constituent is aluminum, titanium, silicon, boron, carbon, sulfur, tantalum, thorium, yttrium, cobalt, nickel, molybdenum, tungsten, vanadium, zirconium, niobium, hafnium, magnesium, scandium, lanthanum, chromium, oxygen, nitrogen, lithium, beryllium, iron, manganese, zinc, tin copper, silver, gold, platinum, or a rare earth element.

Claim 35

Dependent Claim 43 words

The method of claim 32, wherein said solvent metal is aluminum, nickel, titanium, copper, vanadium, chromium, manganese, cobalt, iron, silicon, molybdenum, beryllium, silver, gold, platinum, ruthenium, niobium, tantalum, hafnium, zirconium, magnesium, lead, zinc, tin, tungsten, antimony, bismuth, or an alloy of such metals.

Claim 36

Dependent Claim 20 words

The method of claim 29, wherein the second phase forming constituents and the solvent metal are provided as individual elements.

Claim 37

Dependent Claim 13 words

The method of claim 29, wherein said reaction takes place in liquid state.

Claim 38

Dependent Claim 43 words

The method of claim 35, wherein the solvent metal is aluminum, nickel, titanium, copper vanadium, chromium, manganese, cobalt, iron, silicon, molybdenum, beryllium, ruthenium, silver, gold platinum, niobium, tantalum, hafnium, zirconium, magnesium, lead, zinc, tin, tungsten, antimony, bismuth, or an alloy of such metals.

Claim 39

Dependent Claim 52 words

The method of claim 36, wherein at least one second phase forming constituent is aluminum, titanium, silicon, boron, carbon, sulfur, tantalum, thorium, yttrium, cobalt, nickel, molybdenum, tungsten, vanadium, zirconium, niobium, hafnium, magnesium, scandium, lanthanum, chromium, oxygen, nitrogen, lithium, beryllium, iron, manganese, zinc, tin, copper, silver, gold, platinum, or a rare earth element.

Claim 40

Dependent Claim 26 words

The method of claim 37, wherein at least one other second phase forming constituent is titanium diboride, zirconium diboride, zirconium disilicide, titanium oxide, or titanium nitride.

Claim 41

Dependent Claim 21 words

The method of claim 29, wherein the second phase forming constituents are each provided as an alloy of the solvent metal.

Claim 42

Dependent Claim 43 words

The method of claim 39, wherein said solvent metal is aluminum, nickel, titanium, copper, vanadium, chromium, manganese, cobalt, iron, silicon, molybdenum, beryllium, ruthenium, silver, gold platinum, niobium, tantalum, hafnium, zirconium, magnesium, lead, zinc, tin, tungsten, antimony, bismuth, or an alloy of such metals.

Claim 43

Dependent Claim 55 words

The method of claim 40, wherein said second phase forming constituents are selected from the group consisting of aluminum, titanium, silicon, boron, carbon, sulfur, tantalum, thorium, yttrium, cobalt, nickel, molybdenum, tungsten, vanadium, zirconium, niobium, hafnium, magnesium, scandium, lanthanum, chromium, oxygen, nitrogen, lithium, beryllium, iron, manganese, zinc, tin, copper, silver, gold, platinum and rare earth elements.

Claim 44

Dependent Claim 34 words

The method of claim 29, wherein at least one second phase forming constituent is provided as an individual element, and the other second phase forming constituents are provided as alloys of the solvent metal.

Claim 45

Dependent Claim 43 words

The method of claim 42, wherein said solvent metal is aluminum, nickel, titanium, copper, vanadium, chromium, manganese, cobalt, iron, silicon, molybdenum, beryllium, ruthenium, silver, gold, platinum, niobium, tantalum, hafnium, zirconium, magnesium, lead, zinc, tin, tungsten, ontimony, bismuth, or an alloy of such metals.

Claim 46

Dependent Claim 55 words

The method of claim 43, wherein said second phase forming constituents are selected from the group consisting of aluminum, titanium, silicon, boron, carbon, sulfur, tantalum, thorium, yttrium, cobalt, nickel, molybdenum, tungsten, vanadium, zirconium, niobium, hafnium, magnesium, scandium, lanthanum, chromium, oxygen, nitrogen, lithium, beryllium, iron manganese, zinc, tin, copper, silver, gold, platinum and rare earth elements.

Claim 47

Dependent Claim 19 words

The method of claim 29, wherein the second phase forming constituent is boron nitride, boron carbide, or boron oxide.

Claim 48

Dependent Claim 12 words

The method of claim 29, wherein the second phase is a ceramic.

Claim 49

Dependent Claim 12 words

The method of claim 29, wherein the second phase is an intermetallic.

Claim 50

Dependent Claim 27 words

The method of claim 29, wherein the solvent matrix metal with the second phase precipitated therein is added to a metal or alloy prior to rapid quenching.

Claim 51

Dependent Claim 29 words

The method of claim 29, wherein the solvent metal matrix and the second phase forming constituents are added to a solvent matrix metal or alloy prior to rapid quenching.

Claim 52

Dependent Claim 19 words

The method of claim 29, wherein the second phase forming constituents and the solvent metal are provided as powders.

Claim 53

Dependent Claim 24 words

The method of claim 29, wherein the second phase forming constituents and the solvent metal are provided as powders that are premixed and compacted.

Claim 54

Independent Claim 159 words

A method for dispersion of second phase dispersoids in a metal matrix, the method comprising forming a reaction mixture of reactive second phase forming constituents in the presence of at least two metals, at least one of which acts as a solvent metal, in which second phase forming constituents are more soluble than the second phase dispersoids, raising the temperature of the reaction mixture to a temperature at which sufficient diffusion of the second phase forming constituents into the lowest melting solvent metal occurs to initiate a reaction of the constituents, whereby the exothermic heat of reaction of the constituents causes the temperature of the reaction mixture to exceed the melting point of the higher melting point metal permitting dispersion of the second phase dispersoid in an alloy thereof, rapidly quenching the mixture at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second and recovering a rapidly solidified product.

Claim 55

Independent Claim 159 words

A method for dispersion of second phase dispersoids in a metal matrix, the method comprising forming a reaction mixture of reactive second phase forming constituents in the presence of at least two metals, at least one of which acts as a solvent metal, in which second phase forming constituents are more soluble than the second phase dispersoids, raising the temperature of the reaction mixture to a temperature at which sufficient diffusion of the second phase forming constituents into the lowest melting solvent metal occurs to initiate a reaction of the constituents, whereby the exothermic heat of reaction of the constituents causes the temperature of the reaction mixture to exceed the melting point of the higher melting point metal permitting dispersion of the second phase dispersoid in an alloy thereof, rapidly quenching the mixture at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second and recovering a rapidly solidified product.

Claim 56

Dependent Claim 22 words

The method of claim 52, wherein said higher melting solvent metal is cobalt, chromium, nickel, niobium, tantalum, titanium, vanadium, iron, or silicon.

Claim 57

Dependent Claim 19 words

The method of claim 53, wherein said lowest melting solvent metal is aluminum, copper, tin, zinc, lead or magnesium.

Claim 58

Dependent Claim 21 words

The method of claim 52, wherein additional alloying material is introduced to the solvent matrix metal prior to the rapid quenching.

Claim 59

Dependent Claim 12 words

The method of claim 52, wherein the second phase is a ceramic.

Claim 60

Dependent Claim 21 words

The method of claim 56, wherein additional alloying material is introduced to the solvent matrix metal prior to the rapid quenching.

Claim 61

Independent Claim 160 words

A method for dispersion of second phase dispersoids in a metal matrix, the method comprising forming a reaction mixture of reactive second phase forming constituents in the presence of at least two metals, at least one of which acts as a solvent metal, in which second phase forming constituents are more soluble than the second phase dispersoids, raising the temperature of the reaction mixture to a temperature at which sufficient diffusion of the second phase forming constituents into the lowest melting solvent metal occurs to initiate a reaction of the constituents, whereby the exothermic heat of reaction of the constituents causes the temperature of the reaction mixture to exceed the melting point of the lowest melting point metal permitting dispersion of the second phase dispersoid in a mixed metal matrix, rapidly quenching the mixture at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second and recovering a rapidly solidified product.

Claim 62

Independent Claim 160 words

A method for dispersion of second phase dispersoids in a metal matrix, the method comprising forming a reaction mixture of reactive second phase forming constituents in the presence of at least two metals, at least one of which acts as a solvent metal, in which second phase forming constituents are more soluble than the second phase dispersoids, raising the temperature of the reaction mixture to a temperature at which sufficient diffusion of the second phase forming constituents into the lowest melting solvent metal occurs to initiate a reaction of the constituents, whereby the exothermic heat of reaction of the constituents causes the temperature of the reaction mixture to exceed the melting point of the lowest melting point metal permitting dispersion of the second phase dispersoid in a mixed metal matrix, rapidly quenching the mixture at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second and recovering a rapidly solidified product.

Claim 63

Dependent Claim 21 words

The method of claim 58, wherein additional alloying material is introduced to the solvent matrix metal prior to the rapid quenching.

Claim 64

Dependent Claim 12 words

The method of claim 58, wherein the second phase is a ceramic.

Claim 65

Dependent Claim 12 words

The method of claim 58, wherein the second phase is an intermetallic.

Claim 66

Independent Claim 129 words

A method for the in-situ precipitation of at least one intermetallic material in a metallic matrix, comprising the steps of: (a) preparing a mixture of reactive intermetallic forming constituents and a nonreactive solvent matrix metal in which the intermetallic forming constituents are more soluble than the intermetallic material; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent matrix metal; (c) permitting the resultant exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the matrix metal and to consume the intermetallic forming constituents; (d) rapidly quenching the mixture at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second; and (e) recovering a rapidly solidified product.

Claim 67

Independent Claim 129 words

A method for the in-situ precipitation of at least one intermetallic material in a metallic matrix, comprising the steps of: (a) preparing a mixture of reactive intermetallic forming constituents and a nonreactive solvent matrix metal in which the intermetallic forming constituents are more soluble than the intermetallic material; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent matrix metal; (c) permitting the resultant exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the matrix metal and to consume the intermetallic forming constituents; (d) rapidly quenching the mixture at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second; and (e) recovering a rapidly solidified product.

Claim 68

Dependent Claim 42 words

The method of claim 62, wherein at least one intermetallic forming constituent ins aluminum, magnesium, chromium, manganese, iron, cobalt, copper, zinc, titanium, silicon, nickel, vanadium, molybdenum, niobium, beryllium, tin, silver, gold, hafnium, thorium, tungsten, zirconium, yttrium scandium, lanthanum, tantalum, platinum or lithium.

Claim 69

Dependent Claim 43 words

The method of claim 63, wherein said solvent metal is aluminum, nickel, titanium, copper, vanadium, chromium, manganese, cobalt, iron, silicon, molybdenum, beryllium, ruthenium, silver, gold, platinum, niobium, tantalum, hafnium, zirconium, magnesium, lead, zinc, tin, tungsten, antimony, bismuth, or an alloy of such metals.

Claim 70

Independent Claim 129 words

A method for the in-situ precipitation of at least one ceramic material in a metallic matrix, comprising the steps of: (a) preparing a mixture of reactive ceramic forming constituents and a non-reactive solvent matrix metal in which the ceramic forming constituents are more soluble than the ceramic material; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent matrix metal; (c) permitting the resultant exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the matrix metal and to consume the ceramic forming constituents; (d) rapidly quenching the mixture at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second; and (e) recovering a rapidly solidified product.

Claim 71

Independent Claim 129 words

A method for the in-situ precipitation of at least one ceramic material in a metallic matrix, comprising the steps of: (a) preparing a mixture of reactive ceramic forming constituents and a non-reactive solvent matrix metal in which the ceramic forming constituents are more soluble than the ceramic material; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent matrix metal; (c) permitting the resultant exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the matrix metal and to consume the ceramic forming constituents; (d) rapidly quenching the mixture at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second; and (e) recovering a rapidly solidified product.

Claim 72

Independent Claim 152 words

A method for the in-situ precipitation of dispersoid particles of an intermetallic material and a ceramic material in a metal matrix, the method comprising the steps of: (a) preparing a mixture of reactive intermetallic and ceramic forming constituents and a substantially non-reactive solvent matrix metal in which the intermetallic forming constituents and the ceramic forming constituents are more soluble than the intermetallic or the ceramic material respectively; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent matrix metal; (c) initiating an exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the matrix metal and to consume the intermetallic forming constituents and the ceramic forming constituents; (d) rapidly quenching the mix at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second; and (e) recovering a rapidly solidified product.

Claim 73

Independent Claim 152 words

A method for the in-situ precipitation of dispersoid particles of an intermetallic material and a ceramic material in a metal matrix, the method comprising the steps of: (a) preparing a mixture of reactive intermetallic and ceramic forming constituents and a substantially non-reactive solvent matrix metal in which the intermetallic forming constituents and the ceramic forming constituents are more soluble than the intermetallic or the ceramic material respectively; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent matrix metal; (c) initiating an exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the matrix metal and to consume the intermetallic forming constituents and the ceramic forming constituents; (d) rapidly quenching the mix at a rate in the range approximately 10 4 ° C. per second to 10 8 ° C. per second; and (e) recovering a rapidly solidified product.

Claim 74

Dependent Claim 59 words

The method of claim 66, wherein the intermetallic forming constitutents and the ceramic forming constituents are selected from the group consisting of aluminum, titanium, silicon, boron, carbon, sulfur, tantalum, thorium, yttrium, cobalt, nickel, molybdenum, tungsten, vanadium, zirconium, niobium, hafnium, magnesium, scandium, lanthanum, chromium, oxygen, nitrogen, lithium, beryllium, iron, manganese, zinc, tin, copper, silver, golf, platinum, and rare earth elements.

Claim 75

Dependent Claim 42 words

The method of claim 67, wherein said solvent metal is aluminum, nickel, titanium, copper, vanadium, chromium, manganese, cobalt, iron, silicon, molybdenum, beryllium, silver, gold, platinum, niobium, tantalum, hafnium, zirconium, magnesium, lead, zinc, tin, tungsten, antimony, bismuth, or an alloy of such metals.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1992-06-05	1992-12-05	1993-06-06	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1996-06-05	1996-12-05	1997-06-06	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2000-06-05	2000-12-05	2001-06-06	$7700.00	Window Closed / Lapsed

Rapid solidification of metal-second phase composites

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