US4915902A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Complex ceramic whisker formation in metal-ceramic composites
Assignee: Lockheed Martin Corp
•
Filing: 1988-02-17
•
Granted: 1990-04-10
•
Expires: 2008-02-17
Abstract
Abstract The present invention relates to the formation of whisker reinforced metal matrix composites in which complex boride or carbide whiskers are distributed throughout a metal, metal alloy, or intermetallic matrix. Exemplary complex boride whiskers include TiNbB, TiTaB, TiVB, NbHfB, and TiNbMoB. Exemplary complex carbide whiskers include TiNbC, TiVC, TiZrC, TiHfC, and TiTaC. A method for the in-situ formation of complex boride and complex carbide whiskers within metallic matrices is disclosed which involves reacting a mixture of individual complex ceramic-forming constituents in the presence of a metal to precipitate the desired complex ceramic whiskers in a metal matrix.
Inventors
- 👤 John M. Brupbacher
- 👤 Leontios Christodoulou
- 👤 Dennis C. Nagle
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-06 04:19
CPC Classifications
B; B22; B22F; B22F3/00; B22F3/23; B22F9/00; B22F9/02; B22F9/14; B23; B23K; B23K35/00; B23K35/22; B23K35/24; B23K35/32; B23K35/327; B23K35/40; B82; B82Y; B82Y30/00; C; C22; C22C; C22C1/00; C22C1/10; C22C1/1005; C22C1/1015; C22C1/1036; C22C1/1047; C22C1/1052; C22C1/1068; C22C29/00; C22C32/00; C22C47/00; C22C47/02; C22C47/06; C22C47/08; C22C49/00; C22C49/14
Claims Analysis
Total Claims: 74
Claim 1
Independent Claim
108 words
A method for the formation of complex boride whisker reinforced metal matrix composites, the method comprising precipitating whiskers of at least one complex boride material in a solvent metal matrix by contacting reactive complex boride-forming constituents and a solvent--,.metal at a temperature at which sufficient diffusion of at least one of the complex boride-forming constituents into the solvent metal occurs to cause a reaction of the complex boride-forming constituents to thereby precipitate complex boride whiskers in the solvent metal matrix, said complex boride comprising boron and at least two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W.
Claim 2
Independent Claim
108 words
A method for the formation of complex boride whisker reinforced metal matrix composites, the method comprising precipitating whiskers of at least one complex boride material in a solvent metal matrix by contacting reactive complex boride-forming constituents and a solvent--,.metal at a temperature at which sufficient diffusion of at least one of the complex boride-forming constituents into the solvent metal occurs to cause a reaction of the complex boride-forming constituents to thereby precipitate complex boride whiskers in the solvent metal matrix, said complex boride comprising boron and at least two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W.
Claim 3
Dependent Claim
18 words
The method of claim 1, wherein the complex boride-forming constituents are provided in the form of elemental powders.
Claim 4
Dependent Claim
23 words
The method of claim 1, wherein at least one of the complex boride-forming constituents is provided as an alloy of the solvent metal.
Claim 5
Independent Claim
22 words
The method of claim-,1 wherein at least one of the complex boride-forming constituents is provided as an intermetallic of the solvent metal.
Claim 6
Dependent Claim
23 words
The method of claim 1, wherein at least one of the complex boride-forming constituents is provided as a compound of the solvent metal.
Claim 7
Dependent Claim
21 words
The method of claim 1, wherein the complex boride whiskers are TiNbB, TiTaB, TiHfB, TiVB, NbHfB, TiNbMoB, or a combination thereof.
Claim 8
Dependent Claim
17 words
The method of claim 1, wherein the solvent metal matrix comprises a metal, metal alloy or intermetallic.
Claim 9
Dependent Claim
16 words
The method of claim 7, wherein the solvent metal matrix comprises aluminum, or an alloy thereof.
Claim 10
Dependent Claim
18 words
The method of claim 7, wherein the solvent metal matrix comprises an aluminide of titanium, nickel or niobium.
Claim 11
Dependent Claim
26 words
The method of claim 1, wherein the complex boride whiskers comprise from about 5 volume percent to about 80 volume percent of the metal matrix composite.
Claim 12
Dependent Claim
21 words
The method of claim 1, wherein the complex boride whiskers range in diameter from about 1 micron to about 5 microns.
Claim 13
Dependent Claim
21 words
The method of claim 11, wherein the complex boride whiskers range in length from about 5 microns to about 200 microns.
Claim 14
Dependent Claim
21 words
The method of claim 1, wherein the complex boride whiskers range in diameter from about 1 micron to about 3 microns.
Claim 15
Dependent Claim
21 words
The method of claim 13, wherein the complex boride whiskers range in length from about 5 microns to about 50 microns.
Claim 16
Independent Claim
109 words
A method for the formation of complex carbide whisker reinforced metal matrix composites, the method comprising precipitating whiskers of at least one complex carbide material in a solvent metal matrix by contacting reactive complex carbide-forming constituents and a solvent metal at a temperature at which sufficient diffusion of at least one of the complex carbide-forming constituents into the solvent metal occurs to cause a reaction of the complex carbide-forming constituents to thereby precipitate complex carbide whiskers in the solvent metal matrix, said complex carbide comprising carbon and at least two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W.
Claim 17
Independent Claim
109 words
A method for the formation of complex carbide whisker reinforced metal matrix composites, the method comprising precipitating whiskers of at least one complex carbide material in a solvent metal matrix by contacting reactive complex carbide-forming constituents and a solvent metal at a temperature at which sufficient diffusion of at least one of the complex carbide-forming constituents into the solvent metal occurs to cause a reaction of the complex carbide-forming constituents to thereby precipitate complex carbide whiskers in the solvent metal matrix, said complex carbide comprising carbon and at least two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W.
Claim 18
Dependent Claim
18 words
The method of claim 15, wherein the complex carbide-forming constituents are provided in the form of elemental powders.
Claim 19
Dependent Claim
23 words
The method of claim 15, wherein at least one of the complex carbide-forming constituents is provided as an alloy of the solvent metal.
Claim 20
Dependent Claim
23 words
The method of claim 15, wherein at least one of the complex carbide-forming constituents is provided as an intermetallic of the solvent metal.
Claim 21
Dependent Claim
23 words
The method of claim 15, wherein at least one of the complex carbide-forming constituents is provided as a compound of the solvent metal.
Claim 22
Dependent Claim
20 words
The method of claim 15, wherein the complex carbide whiskers are TiNbC, TiVC, TiZrC, TiHfC, TiTaC, or a combination thereof.
Claim 23
Dependent Claim
17 words
The method of claim 15, wherein the solvent metal matrix comprises a metal, metal alloy or intermetallic.
Claim 24
Dependent Claim
16 words
The method of claim 21, wherein the solvent metal matrix comprises aluminum, or an alloy thereof.
Claim 25
Dependent Claim
18 words
The method of claim 21, wherein the solvent metal matrix comprises an aluminide of titanium, nickel or niobium.
Claim 26
Dependent Claim
26 words
The method of claim 15, wherein the complex carbide whiskers comprise from about 5 volume percent to about 80 volume percent of the metal matrix composite.
Claim 27
Dependent Claim
21 words
The method of claim 15, wherein the complex carbide whiskers range in diameter from about 1 micron to about 5 microns.
Claim 28
Dependent Claim
21 words
The method of claim 25, wherein the complex carbide whiskers range in length from about 5 microns to about 200 microns.
Claim 29
Dependent Claim
21 words
The method of claim 15, wherein the complex carbide whiskers range in diameter from about 1 micron to about 3 microns.
Claim 30
Dependent Claim
21 words
The method of claim 27, wherein the complex carbide whiskers range in length from about 5 microns to about 50 microns.
Claim 31
Independent Claim
130 words
A method for the formation of complex boride whiskers within a solvent metal matrix, wherein the complex boride comprises boron and at least, two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, the method comprising: (a) preparing a mixture comprising powders of reactive complex boride-forming constituents and a solvent metal in which at least one of the complex boride-forming constituents is more soluble than the complex boride phase; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent metal to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture and to form a distribution of complex boride whiskers within the solvent metal matrix; and (d) recovering a product.
Claim 32
Independent Claim
130 words
A method for the formation of complex boride whiskers within a solvent metal matrix, wherein the complex boride comprises boron and at least, two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, the method comprising: (a) preparing a mixture comprising powders of reactive complex boride-forming constituents and a solvent metal in which at least one of the complex boride-forming constituents is more soluble than the complex boride phase; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent metal to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture and to form a distribution of complex boride whiskers within the solvent metal matrix; and (d) recovering a product.
Claim 33
Dependent Claim
19 words
The method of claim 29, wherein the mixture is compressed to form a compact prior to the heating thereof.
Claim 34
Dependent Claim
14 words
The method of claim 30, wherein heating is achieved by bulk heating the compact.
Claim 35
Dependent Claim
18 words
The method of claim 30, wherein heating is achieved by igniting a substantially localized portion of the compact.
Claim 36
Dependent Claim
17 words
The method of claim 29, wherein heating is achieved by introducing the mixture into a plasma flame.
Claim 37
Dependent Claim
18 words
The method of claim 33, wherein the mixture is mechanically alloyed prior to introduction into the plasma flame.
Claim 38
Dependent Claim
15 words
The method of claim 29, wherein the complex boride-forming constituents are provided in elemental form.
Claim 39
Dependent Claim
23 words
The method of claim 29, wherein at least one of the complex boride-forming constituents is provided as an alloy of the solvent metal.
Claim 40
Dependent Claim
23 words
The method of claim 29, wherein at least one of the complex boride-forming constituents is provided as an intermetallic of the solvent metal.
Claim 41
Dependent Claim
23 words
The method of claim 29, wherein at least one of the complex boride-forming constituents is provided as a compound with the solvent metal.
Claim 42
Dependent Claim
21 words
The method of claim 29, wherein the complex boride whiskers are TiNbB, TiTaB, TiHfB, TiVB, NbHfB, TiNbMoB, or a combination thereof.
Claim 43
Dependent Claim
17 words
The method of claim 29, wherein the solvent metal matrix comprises a metal, metal alloy or intermetallic.
Claim 44
Dependent Claim
16 words
The method of claim 40, wherein the solvent metal matrix comprises aluminum, or an alloy thereof.
Claim 45
Dependent Claim
18 words
The method of claim 40, wherein the solvent metal matrix comprises an aluminide of titanium, nickel or niobium.
Claim 46
Dependent Claim
24 words
The method of claim 29, wherein the complex boride whiskers comprise from about 5 volume percent to about 80 volume percent of the product.
Claim 47
Dependent Claim
21 words
The method of claim 29, wherein the complex boride whiskers range in diameter from about 1 micron to about 5 microns.
Claim 48
Dependent Claim
21 words
The method of claim 44, wherein the complex boride whiskers range in length from about 5 microns to about 200 microns.
Claim 49
Dependent Claim
21 words
The method of claim 29, wherein the complex boride whiskers range in diameter from about 1 micron to about 3 microns.
Claim 50
Dependent Claim
21 words
The method of claim 46, wherein the complex boride whiskers range in length from about 5 microns to about 50 microns.
Claim 51
Independent Claim
129 words
A method for the formation of complex carbide whiskers within solvent metal matrix, wherein the complex carbide comprises carbon and at least too of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, the method comprising: (a) preparing a mixture comprising powders of reactive complex carbide-forming constituents and a solvent metal in which at least one of the complex carbide-forming constituents is more soluble than the complex carbide phase; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent metal to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture and to form a distribution of complex carbide whiskers within the solvent metal matrix; and (d) recovering a product.
Claim 52
Independent Claim
129 words
A method for the formation of complex carbide whiskers within solvent metal matrix, wherein the complex carbide comprises carbon and at least too of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, the method comprising: (a) preparing a mixture comprising powders of reactive complex carbide-forming constituents and a solvent metal in which at least one of the complex carbide-forming constituents is more soluble than the complex carbide phase; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent metal to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture and to form a distribution of complex carbide whiskers within the solvent metal matrix; and (d) recovering a product.
Claim 53
Dependent Claim
19 words
The method of claim 48, wherein he mixture is compressed to form a compact prior to the heating thereof.
Claim 54
Dependent Claim
14 words
The method of claim 49, wherein heating is achieved by bulk heating the compact.
Claim 55
Dependent Claim
18 words
The method of claim 49, wherein heating is achieved by igniting a substantially localized portion of the compact.
Claim 56
Dependent Claim
17 words
The method of claim 48, wherein heating is achieved by introducing the mixture into a plasma flame.
Claim 57
Dependent Claim
18 words
The method of claim 52, wherein the mixture is mechanically alloyed prior to introduction into the plasma flame.
Claim 58
Dependent Claim
15 words
The method of claim 48, wherein the complex carbide-forming constituents are provided in elemental form.
Claim 59
Dependent Claim
23 words
The method of claim 48, wherein at least one of the complex carbide-forming constituents is provided as an alloy of the solvent metal.
Claim 60
Dependent Claim
23 words
The method of claim 48, wherein at least one of the complex carbide-forming constituents is provided as an intermetallic of the solvent metal.
Claim 61
Dependent Claim
23 words
The method of claim 48, wherein at least one of the complex carbide-forming constituents is provided as a compound with the solvent metal.
Claim 62
Dependent Claim
20 words
The method of claim 48, wherein the complex carbide whiskers are TiNbC, TiVC, TiZrC, TiHfC, TiTaC, or a combination thereof.
Claim 63
Dependent Claim
17 words
The method of claim 48, wherein the solvent metal matrix comprises a metal, metal alloy or intermetallic.
Claim 64
Dependent Claim
16 words
The method of claim 59, wherein the solvent metal matrix comprises aluminum, or an alloy thereof.
Claim 65
Dependent Claim
18 words
The method of claim 59, wherein the solvent metal matrix comprises an aluminide of titanium, nickel or niobium.
Claim 66
Dependent Claim
24 words
The method of claim 48, wherein the complex carbide whiskers comprise from about 5 volume percent to about 80 volume percent of the product.
Claim 67
Dependent Claim
21 words
The method of claim 48, wherein the complex carbide whiskers range in diameter from about 1 micron to about 5 microns.
Claim 68
Dependent Claim
21 words
The method of claim 63, wherein the complex carbide whiskers range in length from about 5 microns to about 200 microns.
Claim 69
Dependent Claim
21 words
The method of claim 48, wherein the complex carbide whiskers range in diameter from about 1 micron to about 3 microns.
Claim 70
Dependent Claim
21 words
The method of claim 65, wherein the complex carbide whiskers range in length from about 5 microns to about 50 microns.
Claim 71
Independent Claim
147 words
A method for the formation of complex boride whiskers within a final metal matrix, wherein the complex boride comprises boron and at least two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, the method comprising: (a) preparing a mixture comprising powders of reactive complex boride-forming constituents and a solvent metal in which at least one of the complex boride-forming constituents is more soluble than the complex boride phase; (b) adding the mixture to a molten matrix metal, metal alloy or intermetallic at a temperature at which sufficient diffusion of at least one of the complex boride-forming constituents into the solvent metal occur to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture and to form a distribution of complex boride whiskers within the final metal matrix; and (d) recovering a product.
Claim 72
Independent Claim
147 words
A method for the formation of complex boride whiskers within a final metal matrix, wherein the complex boride comprises boron and at least two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, the method comprising: (a) preparing a mixture comprising powders of reactive complex boride-forming constituents and a solvent metal in which at least one of the complex boride-forming constituents is more soluble than the complex boride phase; (b) adding the mixture to a molten matrix metal, metal alloy or intermetallic at a temperature at which sufficient diffusion of at least one of the complex boride-forming constituents into the solvent metal occur to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture and to form a distribution of complex boride whiskers within the final metal matrix; and (d) recovering a product.
Claim 73
Independent Claim
147 words
A method for the formation of complex carbide whiskers within a final metal matrix, wherein the complex carbide comprises carbon and at least two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, the method comprising: (a) preparing a mixture comprising powders of reactive complex carbide-forming constituents and a solvent metal in which at least one of the complex carbide-forming constituents is more soluble than the complex carbide phase; (b) adding the mixture to a molten matrix metal, metal alloy or intermetallic at a temperature at which sufficient diffusion of at least one of the complex carbide-forming constituents into the solvent metal occurs to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture and to form a distribution of complex carbide whiskers within the final metal matrix; and (d) recovering a product.
Claim 74
Independent Claim
147 words
A method for the formation of complex carbide whiskers within a final metal matrix, wherein the complex carbide comprises carbon and at least two of the elements selected from the group consisting of Ti, Zr, Hf, V, Nb, Ta, Cr, Mo and W, the method comprising: (a) preparing a mixture comprising powders of reactive complex carbide-forming constituents and a solvent metal in which at least one of the complex carbide-forming constituents is more soluble than the complex carbide phase; (b) adding the mixture to a molten matrix metal, metal alloy or intermetallic at a temperature at which sufficient diffusion of at least one of the complex carbide-forming constituents into the solvent metal occurs to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture and to form a distribution of complex carbide whiskers within the final metal matrix; and (d) recovering a product.
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