US4915903A
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Process for forming composites having an intermetallic containing matrix
Assignee: Lockheed Martin Corp
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Filing: 1988-05-05
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Granted: 1990-04-10
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Expires: 2008-05-05
Abstract
Abstract A method is taught for the formation of intermetallic-second phase composite materials. The method involves the formation of a first metal-second phase composite comprising a relatively high loading of discrete, second phase particles distributed throughout a metal matrix, dilution of the first composite into an additional amount of metal to form a second composite comprising a lower loading of second phase particles within an intermediate metal matrix, and introduction of the second composite into another metal which is reactive with the intermediate metal matrix of the composite to form an intermetallic. A final intermetallic-second phase composite is thereby formed comprising a dispersion of discrete second phase particles throughout a final intermetallic matrix. The final intermetallic matrix may comprise a wide variety of intermetallic materials, with particular emphasis drawn to the aluminides and silicides. Exemplary intermetallics include Ti 3 Al, TiAl, TiAl 3 , Ni 3 Al, NiAl, Nb 3 Al, NbAl 3 , Co 3 Al, Zr 3 Al, Fe 3 Al, Ta 2 Al, TaAl 3 , Ti 5 Si 3 , Nb 5 Si 3 , Cr 3 Si, CoSi 2 and Cr 2 Nb. The second phase particulate materials may comprise ceramics, such as a borides, carbides, nitrides, oxides, silicides or sulfides, or may comprise an intermetallic other than the matrix intermetallic. Exemplary second phase particulates include TiB 2 , ZrB 2 , HfB 2 , VB 2 , NbB 2 , TaB 2 , MoB 2 , TiC, ZrC, HfC, VC, NbC, TaC, WC, TiN, Ti 5 Si 3 , Nb 5 Si 3 , ZrSi 2 , MoSi 2 , and MoS 2 .
Inventors
- 👤 John M. Brupbacher
- 👤 Leontios Christodoulou
- 👤 Dennis C. Nagle
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-02 11:51
CPC Classifications
C; C22; C22C; C22C1/00; C22C1/04; C22C1/05; C22C1/051; 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; C22C1/10; C22C1/1005; C22C1/1015; C22C1/1036; C22C1/1047; C22C1/1052; C22C1/1068; C22C29/00; C22C32/00; C22C32/0047; C22C32/0078; C22C47/00; C22C47/02; C22C47/06; C22C47/08; C22C49/00; C22C49/14; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12486
Claims Analysis
Total Claims: 54
Claim 1
Independent Claim
117 words
A method for forming intermetallic-second phase composite materials, the method comprising contacting reactive second phase-forming constituents and a solvent metal at a temperature sufficient to initiate an exothermic reaction of the second phase-forming constituents to thereby form a first composite comprising a dispersion of second phase particles within a solvent metal matrix, introducing the first composite into a host metal to form a second composite comprising a dispersion of the second phase particles within an intermediate metal matrix, introducing the second composite into an intermetallic precursor metal which is reactive with the intermediate metal matrix to form an intermetallic containing matrix, and recovering a final composite comprising an intermetallic containing matrix having second phase particles dispersed therein.
Claim 2
Independent Claim
117 words
A method for forming intermetallic-second phase composite materials, the method comprising contacting reactive second phase-forming constituents and a solvent metal at a temperature sufficient to initiate an exothermic reaction of the second phase-forming constituents to thereby form a first composite comprising a dispersion of second phase particles within a solvent metal matrix, introducing the first composite into a host metal to form a second composite comprising a dispersion of the second phase particles within an intermediate metal matrix, introducing the second composite into an intermetallic precursor metal which is reactive with the intermediate metal matrix to form an intermetallic containing matrix, and recovering a final composite comprising an intermetallic containing matrix having second phase particles dispersed therein.
Claim 3
Dependent Claim
52 words
A method as set forth in claim 1, wherein said solvent metal is selected from the group consisting of aluminum, nickel, copper, titanium, cobalt, iron, platinum, gold, silver, niobium, tantalum, boron, lead, zinc, molybdenum, yttrium, hafnium, tin, tungsten, lithium, magnesium, beryllium, thorium, silicon, chromium, vanadium, zirconium, manganese, scandium, lanthanum, cerium and erbium.
Claim 4
Dependent Claim
52 words
A method as set forth in claim 1, wherein said host metal is selected from the group consisting of aluminum, nickel, copper, titanium, cobalt, iron, platinum, gold, silver, niobium, tantalum, boron, lead, zinc, molybdenum, yttrium, hafnium, tin, tungsten, lithium, magnesium, beryllium, thorium, silicon, chromium, vanadium, zirconium, manganese, scandium, lanthanum, cerium and erbium.
Claim 5
Dependent Claim
53 words
A method as set forth in claim 1, wherein said intermetallic precursor metal is selected from the group consisting of aluminum, nickel, copper, titanium, cobalt, iron, platinum, gold, silver, niobium, tantalum, boron, lead, zinc, molybdenum, yttrium, hafnium, tin, tungsten, lithium, magnesium, beryllium, thorium, silicon, chromium, vanadium, zirconium, manganese, scandiu, lanthanum, cerium and erbium.
Claim 6
Dependent Claim
47 words
A method as set forth in claim 1, wherein said second phase-forming constituents are selected from the group consisting of aluminum, titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum, tungsten, iron, cobalt, nickel, copper, silicon, boron, carbon, sulfur, nitrogen, oxygen, thorium, scandium, lanthanum, yttrium, cerium and erbium.
Claim 7
Dependent Claim
25 words
A method as set forth in claim 1, wherein the second phase-forming constituents and the solvent metal are provided in the form of elemental powders.
Claim 8
Dependent Claim
26 words
A method as set forth in claim 1, wherein at least one of the second phase-forming constituents is provided as an alloy of the solvent metal.
Claim 9
Dependent Claim
22 words
A method as set forth in claim 1, wherein at least one of the second phase-forming constituents is provided from a compound.
Claim 10
Dependent Claim
44 words
A method as set forth in claim 8, wherein the compound is selected from the group consisting of BN, B 4 C, B 2 O 3 , AlB 12 , Al 4 C 3 , AlN, SiC, CuO and Fe 2 O 3 .
Claim 11
Dependent Claim
22 words
A method as set forth in claim 1, wherein the intermetallic containing matrix comprises an aluminide of titanium, nickel, cobalt or niobium.
Claim 12
Dependent Claim
19 words
A method as set forth in claim 1, wherein the intermetallic containing matrix comprises a mixture of intermetallic materials.
Claim 13
Dependent Claim
22 words
A method as set forth in claim 1, wherein the intermetallic containing matrix comprises TiAl, Ti 3 Al, or a combination thereof.
Claim 14
Dependent Claim
21 words
A method as set forth in claim 1, wherein the intermetallic containing matrix comprises TiAl, TiAl 3 or a combination thereof.
Claim 15
Dependent Claim
42 words
A method as set forth in claim 1, wherein said second phase is selected from the group consisting of borides, carbides, nitrides, oxides, silicides and sulfides of at least one transition metal of the fourth to sixth groups of the Periodic Table.
Claim 16
Dependent Claim
15 words
A method as set forth in claim 1, wherein plural second phase materials are produced.
Claim 17
Dependent Claim
26 words
A method as set forth in claim 1, wherein the second phase particles comprise from about 20 to about 80 volume percent of the first composite.
Claim 18
Dependent Claim
26 words
A method as set forth in claim 16, wherein the second phase particles comprise from about 2 to about 60 volume percent of the second composite.
Claim 19
Dependent Claim
26 words
A method as set forth in claim 17, wherein the second phase particles comprise from about 1 to about 40 volume percent of the final composite.
Claim 20
Dependent Claim
24 words
A method as set forth in claim 18, wherein the size of the second phase particles is from about 0.01 to about 10 microns.
Claim 21
Dependent Claim
18 words
A method as set forth in claim 1, wherein the solvent metal is aluminum or an alloy thereof.
Claim 22
Dependent Claim
18 words
A method as set forth in claim 20, wherein the host metal is aluminum or an alloy thereof.
Claim 23
Dependent Claim
19 words
A method as set forth in claim 21, wherein the intermetallic precursor metal is titanium or an alloy thereof.
Claim 24
Dependent Claim
53 words
A method as set forth in claim 22, wherein one of the second phase-forming constituents is selected from the group consisting of boron, carbon, nitrogen, oxygen and silicon, and at least one other second phase-forming constituent is selected from the group consisting of titanium, zirconium, hafnium, vanadium, niobium, tantalum, chromium, molybdenum and tungsten.
Claim 25
Dependent Claim
28 words
A method as set forth in claim 1, wherein an additional amount of the solvent metal is introduced along with the second composite into the intermetallic precursor metal.
Claim 26
Dependent Claim
28 words
A method as set forth in claim 1, wherein an additional amount of the first composite is introduced along with the second composite into the intermetallic precursor metal.
Claim 27
Dependent Claim
25 words
A method as set forth in claim 1, wherein metal alloying additions are made during the introduction of the first composite into the host metal.
Claim 28
Dependent Claim
26 words
A method as set forth in claim 1, wherein metal alloying additions are made during the introduction of the second composite into the intermetallic precursor metal.
Claim 29
Independent Claim
109 words
A method for forming intermetallic-second phase composite materials, the method comprising the steps of: (a) introducing a first composite comprising a dispersion of in-situ precipitated second phase particles in a solvent metal matrix into a host metal which combines with the solvent metal matrix to form an intermediate metal matrix, to thereby form a second composite comprising a dispersion of the second phase particles within the intermediate metal matrix; (b) introducing the second composite into an intermetallic precursor metal which is reactive with the intermediate metal matrix to form an intermetallic; and (c) recovering a final composite comprising a dispersion of second phase particles within an intermetallic containing matrix.
Claim 30
Independent Claim
109 words
A method for forming intermetallic-second phase composite materials, the method comprising the steps of: (a) introducing a first composite comprising a dispersion of in-situ precipitated second phase particles in a solvent metal matrix into a host metal which combines with the solvent metal matrix to form an intermediate metal matrix, to thereby form a second composite comprising a dispersion of the second phase particles within the intermediate metal matrix; (b) introducing the second composite into an intermetallic precursor metal which is reactive with the intermediate metal matrix to form an intermetallic; and (c) recovering a final composite comprising a dispersion of second phase particles within an intermetallic containing matrix.
Claim 31
Independent Claim
126 words
A method for forming intermetallic-second phase composite materials, the method comprising the steps of: (a) preparing a mixture comprising reactive second phase-forming constituents and at least one solvent metal; (b) heating the mixture to initiate a reaction of the second phase-forming constituents, thereby forming a first composite comprising a dispersion of second phase particles within a solvent metal matrix; (c) diluting the first composite in a host metal, thereby forming a second composite comprising a dispersion of the second phase particles within an intermediate metal matrix; (d) introducing the second composite into an intermetallic precursor metal which is reactive with the intermediate metal matrix to form an intermetallic; and (e) recovering a final composite comprising a dispersion of second phase particles within an intermetallic containing matrix.
Claim 32
Independent Claim
126 words
A method for forming intermetallic-second phase composite materials, the method comprising the steps of: (a) preparing a mixture comprising reactive second phase-forming constituents and at least one solvent metal; (b) heating the mixture to initiate a reaction of the second phase-forming constituents, thereby forming a first composite comprising a dispersion of second phase particles within a solvent metal matrix; (c) diluting the first composite in a host metal, thereby forming a second composite comprising a dispersion of the second phase particles within an intermediate metal matrix; (d) introducing the second composite into an intermetallic precursor metal which is reactive with the intermediate metal matrix to form an intermetallic; and (e) recovering a final composite comprising a dispersion of second phase particles within an intermetallic containing matrix.
Claim 33
Dependent Claim
22 words
A method as set forth in claim 29, wherein the mixture is compressed to form a compact prior to the heating thereof.
Claim 34
Dependent Claim
18 words
A method as set forth in claim 30, wherein the heating is achieved by bulk heating the compact.
Claim 35
Dependent Claim
22 words
A method as set forth in claim 30, wherein the heating is achieved by igniting a substantially localized portion of the compact.
Claim 36
Dependent Claim
29 words
A method as set forth in claim 30, wherein the heating is achieved by adding the compact to a molten bath comprising an additional amount of the solvent metal.
Claim 37
Dependent Claim
31 words
A method as set forth in claim 29, wherein the first composite is diluted in the host metal by adding the first composite to a molten bath of the host metal.
Claim 38
Dependent Claim
51 words
A method as set forth in claim 29, wherein the first composite is diluted in the host metal by contacting the first composite and the host metal in solid form and then heating to a temperature sufficient to melt the solvent metal matrix of the first composite and the host metal.
Claim 39
Dependent Claim
23 words
A method as set forth in claim 35, wherein heating of the first composite and the host metal is achieved by arc melting.
Claim 40
Dependent Claim
33 words
A method as set forth in claim 29, wherein the second composite is introduced into the intermetallic precursor metal by adding the second composite to a molten bath of the intermetallic precursor metal.
Claim 41
Dependent Claim
53 words
A method as set forth in claim 29, wherein the second composite is introduced into the intermetallic precursor metal by contacting the second composite and the intermetallic precursor metal in solid form and then heating to a temperature sufficient to melt the intermediate metal matrix of the second composite and the host metal.
Claim 42
Dependent Claim
24 words
A method as set forth in claim 38, wherein heating of the second composite and the intermetallic precursor metal is achieved by arc melting.
Claim 43
Dependent Claim
27 words
A method as set forth in claim 29, wherein the intermetallic containing matrix comprises an aluminide of Ti, Ni, Co, Nb, Zr, Fe, Mo, V, or Ta.
Claim 44
Dependent Claim
24 words
A method as set forth in claim 29, wherein the intermetallic containing matrix comprises a silicide of Ti, Cr, Co, Ni, V, or Nb.
Claim 45
Dependent Claim
117 words
A method as set forth in claim 29, wherein the intermetallic containing matrix comprises at least one intermetallic selected from the group consisting of Ti 3 Al, TiAl, TiAl 3 , Ni 3 Al, NiAl, Nb 3 Al, NbAl 3 , Co 3 Al, ZrAl 3 , ZrAl 2 , Zr 2 Al 3 , Zr 4 Al 3 , Zr 3 Al 2 , Zr 3 Al, Fe 3 Al, Ta 2 Al, TaAl 3 , Mo 3 Al, MoAl 2 , VAl 3 , VAl, Ti 5 Si 3 , Nb 5 Si 3 , Cr 3 Si, Cr 2 Si, V 5 Si 3 , Ni 3 Si, CoSi 2 and Cr 2 Nb.
Claim 46
Dependent Claim
42 words
A method as set forth in claim 29, wherein said second phase is selected from the group consisting of borides, carbides, nitrides, oxides, silicides and sulfides of at least one transition metal of the fourth to sixth groups of the Periodic Table.
Claim 47
Dependent Claim
70 words
A method as set forth in claim 29, wherein said second phase is selected from the group consisting of TiB 2 , ZrB 2 , HfB 2 , VB 2 , NbB 2 , TaB 2 , MoB 2 , TiC, ZrC, HfC, VC, NbC, TaC, WC, TiN, Ti 5 Si 3 , Nb 5 Si 3 , ZrSi 2 , MoSi 2 , MoS 2 , and combinations thereof.
Claim 48
Dependent Claim
42 words
A method as set forth in claim 29, wherein said second phase comprises a complex compound selected from the group consisting of borides, carbides, or nitrides of at least two transition metals of the fourth to sixth groups of the Periodic Table.
Claim 49
Dependent Claim
26 words
A method as set forth in claim 29, wherein said second phase particles comprise from about 1 to about 40 volume percent of the final composite.
Claim 50
Dependent Claim
24 words
A method as set forth in claim 29, wherein the size of the second phase particles is from about 0.01 to about 10 microns.
Claim 51
Dependent Claim
23 words
A method as set forth in claim 29, wherein the intermetallic containing matrix has a grain size of less than about 200 microns.
Claim 52
Dependent Claim
23 words
A method as set forth in claim 29, wherein the intermetallic containing matrix has a grain size of less than about 40 microns.
Claim 53
Dependent Claim
22 words
A method as set forth in claim 29, wherein the second phase comprises TiB 2 and the intermetallic containing matrix comprises Ti-45Al.
Claim 54
Dependent Claim
21 words
A method as set forth in claim 29, wherein the second phase comprises TiC and the intermetallic containing matrix comprises Ti-45Al.
References Cited (Backward Citations)
US4710348A
Cited
US4774052A
Cited
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