US4985202A — Process for forming porous metal-second phase com…

Claim 1

Independent Claim 139 words

A method for the production of porous metal-second phase composite material, the method comprising precipitating at least one second phase material in a solvent metal by locally igniting a mixture comprising reactive second phase forming constituents and at least about 20 volume percent of a substantially nonreactive solvent metal in which the second phase-forming constituents are move soluble than the second phase material, substantially at or below atmospheric pressure and at a temperature at which sufficient diffusion of the reactive second phase forming constituents into the substantially nonreactive solvent metal occurs to cause a substantially isothermal second phase forming reaction of the constituents to thereby precipitant second phase particles in the solvent metal so as to produce a solid composite material having a porosity of at least 10 percent comprising finely divided second phase particles in the metal matrix.

Claim 2

Independent Claim 139 words

A method for the production of porous metal-second phase composite material, the method comprising precipitating at least one second phase material in a solvent metal by locally igniting a mixture comprising reactive second phase forming constituents and at least about 20 volume percent of a substantially nonreactive solvent metal in which the second phase-forming constituents are move soluble than the second phase material, substantially at or below atmospheric pressure and at a temperature at which sufficient diffusion of the reactive second phase forming constituents into the substantially nonreactive solvent metal occurs to cause a substantially isothermal second phase forming reaction of the constituents to thereby precipitant second phase particles in the solvent metal so as to produce a solid composite material having a porosity of at least 10 percent comprising finely divided second phase particles in the metal matrix.

Claim 3

Dependent Claim 20 words

The method as set forth in claim 1, wherein the temperature is about the melting temperature of the solvent metal.

Claim 4

Dependent Claim 26 words

The method as set forth in claim 1, wherein the reactive second phase-forming constituents and the substantially nonreactive solvent metal are each provided as individual elements.

Claim 5

Dependent Claim 19 words

The method as set forth in claim 1, wherein the second phase-forming reaction is initiated in the solid state.

Claim 6

Dependent Claim 18 words

The method as set forth in claim 1, wherein the second phase-forming reaction occurs in the liquid state.

Claim 7

Dependent Claim 23 words

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

Claim 8

Dependent Claim 19 words

The method as set forth in claim 6, wherein the second phase-forming reaction takes place in the liquid state.

Claim 9

Dependent Claim 20 words

The method as set forth in claim 1 wherein the mixture is compressed to a compact prior to local ignition.

Claim 10

Dependent Claim 35 words

The method as set forth in 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 11

Dependent Claim 27 words

The method as set forth in claim 1, wherein the particulate second phase is titanium diboride, zirconium diboride, zirconium disilicide, zirconium carbide, titanium carbide, or titanium nitride.

Claim 12

Dependent Claim 20 words

The method as set forth in claim 1, wherein the second phase in substantially less than 5 microns in size.

Claim 13

Dependent Claim 18 words

The method as set forth in claim 1, wherein the second phase-forming constituents are contacted in stoichiometric proportions.

Claim 14

Dependent Claim 18 words

The method as set forth in claim 1, wherein one second phase-forming constituent is present in stoichiometric excess.

Claim 15

Dependent Claim 15 words

The method as set forth in claim 1, wherein the second phase is a ceramic.

Claim 16

Dependent Claim 15 words

The method as set forth in claim 1, wherein the second phase is an intermetallic.

Claim 17

Dependent Claim 16 words

The method as set forth in claim 1, wherein the second phase is submicron in size.

Claim 18

Dependent Claim 22 words

The method as set forth in claim 1, wherein the concentration of solvent metal matrix is greater than 30 percent by volume.

Claim 19

Dependent Claim 24 words

The method as set forth in claim 1, further comprising recovering a porous metal-second phase composite material having a substantially uniform distribution of particles.

Claim 20

Dependent Claim 23 words

The method as set forth in claim 1, wherein the particle size of second phase particles is between about 0.1 and 3 microns.

Claim 21

Dependent Claim 22 words

The method as set forth in claim 1, wherein the metal-second phase composite material has a porosity of greater than 25 percent.

Claim 22

Dependent Claim 22 words

The method as set forth in claim 1, wherein the reactive second-phase forming constituents are shaped in the form of a rod.

Claim 23

Dependent Claim 22 words

The method as set forth in claim 1, wherein the reactive second-phase forming constituents are compressed in the shape of a rod.

Claim 24

Independent Claim 19 words

The method as set forth in claim, wherein the second phase particles are substantially encapsulated by solvent matrix metal.

Claim 25

Dependent Claim 17 words

The method as set forth in claim 1, wherein the reaction further comprises an isothermal wave front.

Claim 26

Independent Claim 131 words

A method for dispersion of a second phase in a metal, metal alloy, or intermetallic matrix, the method comprising steps of: (a) preparing a mixture of reactive second phase-forming constituents and at least about 20 volume percent of a nonreactive solvent metal in which the second phase-forming constituents are moe soluble that the second phase; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal to initiate a substantially isothermal reaction; (c) permitting the reaction wave front to propagate and to further heat the mixture, consuming the second phase-forming constituents, forming a distribution of second phase particles in the matrix; and (d) recovering a solid metal-second phase composite material having a porosity of at least 10 percent.

Claim 27

Independent Claim 131 words

A method for dispersion of a second phase in a metal, metal alloy, or intermetallic matrix, the method comprising steps of: (a) preparing a mixture of reactive second phase-forming constituents and at least about 20 volume percent of a nonreactive solvent metal in which the second phase-forming constituents are moe soluble that the second phase; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal to initiate a substantially isothermal reaction; (c) permitting the reaction wave front to propagate and to further heat the mixture, consuming the second phase-forming constituents, forming a distribution of second phase particles in the matrix; and (d) recovering a solid metal-second phase composite material having a porosity of at least 10 percent.

Claim 28

Dependent Claim 29 words

The method as set forth in claim 25, wherein at least one second phase-forming constituent is a transition metal of the third to sixth groups of the Periodic Table.

Claim 29

Dependent Claim 54 words

The method as set forth in claim 25, 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 30

Dependent Claim 45 words

The method as set forth in claim 27 wherein the 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.

Claim 31

Dependent Claim 22 words

The method as set forth in claim 25, wherein the second phase-forming constituents and the solvent metal are provided as individual elements.

Claim 32

Dependent Claim 17 words

The method as set forth in claim 29, wherein the reaction takes place in the liquid state.

Claim 33

Dependent Claim 29 words

The method as set forth in claim 30, wherein the solvent metal is aluminum, zinc, magnesium, copper, lead, nickel, chromium, iron, titanium, cobalt, or an alloy of such metals.

Claim 34

Dependent Claim 27 words

The method as set forth in claim 31, wherein at least one second phase-forming constituent is aluminum, silicon, titanium, hafnium, tantalum, zirconium, magnesium, vanadium, nickel, or tungsten.

Claim 35

Dependent Claim 23 words

The method as set forth in claim 32, wherein at least one other second phase-forming constituent is aluminum, boron, silicon, nitrogen, or carbon.

Claim 36

Dependent Claim 18 words

The method as set forth in claim 33, wherein the solvent metal is aluminum or an alloy thereof.

Claim 37

Dependent Claim 18 words

The method as set forth in claim 34, wherein the second phase is titanium diboride or titanium carbide.

Claim 38

Dependent Claim 23 words

The method as set forth in claim 25, wherein the second phase-forming constituents are each provided as an alloy of the solvent metal.

Claim 39

Dependent Claim 29 words

The method as set forth in claim 36, wherein the solvent metal is aluminum, zinc, magnesium, copper, lead, nickel, chromium, iron, titanium, cobalt, or an alloy of such metals.

Claim 40

Dependent Claim 31 words

The method as set forth in claim 37, wherein the second phase-forming constituents are selected from aluminum, hafnium, tantalum , vanadium, nickel, tungsten, titanium, zirconium, magnesium, boron, silicon, nitrogen, and carbon.

Claim 41

Dependent Claim 18 words

The method as set forth in claim 36 wherein the solvent metal is aluminum or an alloy thereof.

Claim 42

Dependent Claim 24 words

The method as set forth in claim 39, wherein the second phase-forming constituents are selected from aluminum, titanium, zirconium, magnesium, boron, silicon, or carbon.

Claim 43

Dependent Claim 29 words

The method as set forth in claim 36, wherein the second phase material is titanium diboride or titanium carbide and the solvent metal is aluminum or an alloy thereof.

Claim 44

Dependent Claim 38 words

The method as set forth in claim 25, wherein at least one second phase-forming constituent is provided as an individual element, and at least one other second phase-forming constituent is provided as an alloy of the solvent metal.

Claim 45

Dependent Claim 28 words

The method as set forth in claim 42, wherein the solvent metal is aluminum, zinc, magnesium, copper, nickel, chromium, iron, titanium, cobalt, or an alloy of such metals.

Claim 46

Dependent Claim 24 words

The method as set forth in claim 43, wherein the second phase-forming constituents are selected from aluminum, titanium, zirconium, magnesium, boron, silicon, and carbon.

Claim 47

Dependent Claim 23 words

The method as set forth in claim 44, wherein the solvent metal is aluminum and the second phase-forming constituents are titanium and boron.

Claim 48

Dependent Claim 27 words

The method as set forth in claim 25, wherein the particulate second phase is titanium diboride, zirconium diboride, titanium carbide, zirconium disilicide, zirconium carbide, or titanium nitride.

Claim 49

Dependent Claim 20 words

The method as set forth in claim 46, wherein the second phase is substantially less than 5 microns in size.

Claim 50

Dependent Claim 18 words

The method as set forth in claim 25, wherein the second phase-forming constituents are contacted in stoichiometric proportions.

Claim 51

Dependent Claim 18 words

The method as set forth in claim 25, wherein one second phase-forming constituent is provided in stoichiometric excess.

Claim 52

Dependent Claim 14 words

The method as set forth claim 25, wherein the second phase is a ceramic.

Claim 53

Dependent Claim 14 words

The method as set forth claim 25, wherein the second phase is an intermetallic.

Claim 54

Dependent Claim 21 words

The method as set forth in claim 25, wherein the concentration of solvent metal is greater than 30 percent by volume.

Claim 55

Dependent Claim 21 words

The method as set forth in claim 25, wherein the metal-second phase composite material comprises a substantially uniform distribution of particles.

Claim 56

Dependent Claim 23 words

The method as set forth in claim 25, wherein the particle size of second phase particles is between about 0.1 and 3 microns.

Claim 57

Dependent Claim 22 words

The method as set forth in claim 25, wherein the metal-second phase composite material has a porosity of greater than 25 percent.

Claim 58

Dependent Claim 19 words

The method as set forth in claim 25, wherein the mixture is shaped in the form of a rod.

Claim 59

Dependent Claim 19 words

The method as set forth in claim 25, wherein the mixture is compressed in the shape of a rod.

Claim 60

Dependent Claim 19 words

The method as set forth in claim 25, wherein the second phase particles are substantially encapsulated by solvent metal.

Claim 61

Dependent Claim 17 words

The method as set forth in claim 25, wherein reaction propagation further comprises an isothermal wave front.

Claim 62

Independent Claim 135 words

A method for the production of porous metal-second phase composite materials, the method comprising precipitating at least one second phase material in solvent matrix by locally igniting a mixture of reactive second phase-forming constituents and at lest about 20 volume percent of a substantially nonreactive solvent metal in which the second phase-forming constituents are more soluble than the second phase, substantially at or below atmospheric pressure and at a temperature at which sufficient diffusion of the constituents into the solvent metal occurs, to cause propagation of a substantially isothermal reaction of the reactive second phase-forming constituents to increase the temperature to a temperature exceeding the melting temperature of the solvent metal, to precipitate the second phase in the solvent metal, thereby forming a metal-second phase composite material having a porosity of at least 10 percent.

Claim 63

Independent Claim 135 words

A method for the production of porous metal-second phase composite materials, the method comprising precipitating at least one second phase material in solvent matrix by locally igniting a mixture of reactive second phase-forming constituents and at lest about 20 volume percent of a substantially nonreactive solvent metal in which the second phase-forming constituents are more soluble than the second phase, substantially at or below atmospheric pressure and at a temperature at which sufficient diffusion of the constituents into the solvent metal occurs, to cause propagation of a substantially isothermal reaction of the reactive second phase-forming constituents to increase the temperature to a temperature exceeding the melting temperature of the solvent metal, to precipitate the second phase in the solvent metal, thereby forming a metal-second phase composite material having a porosity of at least 10 percent.

Claim 64

Independent Claim 122 words

A method for providing a second phase in a metallic matrix, the method comprising steps of: (a) preparing a mixture of reactive second phase-forming constituents and at least about 20 volume percent of nonreactive solvent metal in which the second phase-forming constituents are more soluble than the second phase; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal to initiate a substantially isothermal reaction wave front; (c) permitting the exothermic reaction to further heat the mixture and to propagate, forming a uniform distribution of second phase particles in a metallic matrix; and (d) recovering a metal-second phase composite material having a porosity of at least 10 percent.

Claim 65

Independent Claim 122 words

A method for providing a second phase in a metallic matrix, the method comprising steps of: (a) preparing a mixture of reactive second phase-forming constituents and at least about 20 volume percent of nonreactive solvent metal in which the second phase-forming constituents are more soluble than the second phase; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal to initiate a substantially isothermal reaction wave front; (c) permitting the exothermic reaction to further heat the mixture and to propagate, forming a uniform distribution of second phase particles in a metallic matrix; and (d) recovering a metal-second phase composite material having a porosity of at least 10 percent.

Claim 66

Independent Claim 165 words

A method for dispersion of second phase dispersoids in a metallic matrix, the method comprising forming a reaction mixture of reactive second phase-forming constituents in the presence of a substantial volume fraction of at least two metals, at least one of which acts as a solvent metal in which the second phase-forming constituents are more soluble than the second phase dispersoids, holding the mixture substantially at or below atmospheric pressure, raising the temperature of the reaction mixture locally to a temperature at which sufficient diffusion of the second phase-forming constituents into the lowest melting solvent metal occurs to initiate a substantially isothermal reaction of the constituents, whereby the exothermic heat of reaction of the constituents causes the temperature of the reaction mixture to locally exceed the melting point of the highest melting metal, permitting propagation of the reaction, and dispersion of the second phase dispersoid in an alloy to thereby form a solid metal-second phase composite material having a porosity of at least 10 percent.

Claim 67

Independent Claim 165 words

A method for dispersion of second phase dispersoids in a metallic matrix, the method comprising forming a reaction mixture of reactive second phase-forming constituents in the presence of a substantial volume fraction of at least two metals, at least one of which acts as a solvent metal in which the second phase-forming constituents are more soluble than the second phase dispersoids, holding the mixture substantially at or below atmospheric pressure, raising the temperature of the reaction mixture locally to a temperature at which sufficient diffusion of the second phase-forming constituents into the lowest melting solvent metal occurs to initiate a substantially isothermal reaction of the constituents, whereby the exothermic heat of reaction of the constituents causes the temperature of the reaction mixture to locally exceed the melting point of the highest melting metal, permitting propagation of the reaction, and dispersion of the second phase dispersoid in an alloy to thereby form a solid metal-second phase composite material having a porosity of at least 10 percent.

Claim 68

Independent Claim 173 words

A method for dispersion of second phase dispersoids in a metal matrix, the method comprising forming a reaction mixture of reaction second phase-forming constituents in the presence of at least about 20 volume percent of a mixture of at least two metals, at least one of which acts as a solvent metal in which the second phase-forming constituents are more soluble than the second phase dispersoids, holding the mixture substantially at or below atmospheric pressure, raising the temperature of the reaction mixture locally to a temperature at which sufficient diffusion of the second phase-forming constituents into the lowest melting solvent metal occurs to initiate a substantially isothermal 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 solvent metal, permitting propagation of the reaction and dispersion of the second phase dispersoids in a mixed metal matrix to thereby form a solid metal-second phase composite material having a porosity of at least 10 percent.

Claim 69

Independent Claim 173 words

A method for dispersion of second phase dispersoids in a metal matrix, the method comprising forming a reaction mixture of reaction second phase-forming constituents in the presence of at least about 20 volume percent of a mixture of at least two metals, at least one of which acts as a solvent metal in which the second phase-forming constituents are more soluble than the second phase dispersoids, holding the mixture substantially at or below atmospheric pressure, raising the temperature of the reaction mixture locally to a temperature at which sufficient diffusion of the second phase-forming constituents into the lowest melting solvent metal occurs to initiate a substantially isothermal 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 solvent metal, permitting propagation of the reaction and dispersion of the second phase dispersoids in a mixed metal matrix to thereby form a solid metal-second phase composite material having a porosity of at least 10 percent.

Claim 70

Independent Claim 131 words

A method for dispersion of at least one intermetallic material in a metallic matrix, comprising steps of: (a) preparing a mixture of reactive intermetallic-forming constituents and a substantial volume fraction of nonreactive solvent metal, metal alloy, or intermetallic in which the intermetallic-forming constituents are more soluble than the intermetallic material; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal, metal alloy or intermetallic; (c) permitting the resultant exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the solvent metal, and to propagate, as a substantially isothermal wave front consuming the intermetallic-forming constituents; and (d) recovering a solid metal-intermetallic composite material having a porosity of at least 10 percent.

Claim 71

Independent Claim 131 words

A method for dispersion of at least one intermetallic material in a metallic matrix, comprising steps of: (a) preparing a mixture of reactive intermetallic-forming constituents and a substantial volume fraction of nonreactive solvent metal, metal alloy, or intermetallic in which the intermetallic-forming constituents are more soluble than the intermetallic material; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal, metal alloy or intermetallic; (c) permitting the resultant exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the solvent metal, and to propagate, as a substantially isothermal wave front consuming the intermetallic-forming constituents; and (d) recovering a solid metal-intermetallic composite material having a porosity of at least 10 percent.

Claim 72

Independent Claim 125 words

A method for dispersion of at least one ceramic material in a metallic matrix, comprising steps of: (a) preparing a mixture of reactive ceramic-forming constituents and t least about 20 volume percent of nonreactive solvent metal in which the ceramic-forming constituents are more soluble than the ceramic material; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal; (c) permitting the resultant exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the solvent metal, and to propagate, as a substantially isothermal wave front consuming the ceramic-forming constituents; and (d) recovering a slid metal-ceramic composite material having a porosity of at least 10 percent.

Claim 73

Independent Claim 125 words

A method for dispersion of at least one ceramic material in a metallic matrix, comprising steps of: (a) preparing a mixture of reactive ceramic-forming constituents and t least about 20 volume percent of nonreactive solvent metal in which the ceramic-forming constituents are more soluble than the ceramic material; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal; (c) permitting the resultant exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the solvent metal, and to propagate, as a substantially isothermal wave front consuming the ceramic-forming constituents; and (d) recovering a slid metal-ceramic composite material having a porosity of at least 10 percent.

Claim 74

Independent Claim 142 words

A method for dispersing dispersoid particles of an intermetallic material and a ceramic material in a metal matrix, the method comprising steps of: (a) preparing a mixture of reactive intermetallic and ceramic-forming constituents and at least about 20 volume percent of nonreactive solvent metal in which the intermetallic-forming constituents and the ceramic-forming constituents are more soluble than the intermetallic or the ceramic material, respectively; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal; (c) initiating an exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the solvent metal, and to propagate, as a substantially isothermal wave front consuming the intermetallic-forming constituents and ceramic-forming constituents; and (d) recovering a solid composite material having a porosity of at least 10 percent.

Claim 75

Independent Claim 142 words

A method for dispersing dispersoid particles of an intermetallic material and a ceramic material in a metal matrix, the method comprising steps of: (a) preparing a mixture of reactive intermetallic and ceramic-forming constituents and at least about 20 volume percent of nonreactive solvent metal in which the intermetallic-forming constituents and the ceramic-forming constituents are more soluble than the intermetallic or the ceramic material, respectively; (b) locally heating the mixture substantially at or below atmospheric pressure to a reaction initiation temperature approximating the melting point of the solvent metal; (c) initiating an exothermic reaction to raise the temperature of the mixture to a temperature exceeding the melting point of the solvent metal, and to propagate, as a substantially isothermal wave front consuming the intermetallic-forming constituents and ceramic-forming constituents; and (d) recovering a solid composite material having a porosity of at least 10 percent.

Claim 76

Independent Claim 101 words

A method for the production of porous metal-second phase composite material, the method comprising forming at least one second phase material in nonreactive metal by locally igniting a mixture comprising reactive second phase-forming constituents in the presence of at least about 20 volume percent of a substantially nonreactive metal substantially at or below atmospheric pressure and at a temperature that causes a substantially isothermal propagating second phase-forming reaction of the constituents to propagate as an isothermal wave front, to thereby form second phase particles in the metal and recovering a solid composite material having a porosity of at least 10 percent.

Claim 77

Independent Claim 101 words

A method for the production of porous metal-second phase composite material, the method comprising forming at least one second phase material in nonreactive metal by locally igniting a mixture comprising reactive second phase-forming constituents in the presence of at least about 20 volume percent of a substantially nonreactive metal substantially at or below atmospheric pressure and at a temperature that causes a substantially isothermal propagating second phase-forming reaction of the constituents to propagate as an isothermal wave front, to thereby form second phase particles in the metal and recovering a solid composite material having a porosity of at least 10 percent.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1994-01-14	1994-07-16	1995-01-15	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	1998-01-14	1998-07-16	1999-01-15	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2002-01-14	2002-07-16	2003-01-15	$7700.00	Window Closed / Lapsed

Process for forming porous metal-second phase composites

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