US5093148A
Expired / Lapsed
US
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Arc-melting process for forming metallic-second phase composites
Assignee: Lockheed Martin Corp
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Filing: 1991-07-10
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Granted: 1992-03-03
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Expires: 2011-07-10
Abstract
Abstract An arc-melting method is taught for the formation of metallic-second phase composite materials. The method involves the formation of an intermediate composite material comprising a relatively high loading of second phase particles dispersed in a metal matrix. This intermediate material is then combined with an additional amount of metal and arc-melted to form a final composite comprising a lower loading of the second phase particles dispersed in a final metallic matrix. The final metallic matrix may be comprised of a metal, metal alloy, or intermetallic, while the second phase particles may comprise ceramic materials such as borides, carbides, nitrides, silicides, oxides or sulfides.
Inventors
- 👤 Leontios Christodoulou
- 👤 Dennis C. Nagle
- 👤 John M. Brupbacher
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-30 09:32
CPC Classifications
C; C22; C22C; C22C49/00; C22C49/14; B; B22; B22F; B22F3/00; B22F3/23; B22F9/00; B22F9/02; B22F9/14; B82; B82Y; B82Y30/00; C22C1/00; C22C1/02; B22F2998/00; B22F2998/10
Claims Analysis
Total Claims: 33
Claim 1
Independent Claim
68 words
A method for forming a metallic-second phase composite material ingot, the method comprising combining an intermediate composite material comprising a solvent metal matrix having in-situ precipitated second phase particles dispersed therein with a host metal to form a consumable electrode arc-melting the consumable electrode by striking an arc therewith, and recovering a final metallic-second phase composite ingot comprising a final metallic matrix having second phase particles dispersed therein.
Claim 2
Independent Claim
68 words
A method for forming a metallic-second phase composite material ingot, the method comprising combining an intermediate composite material comprising a solvent metal matrix having in-situ precipitated second phase particles dispersed therein with a host metal to form a consumable electrode arc-melting the consumable electrode by striking an arc therewith, and recovering a final metallic-second phase composite ingot comprising a final metallic matrix having second phase particles dispersed therein.
Claim 3
Independent Claim
71 words
A method for forming a metallic-second phase composite material ingot, the method comprising the steps of: (a) forming an intermediate composite material comprising particles of in-situ second precipitated second phase material dispersed in a solvent metal matrix; (b) combining the intermediate compsoite material with a host metal to form a consumable electrode; (c) arc-melting the consumable electrode by striking an arc therewith; and (d) recovering a final metallic-second phase composite ingot.
Claim 4
Independent Claim
71 words
A method for forming a metallic-second phase composite material ingot, the method comprising the steps of: (a) forming an intermediate composite material comprising particles of in-situ second precipitated second phase material dispersed in a solvent metal matrix; (b) combining the intermediate compsoite material with a host metal to form a consumable electrode; (c) arc-melting the consumable electrode by striking an arc therewith; and (d) recovering a final metallic-second phase composite ingot.
Claim 5
Independent Claim
91 words
A method for forming a metallic-second phase compsoite material ingot, the method comprising forming an intermediate composite material comprising particles of in-situ precipitated second phase material dispersed in a solvent metal matrix by contacting reactive second phase-forming constituentw and a solvent metal at a temperature sufficient to initiate a reaction of the second phase-forming constituents, combining the intermediate composite with a host metal, arc-melting the combined intermediate composite material and host metal, and recovering a final metallic-second phase composite ingot comprising a final metallic matrix having second phase particles dispersed therein.
Claim 6
Independent Claim
91 words
A method for forming a metallic-second phase compsoite material ingot, the method comprising forming an intermediate composite material comprising particles of in-situ precipitated second phase material dispersed in a solvent metal matrix by contacting reactive second phase-forming constituentw and a solvent metal at a temperature sufficient to initiate a reaction of the second phase-forming constituents, combining the intermediate composite with a host metal, arc-melting the combined intermediate composite material and host metal, and recovering a final metallic-second phase composite ingot comprising a final metallic matrix having second phase particles dispersed therein.
Claim 7
Dependent Claim
47 words
A method as set forth in claim 3, wherein the second phase-forming constituents are selected from the group consisting of aluminum, titanium, zirconium, fahnium, vanadiun, niobiun, tantalum, chromium, molybdenum, tungsten, iron, cobalt, nickel, copper, silicon, boron, carbon, sulfur, nitrogen, oxygen, thorium, scandium, lanthanum, yttrium, cerium and erbium.
Claim 8
Dependent Claim
52 words
A method as set forth in claim 3, wherein the 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 9
Dependent Claim
52 words
A method as set forth in claim 3, wherein the 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 10
Dependent Claim
19 words
A method as set forth in claim 3, wherein the final metallic matrix comprises a metal or metal alloy.
Claim 11
Dependent Claim
16 words
A method as set forth in claim 3, wherein the final metallic matrix comprises an intermetallic.
Claim 12
Dependent Claim
23 words
A method as set forth in claim 8, wherein the intermetallic is an aluminide of Ti, Ni, Co, Nb, Zr, Fe or Ta.
Claim 13
Dependent Claim
69 words
A method as set forth in claim 8, wherein the intermetallic is selected from the group consisting of 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.
Claim 14
Dependent Claim
43 words
A method as set forth in claim 3, wherein the second phase particles are 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 15
Dependent Claim
67 words
A method as set forth in claim 11, wherein the second phase particles are 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 and MoS 2 .
Claim 16
Dependent Claim
43 words
A method as set forth in claim 3, wherein the second phase particles comprise 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 17
Dependent Claim
28 words
A method as set forth in claim 3, wherein the second phase particles comprise from about 1 to about 40 volume percent of the final metallic-second phase composite.
Claim 18
Dependent Claim
24 words
A method as set forth in claim 3, wherein the size of the second phase particles is from about 0.01 to about 10 microns.
Claim 19
Dependent Claim
25 words
A method as set forth in claim 3, wherein the final metallic matrix has an average grain size of from about 0.1 to about microns.
Claim 20
Dependent Claim
26 words
A method as set forth in claim 3, wherein the final metallic matrix has an average grain size of from about 1 to about 40 microns.
Claim 21
Independent Claim
77 words
A method for forming a metallic-second phase composite material ingot, the method comprising the steps of: (a) forming an intermediate composite material comprising particles of in-situ precipitated second phase material dispersed in a solvent metal matrix; (b) mxing the intermediate composite material with a host metal in solid form; (c) compacting the mixture to form a consumable electrode; (d) arc-melting the consumable electrode by striking an arc therewith; and (e) recovering a final metallic-second phase composite ingot.
Claim 22
Independent Claim
77 words
A method for forming a metallic-second phase composite material ingot, the method comprising the steps of: (a) forming an intermediate composite material comprising particles of in-situ precipitated second phase material dispersed in a solvent metal matrix; (b) mxing the intermediate composite material with a host metal in solid form; (c) compacting the mixture to form a consumable electrode; (d) arc-melting the consumable electrode by striking an arc therewith; and (e) recovering a final metallic-second phase composite ingot.
Claim 23
Dependent Claim
21 words
A method as set forth in claim 18, wherein the intermedi.afe material is crushed prior to mixing with the host metal.
Claim 24
Dependent Claim
27 words
A method as set forth in claim 18, wherein the host metal comprises titanium or an alloy thereof and is provided in the form of crushed sponge.
Claim 25
Dependent Claim
26 words
A method as set forth in claim 18, wherein the host metal comprises aluminum or an alloy thereof and is provided in the form of shot.
Claim 26
Dependent Claim
26 words
A method as set forth in claim 18, wherein multiple compacted mixtures of intermediate composite material and host metal are welded together to form the electrode.
Claim 27
Dependent Claim
24 words
A method as set forth in claim 18, wherein at least one alloying metal is mixed with the intermediate composite material and host metal.
Claim 28
Dependent Claim
26 words
A method as set forth in claim 18, wherein an additional amount of the solvent metal is mixed with the intermediate composite material and host metal.
Claim 29
Dependent Claim
18 words
A method as set forth in claim 18, wherein the arc-melting is performed in an electric arc furnace.
Claim 30
Dependent Claim
15 words
A method as set forth in claim 18, wherein the arc-melting is performed under vacuum.
Claim 31
Dependent Claim
14 words
A method as set forth in claim 18, wherein the electrode is double arc-melted.
Claim 32
Independent Claim
80 words
A method for forming a cast product of metallic-second phase composite material, the method comprising combining intermediate composite material comprising a solvent metl matrix having in-situ precipitated second phase particles dispersed therein with host metal to form a consumable electrode, arc-melting the consumable electrode by striking an arc therewith to form a molten mass, casting the molten mass, and recovering a cast product of final metallic-second phase composite material comprising a final metallic matrix having second phase particles dispersed therein.
Claim 33
Independent Claim
80 words
A method for forming a cast product of metallic-second phase composite material, the method comprising combining intermediate composite material comprising a solvent metl matrix having in-situ precipitated second phase particles dispersed therein with host metal to form a consumable electrode, arc-melting the consumable electrode by striking an arc therewith to form a molten mass, casting the molten mass, and recovering a cast product of final metallic-second phase composite material comprising a final metallic matrix having second phase particles dispersed therein.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1995-03-03 | 1995-09-02 | 1996-03-03 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1999-03-03 | 1999-09-02 | 2000-03-03 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2003-03-03 | 2003-09-02 | 2004-03-03 | $7700.00 | Window Closed / Lapsed |