Patent US5368657A successfully refreshed from Google Patents.
US5368657A
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Gas atomization synthesis of refractory or intermetallic compounds and supersaturated solid solutions
Assignee: Iowa State University Research Foundation Inc
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Filing: 1993-04-13
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Granted: 1994-11-29
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Expires: 2013-04-13
Abstract
Abstract A metallic melt is atomized using a high pressure atomizing gas wherein the temperature of the melt and the composition of the atomizing gas are selected such that the gas and melt react in the atomization spray zone to form a refractory or intermetallic compound in the as-atomized powder particles. A metallic melt is also atomized using a high pressure atomizing gas mixture gas wherein the temperature of the melt and the ratio of a reactive gas to a carrier gas are selected to form powder particles comprising a supersaturated solid solution of the atomic species of the reactive gas in the particles. The powder particles are then heat treated to precipitate dispersoids in-situ therein to form a dispersion strengthened material.
Inventors
- 👤 Iver E. Anderson
- 👤 Barbara K. Lograsso
- 👤 Timothy W. Ellis
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 21:54
CPC Classifications
C; C22; C22C; C22C1/00; C22C1/10; C22C1/1036; C22C1/1042
Claims Analysis
Total Claims: 26
Claim 1
Independent Claim
111 words
A method of making particles, comprising: forming a melt comprising a metal or alloy under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture comprising a carrier gas and a second gas or a liquid so as to form atomized particles, the temperature of said melt and the ratio of said carrier gas to said second gas or liquid being selected to provide a superequilibrium concentration of an atomic specie of said second gas or liquid in solid solution in said atomized particles to a depth below the surface of said atomized particles, and solidifying the atomized particles to retain the superequilibrium concentration of said atomic specie therein.
Claim 2
Independent Claim
111 words
A method of making particles, comprising: forming a melt comprising a metal or alloy under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture comprising a carrier gas and a second gas or a liquid so as to form atomized particles, the temperature of said melt and the ratio of said carrier gas to said second gas or liquid being selected to provide a superequilibrium concentration of an atomic specie of said second gas or liquid in solid solution in said atomized particles to a depth below the surface of said atomized particles, and solidifying the atomized particles to retain the superequilibrium concentration of said atomic specie therein.
Claim 3
Dependent Claim
36 words
The method of claim 1 wherein the atomizing gas mixture comprises an inert gas and a reactive, dispersoid-forming gas that will react when dissolved in solid solution in the metal or alloy to form dispersoids therein.
Claim 4
Independent Claim
87 words
A method of making aluminum particles, comprising: forming a melt comprising aluminum under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture comprising an inert gas and nitrogen so as to produce atomized particles, the temperature of said melt and the ratio of said inert gas to nitrogen gas being effective to provide a superequilibrium concentration of atomic nitrogen in solid solution to a depth below the surface of said particulates and solidifying the atomized particles to retain the superequilibrium concentration of nitrogen therein.
Claim 5
Independent Claim
87 words
A method of making aluminum particles, comprising: forming a melt comprising aluminum under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture comprising an inert gas and nitrogen so as to produce atomized particles, the temperature of said melt and the ratio of said inert gas to nitrogen gas being effective to provide a superequilibrium concentration of atomic nitrogen in solid solution to a depth below the surface of said particulates and solidifying the atomized particles to retain the superequilibrium concentration of nitrogen therein.
Claim 6
Independent Claim
157 words
A method of dispersion strengthening a metallic material, comprising: forming a melt comprising a metal or alloy under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture to produce atomized particulates, said atomizing gas mixture comprising a carrier gas and a reactive gas that is reactive when dissolved in solid solution in said metallic material to form dispersoids therein, the temperature of said melt and the ratio of said carrier gas to said reactive gas being selected to provide a superequilibrium concentration of an atomic specie of said reactive gas in solid solution in said atomized particles to a depth below surface of said atomized particles upon solidification thereof, solidifying the atomized particles to retain the superequilibrium concentration of the atomic specie therein, and heating the atomized particles to a temperature to react said atomic specie of said reactive gas in solid solution with the solidified metal or alloy particles to form dispersoids therein.
Claim 7
Independent Claim
157 words
A method of dispersion strengthening a metallic material, comprising: forming a melt comprising a metal or alloy under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture to produce atomized particulates, said atomizing gas mixture comprising a carrier gas and a reactive gas that is reactive when dissolved in solid solution in said metallic material to form dispersoids therein, the temperature of said melt and the ratio of said carrier gas to said reactive gas being selected to provide a superequilibrium concentration of an atomic specie of said reactive gas in solid solution in said atomized particles to a depth below surface of said atomized particles upon solidification thereof, solidifying the atomized particles to retain the superequilibrium concentration of the atomic specie therein, and heating the atomized particles to a temperature to react said atomic specie of said reactive gas in solid solution with the solidified metal or alloy particles to form dispersoids therein.
Claim 8
Dependent Claim
17 words
The method of claim 4 wherein the atomizing gas comprises an inert gas and said reactive gas.
Claim 9
Independent Claim
118 words
A method of making dispersion strengthened aluminum particles, comprising: forming a melt comprising aluminum under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture comprising an inert gas and nitrogen so as to produce atomized particles, the temperature of said melt and the ratio of said inert gas to nitrogen gas being effective to provide a superequilibrium concentration of atomic nitrogen in solid solution in said atomized particles to a depth below the surface of said atomized particles upon solidification, solidifying the atomized particles to retain the superequilibrium concentration of nitrogen therein, and heating the atomized particles to a temperature to react said atomic nitrogen in solid solution with said aluminum to form dispersoids therein.
Claim 10
Independent Claim
118 words
A method of making dispersion strengthened aluminum particles, comprising: forming a melt comprising aluminum under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture comprising an inert gas and nitrogen so as to produce atomized particles, the temperature of said melt and the ratio of said inert gas to nitrogen gas being effective to provide a superequilibrium concentration of atomic nitrogen in solid solution in said atomized particles to a depth below the surface of said atomized particles upon solidification, solidifying the atomized particles to retain the superequilibrium concentration of nitrogen therein, and heating the atomized particles to a temperature to react said atomic nitrogen in solid solution with said aluminum to form dispersoids therein.
Claim 11
Independent Claim
159 words
A method of making a dispersion strengthened article, comprising: forming a melt comprising a metal or alloy under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture to produce atomized particles, said atomizing gas comprising a carrier gas and a reactive gas that is reactive when dissolved in solid solution in said metallic material to form dispersoids therein, the temperature of said melt and the ratio of said carrier gas to said reactive gas being selected to provide a superequilibrium concentration of an atomic specie of said reactive gas in solid solution in said atomized particles to a depth below a surface of said atomized particles upon solidification, solidifying the atomized particles to retain the superequilibrium concentration of the atomic specie therein, forming an article from said atomized particles, and heating the solidified particles during or after formation of said article to a temperature to react said specie with said metallic material to form dispersoids therein.
Claim 12
Independent Claim
159 words
A method of making a dispersion strengthened article, comprising: forming a melt comprising a metal or alloy under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture to produce atomized particles, said atomizing gas comprising a carrier gas and a reactive gas that is reactive when dissolved in solid solution in said metallic material to form dispersoids therein, the temperature of said melt and the ratio of said carrier gas to said reactive gas being selected to provide a superequilibrium concentration of an atomic specie of said reactive gas in solid solution in said atomized particles to a depth below a surface of said atomized particles upon solidification, solidifying the atomized particles to retain the superequilibrium concentration of the atomic specie therein, forming an article from said atomized particles, and heating the solidified particles during or after formation of said article to a temperature to react said specie with said metallic material to form dispersoids therein.
Claim 13
Independent Claim
135 words
A method of making a dispersion strengthened aluminum article, comprising: forming a melt comprising aluminum under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture comprising a carrier gas and nitrogen so as to produce atomized particles, the temperature of said melt and the ratio of said carrier gas to said nitrogen gas being selected to provide a superequilibrium concentration of atomic nitrogen in solid solution in said atomized particles to a depth below the surface of said atomized particles upon solidification, solidifying the atomized particles to retain the superequilibrium concentration of nitrogen therein, forming an article from said atomized particles, and heating the solidified particles during or after formation of said article to a temperature to react said atomic nitrogen with said aluminum to form aluminum nitride dispersoids in said aluminum.
Claim 14
Independent Claim
135 words
A method of making a dispersion strengthened aluminum article, comprising: forming a melt comprising aluminum under an inert gas atmosphere, atomizing said melt with an atomizing gas mixture comprising a carrier gas and nitrogen so as to produce atomized particles, the temperature of said melt and the ratio of said carrier gas to said nitrogen gas being selected to provide a superequilibrium concentration of atomic nitrogen in solid solution in said atomized particles to a depth below the surface of said atomized particles upon solidification, solidifying the atomized particles to retain the superequilibrium concentration of nitrogen therein, forming an article from said atomized particles, and heating the solidified particles during or after formation of said article to a temperature to react said atomic nitrogen with said aluminum to form aluminum nitride dispersoids in said aluminum.
Claim 15
Independent Claim
132 words
A method of making particles comprising a refractory or intermetallic compound having a first metallic component and a second non-metallic or metallic component, comprising: forming a melt comprising said first metallic component of said compound under an inert gas atmosphere, atomizing said melt with an atomizing gas comprising a reactive material that is reactive with said melt to provide said second non-metallic or metallic component of said compound, the temperature of said melt and amount of said reactive material being selected to effect reaction of said melt and said reactive material in an atomization spray so as to form said compound in atomized particles produced by atomization of said melt to a depth below the surface of said atomized particles, and solidifying the atomized particles to provide particles comprising said compound therein.
Claim 16
Independent Claim
132 words
A method of making particles comprising a refractory or intermetallic compound having a first metallic component and a second non-metallic or metallic component, comprising: forming a melt comprising said first metallic component of said compound under an inert gas atmosphere, atomizing said melt with an atomizing gas comprising a reactive material that is reactive with said melt to provide said second non-metallic or metallic component of said compound, the temperature of said melt and amount of said reactive material being selected to effect reaction of said melt and said reactive material in an atomization spray so as to form said compound in atomized particles produced by atomization of said melt to a depth below the surface of said atomized particles, and solidifying the atomized particles to provide particles comprising said compound therein.
Claim 17
Dependent Claim
13 words
The method of claim 9 wherein the reactive material comprises a reactive gas.
Claim 18
Dependent Claim
16 words
The method of claim 9 wherein the reactive gas is used solely as the atomizing gas.
Claim 19
Dependent Claim
20 words
The method of claim 9 wherein reactive gas comprises nitrogen gas to form a nitride compound in said atomization spray.
Claim 20
Dependent Claim
21 words
The method of claim 9 wherein the reactive gas comprises substantially borane to form a boride compound in said atomization spray.
Claim 21
Dependent Claim
24 words
The method of claim 9 wherein the reactive material comprises a metallo-organic gas or liquid to form an intermetallic compound in said atomization spray.
Claim 22
Dependent Claim
24 words
The method of claim 9 wherein the melt is superheated to supplement the heat of reaction to drive the reaction in said atomization spray.
Claim 23
Independent Claim
118 words
A method of making particles comprising a refractory or intermetallic compound having a first metallic component and a second non-metallic or metallic component, comprising: forming a superheated melt comprising said metallic component of said compound under an inert gas atmosphere, atomizing said melt with an atomizing gas that is reactive with said melt to provide said non-metallic or metallic component of said compound, the temperature of said melt and amount of said reactive atomizing gas being selected to effect reaction of said melt and said reactive material in an atomization spray so as to form said compound throughout atomized particles produced by atomization of said melt, and solidifying the atomized particles to provide particles comprising said compound therein.
Claim 24
Independent Claim
118 words
A method of making particles comprising a refractory or intermetallic compound having a first metallic component and a second non-metallic or metallic component, comprising: forming a superheated melt comprising said metallic component of said compound under an inert gas atmosphere, atomizing said melt with an atomizing gas that is reactive with said melt to provide said non-metallic or metallic component of said compound, the temperature of said melt and amount of said reactive atomizing gas being selected to effect reaction of said melt and said reactive material in an atomization spray so as to form said compound throughout atomized particles produced by atomization of said melt, and solidifying the atomized particles to provide particles comprising said compound therein.
Claim 25
Dependent Claim
21 words
The method of claim 16 wherein the atomizing gas comprises nitrogen gas to form a nitride compound in said atomization spray.
Claim 26
Dependent Claim
20 words
The method of claim 16 wherein the atomizing gas comprises borane to form a boride compound in said atomization spray.
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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) | 1997-11-28 | 1998-05-30 | 1998-11-29 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-11-28 | 2002-05-30 | 2002-11-29 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-11-28 | 2006-05-30 | 2006-11-29 | $7700.00 | Window Closed / Lapsed |