US5561829A — Method of producing structural metal matrix compo…

Claim 1

Independent Claim 138 words

A method of preparing a metal alloy product from a powder blend, said method comprising: (a) forming a blend by mixing a metal powder phase and at least one reinforcement phase having a hardness greater than said metal powder at temperatures greater than 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said metal powder having an oxide coating on its surface; (b) cold pressing said blend to form a compact without mechanically alloying said blend prior to said cold pressing; (c) heating said compact to a temperature greater than about 650° F. to form a preheated compact; and (d) hot working said preheated compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and provide a multi-phase worked product containing reinforcement material.

Claim 2

Independent Claim 138 words

A method of preparing a metal alloy product from a powder blend, said method comprising: (a) forming a blend by mixing a metal powder phase and at least one reinforcement phase having a hardness greater than said metal powder at temperatures greater than 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said metal powder having an oxide coating on its surface; (b) cold pressing said blend to form a compact without mechanically alloying said blend prior to said cold pressing; (c) heating said compact to a temperature greater than about 650° F. to form a preheated compact; and (d) hot working said preheated compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and provide a multi-phase worked product containing reinforcement material.

Claim 3

Dependent Claim 27 words

The method of claim 1 in which said metal is selected from the group consisting of aluminum, magnesium, copper, iron, zinc, nickel, cobalt, titanium, and alloys thereof.

Claim 4

Dependent Claim 33 words

The method of claim 1 in which said reinforcement phase is selected from the group of aluminum, magnesium, copper, iron, zinc, nickel, cobalt, titanium, and alloys thereof, cermets, ceramic materials and mixtures thereof.

Claim 5

Dependent Claim 22 words

The method of claim 1 in which said reinforcement phase is selected from the group of particulate, whiskers, fibers, and mixtures thereof.

Claim 6

Dependent Claim 44 words

The method of claim 1 in which said reinforcement phase is selected from the group consisting of silicon carbide, silicon nitride, SiAlON, titanium nitride, titanium carbide, titanium silicide, molybdenum silicide, nickel aluminate, boron carbide, aluminum nitride, aluminum oxide, magnesium oxide, silicon and mixtures thereof.

Claim 7

Dependent Claim 39 words

The method of claim 1 in which said metal powder blend comprises: 50 to 90 vol. % of a metal powder phase; and 10 to 50 vol. % of a reinforcement phase having a hardness greater than said metal.

Claim 8

Dependent Claim 15 words

The method of claim 1 in which said metal powder phase comprises: a pre-alloyed powder.

Claim 9

Dependent Claim 20 words

The method of claim 1 in which said metal powder phase comprises: a mixture containing at least one elemental powder.

Claim 10

Dependent Claim 26 words

The method of claim 1 in which (b) includes: cold pressing to form a compact having a density of about 60% to about 95% theoretical density.

Claim 11

Dependent Claim 16 words

The method of claim 1 in which (b) includes: cold pressing to form a shaped compact.

Claim 12

Dependent Claim 40 words

The method of claim 1 in which (c) includes: heating said compact in the presence of an atmosphere comprising at least about 70 vol. % of an inert gas selected from the group consisting of nitrogen, argon, and mixtures thereof.

Claim 13

Dependent Claim 14 words

The method of claim 1 in which (c) includes: heating the compact in air.

Claim 14

Dependent Claim 23 words

The method of claim 1 in which (c) includes: heating said compact to a temperature of about 650° F. to about 950° F.

Claim 15

Dependent Claim 15 words

The method of claim 1 in which (c) further includes: hot compacting said preheated compact.

Claim 16

Dependent Claim 13 words

The method of claim 1 in which (d) includes: forging said preheated compact.

Claim 17

Dependent Claim 28 words

The method of claim 1 in which (d) includes: forging or hot compacting said preheated compact to form a product having a density greater than 98% theoretical density.

Claim 18

Dependent Claim 18 words

The method of claim 1 in which (d) includes: extruding said preheated compact to form an extruded product.

Claim 19

Dependent Claim 13 words

The method of claim 17 which further includes: (e) forging said extruded product.

Claim 20

Dependent Claim 29 words

The method of claim 17 which further includes: (e) allowing said extruded product to cool; (f) heating said extruded product; and (g) forging or extruding said heated extruded product.

Claim 21

Dependent Claim 17 words

The method of claim 17 in which (d) includes: forging said preheated compact to near net shape.

Claim 22

Dependent Claim 13 words

The method of claim 17 which further includes: (e) rolling said extruded product.

Claim 23

Dependent Claim 27 words

The method of claim 17 which further includes: (e) allowing said extruded product to cool; (f) heating said extruded product; and (g) rolling said heated extruded product.

Claim 24

Dependent Claim 22 words

The method of claim 17 which further includes: (e) allowing said extruded product to cool; and (f) cold rolling said extruded product.

Claim 25

Independent Claim 168 words

A method of preparing a consolidated metal alloy product from a powder blend which has not been mechanically alloyed, said method comprising: (a) cold pressing a powder metal blend to form a compact, said powder metal blend comprising 50 to 90 vol. % of an aluminum alloy powder and 10 to 50 vol. % of silicon carbide, said silicon carbide particles having a hardness greater than said aluminum alloy powder at temperatures greater than about 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said aluminum alloy powder having an oxide coating on its surface; (b) heating said compact in the presence of nitrogen to a temperature of about 650° F. to about 950° F. to form a preheated compact; (c) extruding said preheated compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and form an extrudate; and (d) forging said extrudate to form a multi-phase metal alloy product containing reinforcement material.

Claim 26

Independent Claim 168 words

A method of preparing a consolidated metal alloy product from a powder blend which has not been mechanically alloyed, said method comprising: (a) cold pressing a powder metal blend to form a compact, said powder metal blend comprising 50 to 90 vol. % of an aluminum alloy powder and 10 to 50 vol. % of silicon carbide, said silicon carbide particles having a hardness greater than said aluminum alloy powder at temperatures greater than about 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said aluminum alloy powder having an oxide coating on its surface; (b) heating said compact in the presence of nitrogen to a temperature of about 650° F. to about 950° F. to form a preheated compact; (c) extruding said preheated compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and form an extrudate; and (d) forging said extrudate to form a multi-phase metal alloy product containing reinforcement material.

Claim 27

Dependent Claim 30 words

The method of claim 24 in which (a) includes: cold pressing said powder metal blend to form a compact having a density of about 60% to about 95% theoretical density.

Claim 28

Independent Claim 188 words

A method of preparing an aluminum alloy product from a pre-alloyed powder blend, said method comprising: (a) cold pressing a blend to form a compact having a density of about 60% to about 95% theoretical density, said blend comprising particles of an aluminum alloy and at least one reinforcement phase, said at least one reinforcement phase being selected from the group consisting of silicon carbide, silicon nitride, SiAlON, titanium nitride, titanium carbide, titanium silicide, molybdenum silicide, nickel aluminate, boron carbide, aluminum nitride, aluminum oxide, magnesium oxide, silicon and mixtures thereof, each said at least one reinforcement phase having a hardness greater than said aluminum alloy particles at temperatures greater than about 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said aluminum alloy powder having an oxide coating on its surface; (b) heating said compact to a temperature greater than about 650° F. to form a preheated compact; and (c) hot working said preheated compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and provide an aluminum alloy product containing reinforcement material.

Claim 29

Independent Claim 188 words

A method of preparing an aluminum alloy product from a pre-alloyed powder blend, said method comprising: (a) cold pressing a blend to form a compact having a density of about 60% to about 95% theoretical density, said blend comprising particles of an aluminum alloy and at least one reinforcement phase, said at least one reinforcement phase being selected from the group consisting of silicon carbide, silicon nitride, SiAlON, titanium nitride, titanium carbide, titanium silicide, molybdenum silicide, nickel aluminate, boron carbide, aluminum nitride, aluminum oxide, magnesium oxide, silicon and mixtures thereof, each said at least one reinforcement phase having a hardness greater than said aluminum alloy particles at temperatures greater than about 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said aluminum alloy powder having an oxide coating on its surface; (b) heating said compact to a temperature greater than about 650° F. to form a preheated compact; and (c) hot working said preheated compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and provide an aluminum alloy product containing reinforcement material.

Claim 30

Dependent Claim 21 words

The method of claim 26 in which (c) working step is selected from the group consisting of forging, extruding, and rolling.

Claim 31

Independent Claim 191 words

A method of preparing an aluminum alloy product from a pre-alloyed powder blend, said method comprising: (a) cold pressing a powder metal blend which has not been mechanically alloyed to form a compact having a density of about 60% to about 95% theoretical density, said powder metal blend comprising an aluminum alloy powder and at least one reinforcement phase having a hardness greater than said aluminum alloy at a temperature greater than about 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said metal powder having an oxide coating on its surface, said at least one reinforcement phase is selected from the group consisting of silicon carbide, silicon nitride, SiAlON, titanium nitride, titanium carbide, titanium silicide, molybdenum silicide, nickel aluminate, boron carbide, aluminum nitride, aluminum oxide, magnesium oxide, silicon and mixtures thereof; (b) heating said compact to a temperature greater than about 650° F. to form a preheated compact; and (c) molding said preheated compact under pressure to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and form a multi-phase metal alloy product containing reinforcement material.

Claim 32

Independent Claim 191 words

A method of preparing an aluminum alloy product from a pre-alloyed powder blend, said method comprising: (a) cold pressing a powder metal blend which has not been mechanically alloyed to form a compact having a density of about 60% to about 95% theoretical density, said powder metal blend comprising an aluminum alloy powder and at least one reinforcement phase having a hardness greater than said aluminum alloy at a temperature greater than about 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said metal powder having an oxide coating on its surface, said at least one reinforcement phase is selected from the group consisting of silicon carbide, silicon nitride, SiAlON, titanium nitride, titanium carbide, titanium silicide, molybdenum silicide, nickel aluminate, boron carbide, aluminum nitride, aluminum oxide, magnesium oxide, silicon and mixtures thereof; (b) heating said compact to a temperature greater than about 650° F. to form a preheated compact; and (c) molding said preheated compact under pressure to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and form a multi-phase metal alloy product containing reinforcement material.

Claim 33

Dependent Claim 164 words

A structural metal alloy product formed by a method comprising: (a) cold pressing a powder metal blend which has not been mechanically alloyed to form a compact, said powder metal blend comprising an aluminum alloy powder and at least one reinforcement phase having a hardness greater than said aluminum alloy powder and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said metal powder having an oxide coating on its surface, said at least one reinforcement phase is selected from the group consisting of silicon carbide, silicon nitride, SiAlON, titanium nitride, titanium carbide, titanium silicide, molybdenum silicide, nickel aluminate, boron carbide, aluminum nitride, aluminum oxide, magnesium oxide, silicon and mixtures thereof; (b) heating said compact in the presence of an inert gas to form a preheated compact; and (c) hot working said hot compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and provide a multi-phase worked product containing reinforcement material.

Claim 34

Dependent Claim 164 words

A structural metal alloy product formed by a method comprising: (a) cold pressing a powder metal blend which has not been mechanically alloyed to form a compact, said powder metal blend comprising an aluminum alloy powder and at least one reinforcement phase having a hardness greater than said aluminum alloy powder and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said metal powder having an oxide coating on its surface, said at least one reinforcement phase is selected from the group consisting of silicon carbide, silicon nitride, SiAlON, titanium nitride, titanium carbide, titanium silicide, molybdenum silicide, nickel aluminate, boron carbide, aluminum nitride, aluminum oxide, magnesium oxide, silicon and mixtures thereof; (b) heating said compact in the presence of an inert gas to form a preheated compact; and (c) hot working said hot compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding and provide a multi-phase worked product containing reinforcement material.

Claim 35

Independent Claim 127 words

A method of preparing a metal alloy product from a powder blend, said method comprising: (a) forming a blend by mixing a metal powder phase and at least one reinforcement phase having a hardness greater than said metal powder at temperatures greater than 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said metal powder having an oxide coating on its surface; (b) cold pressing said blend to form a compact alloying said blend prior to said cold pressing; (c) heating said compact to a temperature greater than about 650° F. to form a preheated compact; and (d) hot working said preheated compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding.

Claim 36

Independent Claim 127 words

A method of preparing a metal alloy product from a powder blend, said method comprising: (a) forming a blend by mixing a metal powder phase and at least one reinforcement phase having a hardness greater than said metal powder at temperatures greater than 650° F. and consisting essentially of a gradation of particles sizes having 90% less than minus 325 mesh, said metal powder having an oxide coating on its surface; (b) cold pressing said blend to form a compact alloying said blend prior to said cold pressing; (c) heating said compact to a temperature greater than about 650° F. to form a preheated compact; and (d) hot working said preheated compact to abrade said oxide coating on said metal powder and thereby increase the particle-to-particle bonding.

Annuity Stage	Window Opens	Payment Deadline	Surcharge Period Until	Estimated Fee	Status
3.5 Years (Year 4)	1999-10-01	2000-04-01	2000-10-01	$2000.00	Window Closed / Lapsed
7.5 Years (Year 8)	2003-10-01	2004-04-01	2004-10-01	$3760.00	Window Closed / Lapsed
11.5 Years (Year 12)	2007-10-01	2008-04-01	2008-10-01	$7700.00	Window Closed / Lapsed

Method of producing structural metal matrix composite products from a blend of powders

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