US5951791A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of preparing porous nickel-aluminum structures
Assignee: Vale Canada Ltd
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Filing: 1997-12-01
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Granted: 1999-09-14
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Expires: 2017-12-01
Abstract
Abstract This process provides a method of fabricating porous aluminide articles. First the process consists of plating a preform with nickel and aluminum to create a metal-plated structure. The plating of nickel consists of electrodeposition or gaseous plating. The plating of aluminum consists of gaseous deposition of an organometallic-aluminum compound. The preform has either an open felt, woven fabric or a reticulated foam shape. Reactive sintering the metal-plated structure leaves an open nickel-aluminum structure having porosity and excellent strength and oxidation properties above 400° C.
Inventors
- 👤 James Alexander Evert Bell
- 👤 Kirt Kenneth Cushnie
- 👤 Anthony Edward Moline Warner
- 👤 George Clayton Hansen
- 👤 Raymond Augustus Bradford
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 01:36
CPC Classifications
H; H01; H01M; H01M4/00; H01M4/86; H01M4/88; H01M4/8878; H01M4/8882; H01M4/8885; B; B01; B01D; B01D39/00; B01D39/14; B01D39/20; B01D39/2027; B01D39/2051; B01J; B01J23/00; B01J23/70; B01J23/74; B01J23/755; C; C23; C23C; C23C16/00; C23C16/01; C23C16/04; C23C16/045; C23C16/06; C23C16/18; C23C16/20; H01M4/98; Y; Y02; Y02E; Y02E60/00; Y02E60/30; Y02E60/50
Claims Analysis
Total Claims: 19
Claim 1
Independent Claim
93 words
A method of fabricating a porous nickel-aluminum article comprising: (a) plating a preform with aluminum and nickel to create a metal-plated structure, said plating of nickel consisting of a coating step selected from the group consisting of electrodeposition and gaseous plating, said plating of aluminum consisting of gaseous deposition of an organometallic-aluminum compound and said preform having a shape selected from the group consisting of an open felt structure, woven fabric and reticulated foam; and (b) reactive sintering said metal-plated structure to leave an open nickel-aluminum structure; said open nickel-aluminum structure having porosity.
Claim 2
Independent Claim
93 words
A method of fabricating a porous nickel-aluminum article comprising: (a) plating a preform with aluminum and nickel to create a metal-plated structure, said plating of nickel consisting of a coating step selected from the group consisting of electrodeposition and gaseous plating, said plating of aluminum consisting of gaseous deposition of an organometallic-aluminum compound and said preform having a shape selected from the group consisting of an open felt structure, woven fabric and reticulated foam; and (b) reactive sintering said metal-plated structure to leave an open nickel-aluminum structure; said open nickel-aluminum structure having porosity.
Claim 3
Dependent Claim
22 words
The method of claim 1 including the additional step of removing said preform from said metal-plated structure before said reactive sintering step.
Claim 4
Dependent Claim
32 words
The method of claim 1 including the additional step of compressing said metal-plated structure before said reactive sintering to decrease said porosity of said open nickel-aluminum structure formed by said reactive sintering.
Claim 5
Dependent Claim
27 words
The method of claim 1 including the additional step of compressing said open nickel-aluminum structure after said reactive sintering to decrease porosity of said open nickel-aluminum structure.
Claim 6
Dependent Claim
42 words
The mood of claim 1 wherein said plating of aluminum consists of thermally decomposing an organometallic-aluminum compound selected from the group consisting of trialkyl-aluminum and dialkyl-aluminum-hydrides on said preform plated with nickel; and said organometallic compound contains 1 to 4 carbon atoms.
Claim 7
Dependent Claim
30 words
The method of claim 5 wherein said organometallic-aluminum compound is a gas selected from the group consisting of triisobutyl-aluminum, triethyl-aluminum, tripropyl-aluminum, diethyl-aluminum hydride, diisobutyl-aluminum hydride and mixtures of said gases.
Claim 8
Dependent Claim
20 words
The method of claim 6 wherein said gas is triisobutyl-aluminum decomposed at a temperature between 100° C. and 310° C.
Claim 9
Dependent Claim
23 words
The method of claim 7 wherein said plating includes depositing aluminum from an atmosphere containing 5 to 100 volume percent of said triisobutyl-aluminum.
Claim 10
Dependent Claim
27 words
The method of claim 1 wherein said plating includes decomposing nickel carbonyl on said preform to form a nickel-coated preform and decomposing triisobutyl-aluminum on said nickel-coated preform.
Claim 11
Dependent Claim
20 words
The method of claim 1 wherein said sintering leaves an open nickel-aluminum structure containing 1 to 58 atomic percent aluminum.
Claim 12
Dependent Claim
36 words
The method of claim 1 wherein said plating comprises coating fibers selected from the group consisting of SiC, alumina-base, silica-base and alumina-silica-base fibers, and said reactive sintering forms an open nickel-aluminum structure reinforced with said fibers.
Claim 13
Independent Claim
149 words
A method of fabricating a porous nickel-aluminum article comprising: (a) plating an organic preform with nickel to create a nickel-plated structure, said plating of nickel consisting of a coating step selected from the group consisting of electrolytic plating and gaseous plating, said preform having a shape selected from the group consisting of an open felt structure, woven fabric and reticulated foam; (b) heating said nickel-plated preform to remove said organic preform and leave a porous nickel structure; (c) decomposing an organometallic aluminum on said porous nickel structure to form a porous aluminum-coated nickel structure, said organometallic-aluminum compound being a gas selected from the group consisting of triisobutyl-aluminum, triethyl-aluminum, tripropyl-aluminum, diethyl-aluminum hydride, diisobutyl-aluminum hydride and mixtures of said gases; (d) reactive sintering said porous aluminum-coated nickel structure to diffuse aluminum into said nickel structure and react said aluminum with said nickel structure to form an open nickel-aluminum structure having porosity.
Claim 14
Independent Claim
149 words
A method of fabricating a porous nickel-aluminum article comprising: (a) plating an organic preform with nickel to create a nickel-plated structure, said plating of nickel consisting of a coating step selected from the group consisting of electrolytic plating and gaseous plating, said preform having a shape selected from the group consisting of an open felt structure, woven fabric and reticulated foam; (b) heating said nickel-plated preform to remove said organic preform and leave a porous nickel structure; (c) decomposing an organometallic aluminum on said porous nickel structure to form a porous aluminum-coated nickel structure, said organometallic-aluminum compound being a gas selected from the group consisting of triisobutyl-aluminum, triethyl-aluminum, tripropyl-aluminum, diethyl-aluminum hydride, diisobutyl-aluminum hydride and mixtures of said gases; (d) reactive sintering said porous aluminum-coated nickel structure to diffuse aluminum into said nickel structure and react said aluminum with said nickel structure to form an open nickel-aluminum structure having porosity.
Claim 15
Dependent Claim
33 words
The method of claim 12 including the additional step of compressing said aluminum-coated nickel structure before said reactive sintering to decrease said porosity of said open nickel-aluminum structure formed by said reactive sintering.
Claim 16
Dependent Claim
30 words
The method of claim 12 wherein said decomposing includes depositing aluminum from an atmosphere containing 5 to 100 volume percent triisobutyl-aluminum at a temperature between 100° C. and 310° C.
Claim 17
Dependent Claim
21 words
The method of claim 12 wherein said reactive sintering leaves an open nickel-aluminum structure containing 1 to 58 atomic percent aluminum.
Claim 18
Dependent Claim
18 words
The method of claim 12 wherein said reactive sintering results in an open nickel-aluminum structure containing nickel aluminide.
Claim 19
Dependent Claim
16 words
The method of claim 16 wherein said open nickel-aluminide contains at least 10 atomic percent aluminum.
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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) | 2002-09-13 | 2003-03-15 | 2003-09-14 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2006-09-13 | 2007-03-15 | 2007-09-14 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2010-09-13 | 2011-03-15 | 2011-09-14 | $7700.00 | Window Closed / Lapsed |