US4772452A
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US
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Process for forming metal-second phase composites utilizing compound starting materials
Assignee: Lockheed Martin Corp
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Filing: 1987-04-03
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Granted: 1988-09-20
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Expires: 2007-04-03
Abstract
Abstract This invention relates to a process for making composite materials involving the in-situ precipitation of second phase particles in a metal matrix, and the products thereof. The process involves the use of initial compound materials as a source of second phase-forming reactants in the production of metal-second phase composites. The composites produced may comprise distributions of either single or multiple second phase materials. Exemplary initial compound precursors include boron nitride, boron carbide, boron oxide, aluminum nitride, aluminum carbide, aluminum boride, iron oxide and copper oxide.
Inventors
- 👤 John M. Brupbacher
- 👤 Leontios Christodoulou
- 👤 Dennis C. Nagle
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-28 01:10
CPC Classifications
C; C22; C22C; C22C1/00; C22C1/10; C22C1/1036; C22C1/1047; C22C1/1052; B; B22; B22F; B22F3/00; B22F3/23; B22F9/00; B22F9/02; B22F9/14
Claims Analysis
Total Claims: 58
Claim 1
Independent Claim
119 words
In a method for the production of metal-second phase composite materials, the method comprising precipitating second phase material in a solvent metal matrix by contacting at least one primary second phase forming reactant and at least one secondary second phase-forming reactant in the presence of a substantially nonreactive solvent metal in which the second phase-forming reactants are more soluble than the second phase material, at a temperature at which sufficient diffusion of the reactants into the solvent metal occurs to cause a second phase-forming reaction of the reactants to thereby precipitate second phase material in the solvent metal, and recovering a metal-second phase composite material, the improvement comprising providing said at least one primary reactant from an initial compound.
Claim 2
Dependent Claim
119 words
In a method for the production of metal-second phase composite materials, the method comprising precipitating second phase material in a solvent metal matrix by contacting at least one primary second phase forming reactant and at least one secondary second phase-forming reactant in the presence of a substantially nonreactive solvent metal in which the second phase-forming reactants are more soluble than the second phase material, at a temperature at which sufficient diffusion of the reactants into the solvent metal occurs to cause a second phase-forming reaction of the reactants to thereby precipitate second phase material in the solvent metal, and recovering a metal-second phase composite material, the improvement comprising providing said at least one primary reactant from an initial compound.
Claim 3
Dependent Claim
21 words
The method of claim 1, wherein the initial compound, at least one secondary reactant, and solvent metal are provided as powders.
Claim 4
Dependent Claim
12 words
The method of claim 2, wherein the powders are premixed and compacted.
Claim 5
Dependent Claim
35 words
The method of claim 1, wherein the initial compound is boron nitride, boron carbide, boron oxide, aluminum nitride, aluminum carbide, aluminum boride, silicon carbide, silicon nitride, copper oxide, iron oxide, titanium aluminide, or nickel aluminide.
Claim 6
Dependent Claim
18 words
The method of claim 1, wherein the solvent metal is aluminum, copper, iron, magnesium, or an alloy thereof.
Claim 7
Dependent Claim
16 words
The method of claim 1, wherein at least one secondary reactant is provided in elemental form.
Claim 8
Dependent Claim
20 words
The method of claim 1, wherein at least one secondary reactant is provided in an alloy of the solvent metal.
Claim 9
Dependent Claim
20 words
The method of claim 1, wherein at least one secondary reactant is provided in an alloy of a reactive metal.
Claim 10
Dependent Claim
13 words
The method of claim 1, wherein the second phase material is a ceramic.
Claim 11
Dependent Claim
12 words
The method of claim 1, wherein the second phase is an intermetallic.
Claim 12
Dependent Claim
22 words
The method of claim 1, wherein the second phase material is particulate and is substantially uniformly distributed throughout the solvent metal matrix.
Claim 13
Dependent Claim
27 words
The method of claim 11, wherein the particulate second phase is titanium diboride, zirconium diboride, zirconium disilicide, titanium oxide, titanium carbide, titanium nitride or a mixture thereof.
Claim 14
Dependent Claim
13 words
The method of claim 12, wherein the second phase is submicron in size.
Claim 15
Dependent Claim
15 words
The method of claim 13, wherein the second phase-forming reactants are contacted in stoichiometric proportions.
Claim 16
Dependent Claim
17 words
The method of claim 13, wherein one second phase-forming reactant is provided in greater than stoichiometric proportion.
Claim 17
Dependent Claim
22 words
The method of claim 13, wherein the concentration of the second phase material is from about 10 to about 90 volume percent.
Claim 18
Dependent Claim
25 words
The method of claim 1, wherein said initial compound comprises aluminum boride, said secondary reactant comprises titanium, and said second phase material comprises titanium diboride.
Claim 19
Dependent Claim
15 words
The method of claim 1, wherein plural primary reactants are provided from multiple initial compounds.
Claim 20
Dependent Claim
18 words
The method of claim 1, wherein said second phase material comprises material of at least two different compositions.
Claim 21
Dependent Claim
28 words
The method of claim 19, wherein said initial compound comprises boron nitride, said secondary reactant comprises titanium, and said second phase material comprises titanium diboride and titanium nitride.
Claim 22
Dependent Claim
28 words
The method of claim 19, wherein said initial compound comprises boron carbide, said secondary reactant comprises titanium, and said second phase material comprises titanium diboride and titanium carbide.
Claim 23
Dependent Claim
116 words
In a method for the production of metal-second phase composite materials, the method comprising precipitating second phase material in a solvent metal matrix by contacting at least two primary second phase-forming reactants in the presence of a substantially nonreactive solvent metal in which at least one of the second phase-forming reactants is more soluble than the second phase material, at a temperature at which sufficient diffusion of said at least one reactant into the solvent metal occurs to cause a second phase-forming reaction to thereby precipitate second phase material in the solvent metal, and recovering a metal-second phase composite material, the improvement comprising providing said at least two primary reactants from at least two initial compounds.
Claim 24
Dependent Claim
116 words
In a method for the production of metal-second phase composite materials, the method comprising precipitating second phase material in a solvent metal matrix by contacting at least two primary second phase-forming reactants in the presence of a substantially nonreactive solvent metal in which at least one of the second phase-forming reactants is more soluble than the second phase material, at a temperature at which sufficient diffusion of said at least one reactant into the solvent metal occurs to cause a second phase-forming reaction to thereby precipitate second phase material in the solvent metal, and recovering a metal-second phase composite material, the improvement comprising providing said at least two primary reactants from at least two initial compounds.
Claim 25
Dependent Claim
16 words
The method of claim 22, wherein the initial compounds and solvent metal are provided as powders.
Claim 26
Dependent Claim
12 words
The method of claim 23, wherein the powders are premixed and compacted.
Claim 27
Dependent Claim
22 words
The method of claim 22, wherein the second phase material is particulate and is substantially uniformly distributed throughout the solvent metal matrix.
Claim 28
Independent Claim
124 words
A method for precipitation of second phase material in a solvent metal matrix, the method comprising steps of: (a) preparing a mixture of an initial compound, at least one secondary second phase-forming reactant, and a substantially non-reactive solvent metal in which at least one secondary second phase-forming reactant is more soluble than the second phase, said initial compound comprising at least one primary second phase-forming reactant; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent metal to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture, consuming the second phase-forming reactants, and to form a substantially uniform distribution of second phase particles in the solvent metal matrix; and (d) recovering a product.
Claim 29
Independent Claim
124 words
A method for precipitation of second phase material in a solvent metal matrix, the method comprising steps of: (a) preparing a mixture of an initial compound, at least one secondary second phase-forming reactant, and a substantially non-reactive solvent metal in which at least one secondary second phase-forming reactant is more soluble than the second phase, said initial compound comprising at least one primary second phase-forming reactant; (b) heating the mixture to a reaction initiation temperature approximating the melting point of the solvent metal to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture, consuming the second phase-forming reactants, and to form a substantially uniform distribution of second phase particles in the solvent metal matrix; and (d) recovering a product.
Claim 30
Dependent Claim
21 words
The method of claim 26, wherein said initial compound, at least one secondary reactant, and solvent metal are provided as powders.
Claim 31
Dependent Claim
12 words
The method of claim 27, wherein the powders are premixed and compacted.
Claim 32
Dependent Claim
19 words
The method of claim 28, wherein initiation of the exothermic reaction is achieved by bulk heating of the mixture.
Claim 33
Dependent Claim
22 words
The method of claim 28, wherein initiation of the exothermic reaction is achieved by heating a substantially localized portion of the mixture.
Claim 34
Dependent Claim
24 words
The method of claim 28, wherein initiation of the exothermic reaction is achieved by introducing the mixture into a molten bath of matrix metal.
Claim 35
Dependent Claim
14 words
The method of claim 26, wherein the reaction takes place in the liquid state.
Claim 36
Dependent Claim
37 words
The method of claim 26, wherein the initial compound is selected from boron nitride, boron carbide, boron oxide, aluminum nitride, aluminum carbide, aluminum boride, silicon carbide, silicon nitride, iron oxide, copper oxide, titanium aluminide, or nickel aluminide.
Claim 37
Dependent Claim
26 words
The method of claim 26, wherein at least one second phase-forming reactant is a transition metal of the third to sixth groups of the Periodic Table.
Claim 38
Dependent Claim
51 words
The method of claim 26, wherein at least one second phase-forming reactant 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 39
Dependent Claim
22 words
The method of claim 26, wherein at least one secondary second phase-forming reactant and the solvent metal are provided as individual elements.
Claim 40
Dependent Claim
23 words
The method of claim 26, wherein at least one secondary second phase forming reactant is provided as an alloy of the solvent metal.
Claim 41
Dependent Claim
42 words
The method of claim 26, 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 42
Dependent Claim
12 words
The method of claim 26, wherein the second phase material is ceramic.
Claim 43
Dependent Claim
12 words
The method of claim 26, wherein the second phase material is intermetallic.
Claim 44
Dependent Claim
24 words
The method of claim 26, wherein the second phase material is an oxide, nitride, boride, carbide, silicide, oxynitride, sulfide, oxysulfide, or a mixture thereof.
Claim 45
Dependent Claim
26 words
The method of claim 41, wherein the second phase material is titanium diboride, zirconium diboride, zirconium disilicide, titanium oxide, titanium carbide, titanium nitride, or mixtures thereof.
Claim 46
Independent Claim
105 words
A method for precipitation of second phase material in a solvent metal matrix, the method comprising steps of: (a) preparing a mixture of at least two initial compounds, each of which comprises at least one primary second phase-forming reactant, and a substantially non-reactive solvent metal in which at least one of said reactants are more soluble than the second phase; (b) heating the mixture to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture, consuming the second phase-forming reactants, and to form a substantially uniform distribution of second phase particles in the solvent metal matrix; and (d) recovering a product.
Claim 47
Independent Claim
105 words
A method for precipitation of second phase material in a solvent metal matrix, the method comprising steps of: (a) preparing a mixture of at least two initial compounds, each of which comprises at least one primary second phase-forming reactant, and a substantially non-reactive solvent metal in which at least one of said reactants are more soluble than the second phase; (b) heating the mixture to initiate an exothermic reaction; (c) permitting the exothermic reaction to further heat the mixture, consuming the second phase-forming reactants, and to form a substantially uniform distribution of second phase particles in the solvent metal matrix; and (d) recovering a product.
Claim 48
Dependent Claim
16 words
The method of claim 43, wherein said initial compounds and solvent metal are provided as powders.
Claim 49
Dependent Claim
13 words
The method of claim 44, wherein the mixture is compacted prior to heating.
Claim 50
Dependent Claim
19 words
The method of claim 45, wherein initiation of the exothermic reaction is achieved by bulk heating of the mixture.
Claim 51
Dependent Claim
22 words
The method of claim 45, wherein initiation of the exothermic reaction is achieved by heating a substantially locallized portion of the mixture.
Claim 52
Dependent Claim
24 words
The method of claim 45, wherein initiation of the exothermic reaction is achieved by introducing the mixture into a molten bath of matrix metal.
Claim 53
Independent Claim
148 words
A method for dispersion of second phase dispersoids in a solvent metal matrix, the method comprising forming a reaction mixture of at least one primary second phase-forming reactant provided from an initial compound and at least one secondary second phase-forming reactant, in the presence of at least two metals, at least the lower melting of which acts as a solvent metal in which second phase-forming reactants are more soluble than the second phase dispersoids, raising the temperature of the reaction mixture to a temperature at which sufficient diffusion of the second phase-forming reactants into the solvent metal occurs to initiate a reaction of the reactants, whereby the exothermic heat of reaction of the reactants causes the temperature of the reaction mixture to exceed the melting point of the higher melting point metal, permitting dispersion of the second phase dispersoids in a mixed metal matrix, and recovering a product.
Claim 54
Independent Claim
148 words
A method for dispersion of second phase dispersoids in a solvent metal matrix, the method comprising forming a reaction mixture of at least one primary second phase-forming reactant provided from an initial compound and at least one secondary second phase-forming reactant, in the presence of at least two metals, at least the lower melting of which acts as a solvent metal in which second phase-forming reactants are more soluble than the second phase dispersoids, raising the temperature of the reaction mixture to a temperature at which sufficient diffusion of the second phase-forming reactants into the solvent metal occurs to initiate a reaction of the reactants, whereby the exothermic heat of reaction of the reactants causes the temperature of the reaction mixture to exceed the melting point of the higher melting point metal, permitting dispersion of the second phase dispersoids in a mixed metal matrix, and recovering a product.
Claim 55
Dependent Claim
21 words
The method of claim 49, wherein the higher melting metal is cobalt, chromium, nickel, niobium, tantalum, titanium, vanadium, iron, or silicon.
Claim 56
Dependent Claim
19 words
The method of claim 50, wherein the lowest melting solvent metal is aluminum, copper, tin, zinc, lead or magnesium.
Claim 57
Independent Claim
149 words
A method for dispersion of second phase dispersoids in a solvent metal matrix, the method comprising forming a reaction mixture of at least one primary second phase-forming reactant provided from an initial compound and at least one secondary second phase-forming reactant, in the presence of at least two metals, at least one of which acts as a solvent metal in which said second phase-forming reactants are more soluble than said second phase dispersoids, raising the temperature of the reaction mixture to a temperature at which sufficient diffusion of the second phase-forming reactants into the lowest melting solvent metal occurs to initiate a reaction of the reactants, whereby the exothermic heat of reaction of the reactants causes the temperature of the reaction mixture to exceed the melting point of the lowest melting point metal permitting dispersion of the second phase dispersoids in a mixed metal matrix and recovering a product.
Claim 58
Independent Claim
149 words
A method for dispersion of second phase dispersoids in a solvent metal matrix, the method comprising forming a reaction mixture of at least one primary second phase-forming reactant provided from an initial compound and at least one secondary second phase-forming reactant, in the presence of at least two metals, at least one of which acts as a solvent metal in which said second phase-forming reactants are more soluble than said second phase dispersoids, raising the temperature of the reaction mixture to a temperature at which sufficient diffusion of the second phase-forming reactants into the lowest melting solvent metal occurs to initiate a reaction of the reactants, whereby the exothermic heat of reaction of the reactants causes the temperature of the reaction mixture to exceed the melting point of the lowest melting point metal permitting dispersion of the second phase dispersoids in a mixed metal matrix and recovering a product.
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