Uniformly controlled nanoscale oxide dispersion strengthened alloys

Patent metadata

Field	Value
Publication number	US-10906105-B2
Application number	US-201815958203-A
Country	US
Kind code	B2
Filing date	Apr 20, 2018
Priority date	Apr 20, 2018
Publication date	Feb 2, 2021
Grant date	Feb 2, 2021

Abstract

A process of forming an oxide dispersion strengthened alloy, comprises distributing an alloy powder on a platform; applying a uniform nanometer-scale metal oxide onto the alloy powder; applying an energy beam onto the alloy powder and the uniform nanometer-scale metal oxide; and forming an oxide dispersion strengthened alloy.

First claim

What is claimed is:

1. A process of forming an oxide dispersion strengthened alloy, comprising:
distributing an alloy powder on a platform;
applying a uniform nanometer-scale metal oxide onto said alloy powder, said uniform nanometer-scale metal oxide comprises polynuclear metal oxide-hydroxide clusters;
applying an energy beam onto said alloy powder and said uniform nanometer-scale metal oxide, so as to form an oxide dispersion strengthened alloy.

2. The process of claim 1 , where the uniform nanometer-scale metal oxide are produced by spray atomization of nanoscale polynuclear metal oxide-hydroxide clusters in a carrier fluid.

3. The process of claim 2 , where the uniform nanometer-scale metal oxide are produced by electrospray of nanoscale polynuclear metal oxide-hydroxide clusters in a carrier fluid.

4. The process of claim 1 , wherein said oxide dispersion strengthened alloy comprises an aluminum based alloy and the uniform nanometer-scale metal oxide.

5. The process of claim 1 , wherein uniform nanometer-scale metal oxide is dispersed throughout said oxide dispersion strengthened alloy.

6. The process of claim 5 , wherein said uniform nanometer-scale metal oxide comprises about 0.1 vol. % to about 10 vol. % of said oxide dispersion strengthened alloy.

7. The process of claim 5 , wherein said uniform nanometer-scale metal oxide comprises between 1 nanometer and 300 nanometers in diameter.

8. The process of claim 1 , further comprising rapid melting, mixing and solidification of the uniform nanometer-scale metal oxide with said alloy powder.

9. The process of claim 1 , further comprising:
consolidating said uniform nanometer-scale metal oxide with said alloy powder comprising a laser powder bed fusion of said uniform nanometer-scale metal oxide with said alloy powder.

10. The process of claim 1 , wherein said uniform nanometer-scale metal oxide is derived from Al 13 polynuclear oxide-hydroxide clusters.

11. The process of claim 1 , wherein deposition of atomized oxide precursors is conducted in combination with laser processing, wherein an oxide conversion and an alloy consolidation occurs simultaneously.

12. The process of claim 1 , wherein said polynuclear metal oxide-hydroxide clusters are selected from the group consisting of Y, Fe, Cr, group VI transition metals, La, Ce and other rare earth metals.

13. The process of claim 1 , wherein said oxide dispersion strengthened alloy comprises a copper based alloy and alumina nano-oxide dispersion.

14. The process of claim 1 , wherein said oxide dispersion strengthened alloy comprises a nickel based alloy and one of an alumina, a chromia, an yttria, a ceria, a lanthanum oxide, rare earth oxide, nano-oxide dispersion.

15. The process of claim 1 , wherein said oxide dispersion strengthened alloy comprises an iron based alloy and one of an alumina, a chromia, an yttria, a ceria, a lanthanum oxide, other rare earth oxide, nano-oxide dispersion.

16. The process of claim 1 , wherein said oxide dispersion strengthened alloy comprises a molybdenum based alloy and one of an alumina, a chromia, an yttria, a ceria, a lanthanum oxide, other rare earth oxide, nano-oxide dispersion.

17. The process of claim 1 , wherein said uniform nanometer-scale metal oxide is formed separately.

18. The process of claim 1 , wherein said uniform nanometer-scale metal oxide is formed ex-situ.

19. The process of claim 1 , wherein said uniform nanometer-scale metal oxide powder is formed by electrospray atomization.

20. A process of forming an oxide dispersion strengthened alloy, comprising:
distributing an alloy powder on a platform;
applying a material containing uniform nanometer-scale metal oxide precursor and said alloy powder;
applying an energy beam onto said uniform nanometer-scale metal oxide precursor precursor and said alloy powder, wherein a nanometer-scale metal oxide is formed in-situ by use of the uniform nanometer-scale metal oxide precursor so as to form an oxide dispersion strengthened alloy.

21. A process of forming an oxide dispersion strengthened alloy, comprising:
distributing an alloy powder on a platform;
applying a uniform nanometer-scale metal oxide onto said alloy powder;
applying an energy beam onto said alloy powder and said uniform nanometer-scale metal oxide, so as to form an oxide dispersion strengthened alloy, wherein said oxide dispersion strengthened alloy comprises a copper based alloy and alumina nano-oxide dispersion.

Assignees

• United Technologies Corp
• Raytheon Tech Corp

Inventors

• Opalka Susanne M
• Sharon John A
• El-Wardany Tahany Ibrahim

Classifications

• C22C1/1042

  by atomising · CPC title

• C22C32/0036

  Matrix based on Al, Mg, Be or alloys thereof · CPC title

• C22C32/0031

  Matrix based on refractory metals, W, Mo, Nb, Hf, Ta, Zr, Ti, V or alloys thereof · CPC title

• C22C32/0026

  Matrix based on Ni, Co, Cr or alloys thereof · CPC title

• C22C32/0021

  Matrix based on noble metals, Cu or alloys thereof · CPC title