Materials and methods for producing metal nanocomposites, and metal nanocomposites obtained therefrom

Patent metadata

Field	Value
Publication number	US-2018133789-A1
Application number	US-201715808877-A
Country	US
Kind code	A1
Filing date	Nov 9, 2017
Priority date	Nov 16, 2016
Publication date	May 17, 2018
Grant date	—

Abstract

Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure. The methods disclosed enable various loadings of nanoparticles in metal matrix nanocomposites with a wide variety of compositions.

First claim

What is claimed is:

1 . A composition comprising metal-containing microparticles and nanoparticles, wherein said nanoparticles are chemically and/or physically disposed on surfaces of said microparticles, and wherein said nanoparticles are consolidated in a three-dimensional architecture throughout said composition.

2 . The composition of claim 1 , wherein said composition is an ingot for producing a metal nanocomposite.

3 . The composition of claim 1 , wherein said composition is a metal nanocomposite.

4 . The composition of claim 1 , wherein said microparticles contain an element selected from the group consisting of Al, Mg, Ni, Fe, Cu, Ti, V, Si, and combinations thereof.

5 . The composition of claim 1 , wherein said nanoparticles contain a compound selected from the group consisting of metals, ceramics, cermets, intermetallic alloys, oxides, carbides, nitrides, borides, polymers, carbon, and combinations thereof.

6 . The composition of claim 1 , wherein said microparticles contain Al, Si, and Mg, and wherein said nanoparticles contain tungsten carbide (WC).

7 . The composition of claim 1 , wherein said microparticles have an average microparticle size from about 1 micron to about 1 millimeter.

8 . The composition of claim 1 , wherein said nanoparticles have an average nanoparticle size from about 1 nanometer to about 1000 nanometers.

9 . The composition of claim 1 , wherein said composition contains from about 10 wt % to about 99.9 wt % of said microparticles.

10 . The composition of claim 1 , wherein said composition contains from about 0.1 wt % to about 10 wt % of said nanoparticles.

11 . A metal nanocomposite comprising a metal phase containing Al, Si, and Mg and a reinforcement phase containing W and C.

12 . The metal nanocomposite of claim 11 , wherein said metal phase contains aluminum alloy AlSi10Mg.

13 . The metal nanocomposite of claim 11 , wherein said reinforcement phase contains tungsten carbide (WC).

14 . The metal nanocomposite of claim 11 , wherein said nanocomposite has a cast microstructure.

15 . The metal nanocomposite of claim 11 , wherein said metal phase and said reinforcement phase are disposed in a layered configuration within said metal nanocomposite, wherein said layered configuration includes a first layer comprising said W and C and said Al, Si, and Mg, and a second layer comprising said Al, Si, and Mg.

16 . A method of making a metal nanocomposite, said method comprising:
(a) providing a precursor composition comprising metal-containing microparticles and nanoparticles, wherein said nanoparticles are chemically and/or physically disposed on surfaces of said microparticles; (b) consolidating said precursor composition into an intermediate composition comprising said metal-containing microparticles and said nanoparticles, wherein said nanoparticles are consolidated in a three-dimensional architecture throughout said intermediate composition; and (c) processing said intermediate composition to convert said intermediate composition into a metal nanocomposite.

17 . The method of claim 15 , wherein said precursor composition is in powder form.

18 . The method of claim 15 , wherein said intermediate composition is in ingot form.

19 . The method of claim 15 , wherein said microparticles contain an element selected from the group consisting of Al, Mg, Ni, Fe, Cu, Ti, V, Si, and combinations thereof.

20 . The method of claim 15 , wherein said nanoparticles contain a compound selected from the group consisting of metals, ceramics, cermets, intermetallic alloys, oxides, carbides, nitrides, borides, polymers, carbon, and combinations thereof.

21 . The method of claim 15 , wherein step (b) includes pressing, binding, sintering, or a combination thereof.

22 . The method of claim 15 , wherein step (c) includes pressing, sintering, mixing, dispersing, friction stir welding, extrusion, binding, melting, semi-solid melting, capacitive discharge sintering, casting, or a combination thereof.

23 . The method of claim 15 , wherein said metal nanocomposite has a cast microstructure.

25 . The method of claim 15 , wherein said metal-containing microparticles and said nanoparticles are each dispersed throughout said metal nanocomposite.

26 . The method of claim 15 , wherein said metal nanocomposite has a layered configuration including at least a first layer comprising said nanoparticles and at least a second layer comprising said metal-matrix phase.

Assignees

• Hrl Lab Llc

Inventors

• Martin John H
• Yahata Brennan D

Classifications

• Y10T428/12021

  having composition or density gradient or differential porosity · CPC title

• B22F2998/10

  Processes characterised by the sequence of their steps · CPC title

• B22F7/04

  with one or more layers not made from powder, e.g. made from solid metal · CPC title

• B22F2007/045

  accompanied by fusion or impregnation · CPC title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title