Methods for nanofunctionalization of powders, and nanofunctionalized materials produced therefrom

Patent metadata

Field	Value
Publication number	US-2023398604-A1
Application number	US-202318204791-A
Country	US
Kind code	A1
Filing date	Jun 1, 2023
Priority date	Feb 1, 2017
Publication date	Dec 14, 2023
Grant date	—

Abstract

Some variations provide a method of making a nanofunctionalized metal powder, comprising: providing metal particles containing metals selected from iron, nickel, copper, titanium, magnesium, zinc, silicon, lithium, silver, chromium, manganese, vanadium, bismuth, gallium, or lead; providing nanoparticles selected from zirconium, tantalum, niobium, or titanium; disposing the nanoparticles onto surfaces of the metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and isolating and recovering the nanofunctionalized metal particles as a nanofunctionalized metal powder. Some variations provide a composition comprising a nanofunctionalized metal powder, the composition comprising metal particles and nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, or combinations of the foregoing.

First claim

What is claimed is:

1 . A composition comprising a nanofunctionalized metal powder, said composition comprising:
(a) metal particles containing nickel; and (b) nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, carbides, or borides thereof, and combinations of the foregoing.

2 . The composition of claim 1 , wherein said nanoparticles are present at a concentration of at least 0.1 vol % in said nanofunctionalized metal powder.

3 . The composition of claim 2 , wherein said nanoparticles are present at a concentration of at least 1 vol % in said nanofunctionalized metal powder.

4 . The composition of claim 1 , wherein the average number ratio of said nanoparticles to said metal particles is from about 10 to about 10 6 .

5 . The composition of claim 1 , wherein said nanoparticles have an average largest dimension from about 50 nanometers to about 5000 nanometers.

6 . The composition of claim 1 , wherein the ratio of average particle size of said metal particles to average particle size of said nanoparticles is from about 1 to about 10 4 .

7 . The composition of claim 6 , wherein said ratio is from about 10 to about 1000.

8 . The composition of claim 1 , wherein said composition includes an assembly aid disposed between said nanoparticles and surfaces of said metal particles.

9 . The composition of claim 8 , wherein said assembly aid is selected from the group consisting of surfactants, salts, dissolved ions, charged molecules, polar or non-polar solvents, hierarchically sized particulates, surface etchants, and combinations thereof.

10 . The composition of claim 1 , wherein said nanoparticles are lattice-matched to within ±5% of said metal particles.

11 . The composition of claim 10 , wherein said nanoparticles are lattice-matched to within ±2% of said metal particles.

12 . The composition of claim 1 , wherein at least 90% of said nanoparticles are disposed chemically or physically on said surfaces of said metal particles.

13 . A composition comprising a nanofunctionalized metal powder, said composition comprising:
(a) metal particles containing nickel; and (b) nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, hydrides, carbides, or borides thereof, and combinations of the foregoing, wherein said nanoparticles are present at a concentration of at least 0.1 vol % in said nanofunctionalized metal powder, and wherein said nanoparticles are disposed chemically or physically on at least 90% of the surface area of said surfaces of said metal particles.

14 . The composition of claim 13 , wherein said nanoparticles are present at a concentration of at least 1 vol % in said nanofunctionalized metal powder.

15 . The composition of claim 13 , wherein the average number ratio of said nanoparticles to said metal particles is from about 10 to about 10 6 .

16 . The composition of claim 13 , wherein said nanoparticles have an average largest dimension from about 50 nanometers to about 5000 nanometers.

17 . The composition of 13 , wherein the ratio of average particle size of said metal particles to average particle size of said nanoparticles is from about 1 to about 10 4 .

18 . The composition of claim 13 , wherein said composition includes an assembly aid disposed between said nanoparticles and said surfaces of said metal particles.

19 . The composition of claim 18 , wherein said assembly aid is selected from the group consisting of surfactants, salts, dissolved ions, charged molecules, polar or non-polar solvents, hierarchically sized particulates, surface etchants, and combinations thereof.

20 . The composition of claim 13 , wherein said nanoparticles are lattice-matched to within ±5% of said metal particles.

21 . The composition of claim 20 , wherein said nanoparticles are lattice-matched to within ±2% of said metal particles.

22 . A nanofunctionalized metal powder produced by a process comprising:
(a) providing metal particles containing nickel; (b) providing nanoparticles containing one or more elements selected from the group consisting of zirconium, tantalum, niobium, titanium, and oxides, nitrides, carbides, or borides thereof, and combinations of the foregoing; (c) disposing said nanoparticles onto surfaces of said metal particles, in the presence of mixing media, thereby generating nanofunctionalized metal particles; and (d) isolating and recovering said nanofunctionalized metal particles as a nanofunctionalized metal powder.

23 . The composition of claim 22 , wherein said nanoparticles are present at a concentration of at least 0.1 vol % in said nanofunctionalized metal powder, and wherein at least some of said nanoparticles are disposed chemically or physically on surfaces of said metal particles.

24 . The composition of claim 22 , wherein said nanoparticles are lattice-matched to within ±5% of said metal particles.

25 . The composition of claim 22 , wherein at least 90% of said nanoparticles are disposed chemically or physically on said surfaces of said metal particles.

Assignees

• Hrl Lab Llc

Inventors

• Martin John H
• Yahata Brennan
• Gross Adam F

Classifications

• B22F9/04 Primary

  starting from solid material, e.g. by crushing, grinding or milling ({C22C1/1084 takes precedence}; crushing, grinding or milling, in general, see the relevant subclasses, e.g. B02C) · CPC title

• B22F9/06

  starting from liquid material · CPC title

• B33Y70/00

  Materials specially adapted for additive manufacturing · CPC title

• B22F1/054

  Nanosized particles · CPC title

• B22F1/17

  Metallic particles coated with metal · CPC title