Method for eggshell milling to form reinforced composite

Patent metadata

Field	Value
Publication number	US-2025033116-A1
Application number	US-202418911871-A
Country	US
Kind code	A1
Filing date	Oct 10, 2024
Priority date	Jun 23, 2022
Publication date	Jan 30, 2025
Grant date	—

Abstract

A method to form a metal matrix composite reinforced with eggshell (ES). The method includes preparing an ES powder, blending and milling the ES powder with at least one metal powder selected from the group consisting of magnesium (Mg), zirconium (Zr) to form a powder mixture, compacting and sintering the powder mixture to form the metal matrix composite. In addition, a Mg—Zr-ES metal matrix composite with improved corrosion resistance, having an amount of magnesium from 95 to 97 wt. %, an amount of zirconium from 1 to 2 wt. %, and an amount of ES from 1 to 4 wt. %, may be used for biomedical applications.

First claim

1 . A method to form a metal matrix composite reinforced with eggshell (ES), comprising:
blending and milling with a planetary mill a powder consisting of at least one magnesium (Mg) powder and at least one zirconium (Zr) powder and at least one ES powder to form a powder mixture; compacting the powder mixture in a uniaxial press to form a compacted powder mixture; and sintering the compacted powder mixture to form a composite matrix by making the compacted powder mixture coalesce into a solid or porous mass by heating it without complete liquifaction; wherein said at least one Mg powder has a particle size in a range of 20 to 70 micrometers (μm); wherein said at least one Zr powder has a particle size in a range of 20 to 60 μm; wherein after the sintering, the composite matrix consists of magnesium, zirconium, and ES; and wherein the amount of magnesium in the composite matrix is from 89.9 to 99.9 wt. %, the amount of zirconium in the composite matrix is from 0.1 to 10 wt. %, and the amount of ES in the composite matrix is from 0.1 to 10 wt. %.

2 . The method of claim 1 , wherein:
the amount of magnesium in the composite matrix is from 95 to 97 wt. %, the amount of zirconium in the composite matrix is from 1 to 2 wt. %, and the amount of ES in the composite matrix is from 1 to 4 wt. %.

3 . The method of claim 1 , further comprising:
heating, drying and crushing the eggshell (ES) to form a crushed ES; and grinding the crushed ES to form the ES powder, wherein the ES powder has a reduced particle size compared to the crushed ES.

4 . The method of claim 3 , wherein:
the ES powder has an irregular size and shape; and the ES powder has an average particle size in a range of 1 to 10 μm.

5 . The method of claim 3 , wherein:
the ES powder has a peak in a range of 2 theta (θ) value 28 to 32° in the XRD spectrum.

6 . The method of claim 1 , wherein:
the composite matrix has a density of from 1.7 to 2.0 g/cm 3 .

7 . The method of claim 1 , wherein:
the composite matrix has a microhardness of from 30 to 80 vickers pyramid number (HV).

8 . The method of claim 1 , wherein:
Zr and ES are uniformly distributed throughout the composite matrix.

9 . The method of claim 1 , wherein after the sintering of the compacted powder mixture, the composite matrix has a densification of from 90 to 100%.

10 . The method of claim 1 , wherein after the sintering of the compacted powder mixture, the composite matrix has a densification of from 98% to 99.9%.

11 . The method of claim 1 , wherein the milling of the powder mixture occurs at a speed of from 175 to 225 rotations per minute (rpm);
wherein the compacting of the powder mixture occurs at a pressure of from 300 to 800 megapascal (MPa); and wherein the sintering of the compacted powder mixture occurs at a temperature of from 300 to 600 degrees Celsius (° C.).

12 - 20 . (canceled)

Assignees

• Univ King Fahd Pet & Minerals

Inventors

• Hussein Mohamed Abdrabou
• Azeem Mohammed Abdul
• Kumar A Madhan
• Emara Noha Mohamed

Classifications

• C22C1/05

  Mixtures of metal powder with non-metallic powder (C22C1/08 takes precedence) · CPC title

• C22C1/0408

  Light metal alloys · CPC title

• B22F3/12

  Both compacting and sintering (by forging B22F3/17) · CPC title

• B22F2302/45

  Others, including non-metals · CPC title

• B22F2301/205

  Titanium, zirconium or hafnium · CPC title