Methods of making metal matrix composite and alloy articles

Patent metadata

Field	Value
Publication number	US-9862029-B2
Application number	US-201313832635-A
Country	US
Kind code	B2
Filing date	Mar 15, 2013
Priority date	Mar 15, 2013
Publication date	Jan 9, 2018
Grant date	Jan 9, 2018

Abstract

In one aspect, methods of making freestanding metal matrix composite articles and alloy articles are described. A method of making a freestanding composite article described herein comprises disposing over a surface of the temporary substrate a layered assembly comprising a layer of infiltration metal or alloy and a hard particle layer formed of a flexible sheet comprising organic binder and the hard particles. The layered assembly is heated to infiltrate the hard particle layer with metal or alloy providing a metal matrix composite, and the metal matrix composite is separated from the temporary substrate. Further, a method of making a freestanding alloy article described herein comprises disposing over the surface of a temporary substrate a flexible sheet comprising organic binder and powder alloy and heating the sheet to provide a sintered alloy article. The sintered alloy article is then separated from the temporary substrate.

First claim

That which is claimed is:

1. A method of making a freestanding metallic article comprising:
providing a temporary substrate;
disposing over a surface of the temporary substrate a flexible sheet comprising organic binder and powder nickel-based alloy;
heating the sheet comprising the organic binder and powder nickel-based alloy to provide a sintered nickel-based alloy article comprising 12-20 wt. % chromium, 5-11 wt. % iron, 0.5-2 wt. % manganese 0-2 wt. % silicon, 0-1 wt. % copper, 0-2 wt. % carbon, 0-5 wt. % boron and the balance nickel; and
separating the sintered nickel-based alloy article from the temporary substrate.

2. The method of claim 1 , wherein the organic binder comprises one or more polymeric materials.

3. The method of claim 1 , wherein the sintered nickel-based alloy article has a thickness of 100 μm to 20 mm.

4. The method of claim 1 , wherein the sintered nickel-based alloy article is near-net-shape.

5. The method of claim 1 , wherein the temporary substrate is reusable.

6. The method of claim 1 , wherein the sintered nickel-based alloy article has a wall thickness less than 0.5 mm.

7. The method of claim 1 , wherein the temporary substrate is formed of a material selected from the group consisting of hexagonal boron nitride, alumina, silica, silicon carbide, zirconia, magnesium oxide and graphite coated with hexagonal boron nitride.

8. The method of claim 1 , wherein the temporary substrate comprises graphite.

9. The method of claim 1 , wherein the temporary substrate comprises hexagonal boron nitride or graphite coated with hexagonal boron nitride.

10. The method of claim 1 , wherein the powder nickel-based alloy has an average particle size less than 200 μM.

11. The method of claim 1 , wherein the powder nickel-based alloy has an average particle size less than 55 μm.

12. The method of claim 1 , wherein the powder nickel-based alloy has a bimodal or multi-modal particle size distribution.

13. The method of claim 1 , wherein the sintered nickel-based alloy article has at least one lateral dimension in excess of 500 mm and a thickness less than 1 mm.

14. The method of claim 1 , wherein the sintered nickel-based alloy article is fully dense.

15. The method of claim 1 further comprising coating the sintered nickel-based alloy article with a refractory material.

Assignees

• Kennametal Inc
• Kennametal Inc

Inventors

• Zheng Qingjun
• Liu Yixiong
• Faust James A
• Rowe Mark J
• De Wet Danie J
• Subbaiyan Sudharsan
• Meyer Michael J

Classifications

• C22C38/38

  with more than 1.5% by weight of manganese · CPC title

• B23K35/3033

  Ni as the principal constituent · CPC title

• B23K35/0222

  for use in soldering or brazing (B23K35/0205 takes precedence) · CPC title

• C22C19/058

  without Mo and W · CPC title

• B22F3/10

  Sintering only · CPC title