Alliedsignal Inc.

Allied Corporation

Colin M Adam

David J Skinner

Richard L Bye, Jr

Santosh K Das

Kenji Okazaki

Amitava Datta

Debasis Bose

Robert G Corey

Apparatus is provided for fabricating continuous metal strip composed of a low density, readily oxidizable aluminum based alloy. The allow is cast directly from the melt through a slotted nozzle onto a moving chill substrate. A scraping mechanism located upstream of the nozzle is adapted to ride on the substrate and remove therefrom the gaseous boundary layer associated therewith. Disposed between the scraping mechanism and the nozzle is a gas supply mechanism adapted to introduce a replacement gas that is carried by the substrate to the nozzle. A shielding means configured to form a semi-enclosed chamber around the nozzle and the substrate apparatus to direct and confine the replacement gas in the vicinity of the nozzle. The alloy preferably has the form of a foil and a composition consisting essentially of about 10 to 13 weight percent silicon, 0 to 3 weight percent magnesium, 0 to 4 weight percent copper, 0 to 0.2 weight percent of at least one of bismuth, phosphorous, strontium, lithium, scandium, yttrium, sodium and calcium and 0 to 2 weight percent of at least one of the rare earth elements, the balance being aluminum and incidental impurities.

Low temperature aluminum based brazing alloys

The present invention provides a method for producing an aluminum alloy which includes the step of carbo-thermically reducing an aluminous material to provide an alloy consisting essentially of the formula Al.sub.bal TM.sub.d Si.sub.e, wherein TM is at least one element selected from the group consisting of Fe, Ni, Co, Ti, V, Zr, Cu and Mn, 'd' ranges from about 2-20 wt %, 'e' ranges from about 2.1-20 wt %, and the balance is aluminum and incidental impurities. The alloy is placed in the molten state and rapidly solidified at a quench rate of at least about 10.sup.6 K/sec to produce a rapidly solidified alloy composed of a predominately microeutectic and/or microcellular structure.

Rapidly solidified aluminum-transition metal-silicon alloys

A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, wherein 'a' ranges from 3.0 to 7.1 atom percent, 'b' ranges from 1.0 to 3.0 atom percent, 'c' ranges from 0.25 to 1.25 atom percent and the balance is aluminum plus incidental impurities, with the provisos that (i) the ratio (Fe+V): Si ranges from about 2.33:1 to 3:33:1 and (ii) the ratio Fe:V ranges from 11.5:1 to 5:1. The alloy exhibits high strength, ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engines, missiles, airframes and landing wheels.

Rapidly solidified aluminum based silicon containing, alloys for

A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b X.sub.c wherein X is at least one element selected from the group consisting of Mn,V,Cr,Mo,W,Nb,Ta, 'a' ranges from 2.0 to 7.5 atom percent, 'b' ranges from 0.5 to 3.0 atom percent, 'c' ranges from 0.05 to 3.5 atom percent and the balance is aluminum plus incidental impurities, with the proviso that the ratio {Fe+X}:Si ranges from about 2.0:1 to 5.0:1. The alloy exhibits high strength, ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engines, missiles, airframes and landing wheels.

Rapidly solidified aluminum based, silicon containing alloys for

Apparatus is provided for fabricating continuous metal strip composed of a low density, readily oxidizable aluminum based alloy. The alloy is cast directly from the metal through a slotted nozzle onto a moving chill substrate. A scraping mechanism located upstream of the nozzle is adapted to ride on the substrate and remove therefrom the gaseous boundary layer associated therewith. Disposed between the scraping mechanism and the nozzle is a gas supply mechanism adapted to introduce a replacement gas that is carried by the substrate to the nozzle. A shielding means configured to form a semi-enclosed chamber around the nozzle and the substrate apparatus to direct and confine the replacement gas in the vicinity of the nozzle. The alloy preferably has the form of a foil and a composition consisting essentially of about 10 to 13 weight percent silicon, 0 to 3 weight percent magnesium, 0 to 4 weight percent copper, 0 to 0.2 weight percent of at least one of bismuth, phosphorous, strontium, lithium, scandium, yttrium, sodium and calcium and 0 to 2 weight percent of at least one of the rare earth elements, the balance being aluminum and incidental impurities.

Production of low temperature aluminum based brazing alloys

A rapidly solidified aluminum-base alloy consists essentially of the formula Al.sub.bal Fe.sub.a Si.sub.b V.sub.c, wherein 'a' ranges from 3.0 to 7.1 atom percent, 'b' ranges from 1.0 to 3.0 atom percent, 'c' ranges from 0.25 to 1.25 atom percent and the balance is aluminum plus incidental impurities, with the provisos that (i) the ratio [Fe+V]:Si ranges from about 2.33:1 to 3:33:1 and (ii) the ratio Fe:V ranges from 11.5:1 to 5:1. The alloy exhibits high strength ductility and fracture toughness and is especially suited for use in high temperature structural applications such as gas turbine engine components, automotive engine components, missiles and airframes.

The present invention provides a method for producing an aluminum alloy which includes the step of carbothermically reducing an aluminous material to provide an alloy consisting essentially of the formula Al.sub.bal TM.sub.d Si.sub.e, wherein TM is at least one element selected from the group consisting of Fe, Ni, Co, Ti, V, Zr, Cu and Mn, 'd' ranges from about 2-20 wt %, 'e' ranges from about 2.1-20 wt %, and the balance is aluminum and incidental impurities. The alloy is placed in the molten state and rapidly solidified at a quench rate of at least about 10.sup.6 K/sec to produce a rapidly solidified alloy composed of a predominately microeutectic and/or microcellular structure.

Method of producing rapidly solidified aluminum-transition metal-silicon

The invention provides an aluminum based alloy consisting essentially of the formula Al.sub.bal Fe.sub.a V.sub.b X.sub.c, wherein X is at least one element selected from the group consisting of Zn, Co, Ni, Cr, Mo, Zr, Ti, Hf, Y and Ce, 'a' ranges from about 7-15 wt %, 'b' ranges from about 2-10 wt %, 'c' ranges from about 0-5 wt % and the balance is aluminum. The alloy has a distinctive microstructure which is at least about 50% composed of a generally spherical, intermetallic O-phase. Particles composed of the alloys of the invention can be heated in a vacuum and compacted to form a consolidated metal article have high strength and good ductility at both room temperature and at elevated temperatures of about 350.degree. C. The consolidated article is composed of an aluminum solid solution phase containing a substantially uniform distribution of dispersed intermetallic phase precipitates therein. These precipitates are fine intermetallics measuring from about 10 nm to about 100 nm in diameter with an average interparticle spacing ranging from 50-500 nm.

Aluminum-iron-vanadium alloys having high strength at elevated

The present invention provides a low density aluminum-base alloy, consisting essentially of the formula Al.sub.bal Zr.sub.a Li.sub.b Mg.sub.c T.sub.d, wherein T is at least one element selected from the group consisting of Cu, Si, Sc, Ti, V, Hf, Be, Cr, Mn, Fe, Co and Ni, 'a' ranges from about 0.25-2 wt %, 'b' ranges from 2.7-5 wt %, 'c' ranges from about 0.5-8 wt %, 'd' ranges from about 0.5-5% and the balance is aluminum. The alloy has a primary, cellular-dendritic, fine-grained, supersaturated aluminum alloy solid solution phase with intermetallic phases of the constituent elements uniformly dispersed therein. A consolidated article can be produced by compacting together particles composed of the aluminum alloy of the invention in a vacuum at elevated temperature. The compacted alloy is solutionized by heat treatment, quenched in a fluid bath, and optionally, stretched and aged. The microstructure of the consolidated article is composed of an aluminum solid solution containing a substantially uniform distribution of fine intermetallic precipitates.

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Morristown, NJ, United States of America

Colin M Adam