United Kingdom Atomic Energy Authority

Eric A Feest

Jeffrey S Coombs

Peter F Chesney

Fred Leach

Stuart R Brown

A metal, e.g. in the form of a shaped article, is made by atomizing a stream of molten metal and directing the atomized stream at a collecting surface to form a deposit of the metal. Fine, solid particulate material of different composition from the metal, e.g., nonmetallic particles, and of mean particle size less than 20 micrometers, preferably less than 10 micrometers, is applied to the stream or spray so that it becomes incorporated into the deposit. The particulate material is applied by generating a fluidized bed thereof and feeding it from the bed into the stream or spray. Uniform dispersion of material such as SiC at a high volume percentage (e.g. greater than 15%) may be achieved.

Metal matrix composite manufacture

A metal matrix composite (e.g. of SiC in a metal alloy) is made by the steps of atomizing a stream of molten metal to form a spray of hot metal particles by subjecting the stream to relatively cold gas directed at the stream, applying to the stream or spray relatively cold solid particles of a material of different composition from the metal, and depositing the metal having the particles incorporated therein. The deposit is made into a shaped metal matrix composite by reheating it to a controlled temperature substantially above the liquidus of the metal at which it flows under pressure and casting the fluid deposit to give the shaped product.

Metal product fabrication

The invention relates to the coating of particles for use, for example, as inoculants in the metallurgical field. A fluidized bed of metallic-particles (e.g. Fe/Si, Fe/Mn of size range 50 .mu.m to 3000 .mu.m or higher) is contacted with a wash-coat comprising a suspension of a non-dispersible ceramic powder in a sol (e.g. a suspension of Al(OH).sub.3 powder in a boehmite sol). Subsequent controlled drying and firing produces a ceramic coating on the particles which has good adhesion and thermal stability and whose thickness and density can readily be controlled.

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Didcot, United Kingdom

Eric A Feest