Wisconsin Alumni Research Foundation

USA As Represented by Secretary of the Navy

Other

Lawrence Livermore National Security, LLC

University of California

Sandia Corporation

John Harry Perepezko

Ridwan Sakidja

Joseph Collin Farmer

Craig A Blue

Jeffery J Haslam

Enrique J Lavernia

Nancy Yuan Yang

Larry Kaufman

Robert Bayles

Frank M G Wong

John D Wiley

Alan Shane Edelstein

Arthur H Heuer

Louis F Aprigliano

Joon S Park

Richard K Everett

Don H Rasmussen

Carl R Loper, Jr

Olivia A Graeve

Sumner Daniel Day

Julie M Schoenung

Edward J Lemieux

Leo Ajdelsztajn

Xiaoyan (Jane) Ji

John D K Rivard

Leslie K Kohler

Joon Sang Park

Jeffery S Smith

Jeffrey Waldman

Eui W Lee

Rabindra Mahapatra

James C Foley

Donald R Allen

Patrick Ritt

Mark K Hoffmeyer

Functional materials and methods for making the functional materials are provided. Also provided are methods for utilizing the functional materials in a variety of applications, including catalysis, adsorption, energy storage, and biomedical applications. The functional materials are made from metal alloys via an oxidative dealloying process that selectively removes one or more elements from the metal alloy and converts one or more of the remaining elements into a stable metal-oxygen matrix having a controlled porosity.

Synthesis of metal-oxygen based materials with controlled porosity by oxidative dealloying

Alumina-containing coatings based on molybdenum (Mo), silicon (Si), and boron (B) ('MoSiB coatings') that form protective, oxidation-resistant scales on ceramic substrate at high temperatures are provided. The protective scales comprise an aluminoborosilicate glass, and may additionally contain molybdenum. Two-stage deposition methods for forming the coatings are also provided.

Mo&#x2014;Si&#x2014;B&#x2014;based coatings for ceramic base substrates

Methods for the low-temperature synthesis of an integrated, corrosion-resistant coating structure for metal substrates by means of multi-component pack cementation are provided. The synthesis of the integrated coating structures at low temperatures can avoid or minimize degradation of the mechanical properties of the substrates. The integrated coating structures can increase the lifetime of high temperature steels under severe steam environments and, therefore, provide a technological enabler for the high-temperature operation of steam power generation plants.

Low-temperature synthesis of integrated coatings for corrosion resistance

A system for coating a surface comprises providing a source of amorphous metal, providing ceramic particles, and applying the amorphous metal and the ceramic particles to the surface by a spray. The coating comprises a composite material made of amorphous metal that contains one or more of the following elements in the specified range of composition: yttrium (&#x2267;1 atomic %), chromium (14 to 18 atomic %), molybdenum (&#x2267;7 atomic %), tungsten (&#x2267;1 atomic %), boron (&#x2266;5 atomic %), or carbon (&#x2267;4 atomic %).

Corrosion resistant amorphous metals and methods of forming corrosion resistant amorphous metals

A method of coating a surface comprising providing a source of amorphous metal that contains manganese (1 to 3 atomic %), yttrium (0.1 to 10 atomic %), and silicon (0.3 to 3.1 atomic %) in the range of composition given in parentheses; and that contains the following elements in the specified range of composition given in parentheses: chromium (15 to 20 atomic %), molybdenum (2 to 15 atomic %), tungsten (1 to 3 atomic %), boron (5 to 16 atomic %), carbon (3 to 16 atomic %), and the balance iron; and applying said amorphous metal to the surface by a spray.

Compositions of corrosion-resistant Fe-based amorphous metals suitable for producing thermal spray coatings

Methods for producing multilayered, oxidation-resistant structures on substrates are provided. The methods comprise depositing silicon dioxide on a substrate comprising molybdenum and boron and annealing the silicon dioxide at a temperature and for a time sufficient to form a coating comprising a borosilicate scale on the substrate.

Methods for producing multilayered, oxidation-resistant structures on substrates

The invention provides oxidation resistant coatings for transition metal substrates and transition metal alloy substrates and method for producing the same. The coatings may be multilayered, multiphase coatings or gradient multiphase coatings. In some embodiments the transition metal alloys may be boron-containing molybdenum silicate-based binary and ternary alloys. The coatings are integrated into the substrates to provide durable coatings that stand up under extreme temperature conditions.

Oxidation resistant coatings for ultra high temperature transition metals and transition metal alloys

A process of preparing aligned, in-situ, two-phase single crystal alloys of titanium, aluminum and niobium which comprises growing the alloys at rates of about 3.0 mm. to about 6.0 mm. per hour by rotating a seed rod alloy consisting essentially of Ti-43 to 45 Al-10 to 12 Nb&plus;0.5 Si, in atomic percent, at about 7.75 to 8.25 RPM while in contact with a rotating feed rod alloy consisting essentially of Ti-43 to 45 Al-10 to 12 Nb, in atomic-percent, rotating at about 5.75 to 6.25 RPM in an atmosphere of substantially pure argon at melt temperatures ranging from about 1650&deg; C. to 1750&deg; C. to obtain two-phase single crystal alloys of Ti-43 to 45Al-10 to 12 Nb characterized as having improved ductility, excellent oxidation resistance, and high-temperature creep strength. These alloys are particularly useful for manufacturing high-temperature material components for internal combustion engines, gas turbines, and advanced aircraft engines.

Process for preparing aligned in-situ two phase single crystal composites of titanium-niobium alloys

A debonding layer is formed on fibers such as silicon carbide fibers by forming a thin film of a metal such as nickel or iron on the silicon carbide fibers and then annealing at a temperature of about 350-550&deg; C. to form a debond layer of a metal silicide and carbon. These fibers having the debond coating can be added to composite forming materials and the mixture treated to form a consolidated composite. A one heating-step method to form a consolidated composite involves inserting the silicon carbide fibers with just the initial metal film coating into the composite forming materials and then heating the mixture to form the debond coating in situ on the fibers and to form the consolidated composite. Preferred heating techniques include high temperature annealing, hot-pressing, or hot isostatic pressing (HIP).

In situ-formed debond layer for fibers

Compositions and methods for obtaining nanocrystal dispersed amorphous alloys are described. A composition includes an amorphous matrix forming element (e.g., Al or Fe); at least one transition metal element; and at least one crystallizing agent that is insoluble in the resulting amorphous matrix. During devitrification, the crystallizing agent causes the formation of a high density nanocrystal dispersion. The compositions and methods provide advantages in that materials with superior properties are provided.

Nanocrystal dispersed amorphous alloys

A debonding layer is formed on fibers such as silicon carbide fibers by fing a thin film of a metal such as nickel or iron on the silicon carbide fibers and then annealing at a temperature of about 350-550.degree. C. to form a debond layer of a metal silicide and carbon. These fibers having the debond coating can be added to composite forming materials and the mixture treated to form a consolidated composite. A one heating-step method to form a consolidated composite involves inserting the silicon carbide fibers with just the initial metal film coating into the composite forming materials and then heating the mixture to form the debond coating in situ on the fibers and to form the consolidated composite. Preferred heating techniques include high temperature annealing, hot-pressing, or hot isostatic pressing (HIP).

The Droplet Emulsion Technique is used to produce droplets of bulk metal or metal alloys containing inoculant particles. Heterogeneous nucleation responses are then separated and identified with variances in inoculant chemistry, size, morphology, and surface conditions in the different droplets. Differential Thermal Analysis (DTA) is used to detect and to correlate thermal signals generated from as little as 50 droplets 75-100 .mu.m in size, allowing the separation of signals generated by a minor fraction of the total droplet population. Quenching treatments are used on the samples during thermal analysis to retain the original solidification microstructures produced from effective inoculation. Differences between droplet solidification microstructures preserved from the quenching treatments allow for visual identification of effective and ineffective inoculant particles. The factors controlling effective inoculation of solid include the chemistry, morphology, crystal structure, and surface conditions of inoculant particles which are identified by using analytical x-ray and electron microbeam techniques.

Method of evaluation and identification for the design of effective

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Madison, WI, United States of America

John Harry Perepezko