Gte Products Corporation

Muktesh Paliwal

Walter A Johnson

Lori S Pruyne

Robert J Holland, Sr

John E Miller

A process for producing fine powder, which includes entraining a starting powder material in a carrier gas, injecting the starting powder material using the carrier gas into a high temperature jet to form a high velocity stream of molten droplets, fragmenting the resulting high velocity molten droplets by impacting against a substrate wherein the temperature of the substrate is above the melting point of the powder material, to form smaller droplets, and allowing the resulting fragmented smaller droplets to spheroidize and solidify in flight.

Process for producing fine powders by hot substrate microatomization

Composite powder particles which are essentially spherical in shape are disclosed which consist essentially of particles of a matrix phase which consists essentially of a metal selected from the group consisting of aluminum and aluminum based alloys and a reinforcement phase which is relatively uniformly dispersed in and bonded to the matrix, the reinforcement phase comprising titanium diboride. A process is disclosed for producing the above composite particles which involves entraining in a carrier gas a plurality of agglomerated powders, at least one of the powders supplying aluminum, at least one of the powders supplying titanium without boron and at least one of the powders supplying boron without titanium. The powders are fed through a high temperature zone to cause essentially complete melting and coalescence of the powders wherein at least a part of the titanium and at least a part of the boron combine to form titanium diboride and thereafter resolidified to form the composite powder particles. The resolidification can be done by impacting the high temperature treated powder against a surface having a temperature below the solidification temperature of the matrix, in which case a composite material is formed.

Aluminum based composite powders and process for producing same

A process is disclosed for producing agglomerates of aluminum based material which is suitable for plasma melting rapid solidification processing. The process involves first forming a slurry comprising the aluminum based material and one or more fluxing agents and then removing the liquid medium from the slurry to produce agglomerates of the aluminum based material and the fluxing agent or agents.

Process for producing agglomerates of aluminum based material

A process is disclosed for producing composite powder particles consisting essentially of a matrix phase and a reinforcement phase. The process involves entraining agglomerated particles in a carrier gas, the agglomerated particles consisting essentially of titanium diboride and particles of a metal selected from the group consisting of aluminum and aluminum based alloys. The agglomerated particles are fed through a high temperature zone having a temperature sufficient to allow the metal particles to melt, coalesce together, and encapsulate the titanium diboride particles. The metal is then resolidified, resulting in the formation of the composite powder particles wherein the matrix phase consists essentially of the metal and the reinforcement phase consists essentially of the titanium diboride particles. A process is disclosed for producing a composite material in which the metal which is selected from the group consisting of aluminum and aluminum based alloys is the matrix phase and titanium diboride is the reinforcement phase. The process involves entraining agglomerates in a carrier gas and passing the agglomerates through a high temperature zone as described above. The metal is resolidified by impacting the resulting high temperature treated particles against a surface having a temperature below the solidification temperature of the metal.

Process for producing aluminum-titanium diboride composites

A composite powdered material is disclosed consisting essentially of particles having a metal matrix and one or more relatively uniform discrete dispersed reinforcement phases in the matrix, the reinforcement phases being of high strength or high hardness compounds selected from intermetallic compounds and metal compounds selected from the group consisting of metal borides, carbides, nitrides, oxides, carbonitrides, and mixtures thereof. The composite powdered particles are spheres of from about 25 to about 200 micrometers and the reinforcement phases have particles of a maximum size of less than about 10 micrometers. A process for producing this composite powder is disclosed which involves entraining in a carrier gas a plurality of powders wherein at least one of the powders supplies the metal from which the matrix is to be formed, and wherein at least two of the powders supply the constituents from which the reinforcement phases are to be formed. The powders are then fed through a high temperature zone to cause essentially complete melting and coalescence of the powders and to cause at least part of the constituents to combine to form at least one of the reinforcement phases, followed by resolidification.

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Sayre, PA, United States of America

Muktesh Paliwal