The Boeing Company

Thomas J Van Daam

Clifford C Bampton

Daniel Edward Matejczyk

Leslie G Fritzemeier

Timothy J Hosking

A method of producing high strength nanophase metal alloy powder by cryomilling metal powder under conditions which cause the formation of intrinsic nitrides, and of producing high strength metal articles by subjecting the nitrided cryomilled powder to thermo-mechanical processing. The intrinsic nitrides present within the alloy significantly reduce grain growth during thermo-mechanical processing, resulting in formed metal products of high strength and improved ductility.

Method for preparing nanostructured metal alloys having increased nitride content

High strength aluminum alloy powders, extrusions, and forgings are provided in which the aluminum alloys exhibit high strength at atmospheric temperatures and maintain high strength and ductility at extremely low temperatures. The alloy is produced by blending about 89 atomic % to 99 atomic % aluminum, 1 atomic % to 11 atomic % of a secondary metal selected from the group consisting of magnesium, lithium, silicon, titanium, zirconium, and combinations thereof, and up to about 10 atomic % of a tertiary metal selected from the group consisting of Be, Ca, Sr, Ba, Ra, Sc, V, Cr, Mn, Fe, Co, Ni, Cu, Zn, Y, Nb, Mo, Tc, Ru, Rh, Pd, Ag, Cd, W, and combinations thereof. The alloy is produced by nanostructure material synthesis, such as cryomilling, in the absence of refractory dispersoids. The synthesized alloy is then canned, degassed, consolidated, extruded, and optionally forged into a solid metallic component. Grain size within the alloy is less than 0.5 &#x3bc;m, and alloys with grain size less than 0.1 &#x3bc;m may be produced.

Cryomilled aluminum alloys and components extruded and forged therefrom

Method for preparing cryomilled aluminum alloys and components extruded and forged therefrom

A nanophase composite duct assembly and method of fabricating the same are provided that comprise an ultra-high strength nanophase aluminum alloy duct joined with a ceramic particulate reinforced metal matrix fitting, preferably using solid-state friction welding. The nanophase aluminum alloy duct is fabricated by extruding a billet formed by a process of cryogenic milling the alloy, followed by out-gassing, then hot isostatic pressing. The fitting is fabricated by combining a ceramic particulate with a metal matrix, preferably by powder processing or liquid metal infiltration. Further, the solid-state friction welding may comprise inertial welding, friction stir welding, or a combination thereof. As a result, a lightweight duct assembly is provided for high-pressure liquids such as propellants in rocket engines.

Nanophase composite duct assembly

An article that is configured to be rotatably mounted includes an embedded hollow cavity into which at least one dampening member is inserted. The dampening member or members frictionally engage the hollow cavity such that relative movement between the dampening member or members and the hollow cavity operates to attenuate vibration that is generated when the article is rotated.

Article having dampening member installed into an imbedded cavity

An article having a hollow cavity formed therein and a method for forming the same. The article includes a hollow structure having an open end and a body portion that is surrounded by a powdered material. The article is processed in, for example, a hot isostatic pressing operation, to permit a pressurized fluid to consolidate the powdered material. The pressurized fluid is permitted to pass through the open end of the hollow structure and into the body portion to thereby prevent the body portion from collapsing while the powdered material is being consolidated.

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Simi Valley, CA, United States of America

Thomas J Van Daam