# US 10,865,464 B2 · Materials and methods for producing metal nanocomposites, and metal nanocomposites obtained therefrom

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- Number: US 10,865,464 B2
- Document ID: US10865464B2
- Status: Granted
- Kind: B2
- Application number: 15/808,877
- Filed: 2017-11-09
- Published: 2018-05-17
- Granted: 2020-12-15
- Earliest claimed: 2016-11-16
- Assignees: HRL Laboratories, LLC
- Applicants: HRL Laboratories, LLC
- Inventors: John H. Martin; Brennan D. Yahata
- Web page: https://patentgrep.com/patent/US10865464B2

## CPC

- C22C 32/0052: {only carbides}
- B22D 23/06: Melting-down metal, e.g. metal particles, in the mould
- B22F 1/054: Nanosized particles
- B22F 1/16: Metallic particles coated with a non-metal (coated with lubricating or binding agents or with organic material B22F1/10)
- B22F 1/17: Metallic particles coated with metal
- B22F 1/18: Non-metallic particles coated with metal
- B22F 7/04: with one or more layers not made from powder, e.g. made from solid metal
- C22C 1/1036: {starting from a melt}
- C22C 21/02: with silicon as the next major constituent
- B22F 2007/045: {accompanied by fusion or impregnation}
- B22F 2301/052: Aluminium
- B22F 2302/10: Carbide
- B22F 2998/10: Processes characterised by the sequence of their steps
- B22F 2999/00: Aspects linked to processes or compositions used in powder metallurgy
- Y10T 428/12021: having composition or density gradient or differential porosity
- C22C: ALLOYS (treatment of alloys C21D, C22F)
- B22D: CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES (shaping of plastics or substances in a plastic state B29C; metallurgical processing, selection of substances to be added to metal C21, C22)
- B22F: WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER (making alloys by powder metallurgy C22C); APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

Some variations provide a metal matrix nanocomposite composition comprising metal-containing microparticles and nanoparticles, wherein the nanoparticles are chemically and/or physically disposed on surfaces of the microparticles, and wherein the nanoparticles are consolidated in a three-dimensional architecture throughout the composition. The composition may serve as an ingot for producing a metal matrix nanocomposite. Other variations provide a functionally graded metal matrix nanocomposite comprising a metal-matrix phase and a reinforcement phase containing nanoparticles, wherein the nanocomposite contains a gradient in concentration of the nanoparticles. This nanocomposite may be or be converted into a master alloy. Other variations provide methods of making a metal matrix nanocomposite, methods of making a functionally graded metal matrix nanocomposite, and methods of making a master alloy metal matrix nanocomposite. The metal matrix nanocomposite may have a cast microstructure. The methods disclosed enable various loadings of nanoparticles in metal matrix nanocomposites with a wide variety of compositions.

## Claims

### Claim 1

A composition comprising metal-containing microparticles and nanoparticles, wherein said nanoparticles are chemically and/or physically disposed on surfaces of said microparticles, wherein said nanoparticles are consolidated in a three-dimensional architecture throughout said composition, and wherein said composition has an equiaxed, fine-grained, dispersed microstructure with a dispersion length scale from 10 nanometers to 1 micron, wherein said dispersion length scale is calculated as the average length scale of said metal-containing microparticles between said nanoparticles.

### Claim 2 (depends on 1)

The composition of claim 1, wherein said composition is an ingot for producing a metal nanocomposite.

### Claim 3 (depends on 1)

The composition of claim 1, wherein said composition is a metal nanocomposite.

### Claim 4 (depends on 1)

The composition of claim 1, wherein said microparticles contain an element selected from the group consisting of Al, Mg, Ni, Fe, Cu, Ti, V, Si, and combinations thereof.

### Claim 5 (depends on 1)

The composition of claim 1, wherein said nanoparticles contain a compound selected from the group consisting of metals, ceramics, cermets, intermetallic alloys, oxides, carbides, nitrides, borides, polymers, carbon, and combinations thereof.

### Claim 6 (depends on 1)

The composition of claim 1, wherein said microparticles contain Al, Si, and Mg, and wherein said nanoparticles contain tungsten carbide (WC).

### Claim 7 (depends on 1)

The composition of claim 1, wherein said nanoparticles have an average nanoparticle size from about 1 nanometer to about 1000 nanometers.

### Claim 8 (depends on 1)

The composition of claim 1, wherein said composition contains from about 10 wt % to about 99.9 wt % of said microparticles.

### Claim 9 (depends on 1)

The composition of claim 1, wherein said composition contains from about 0.1 wt % to about 10 wt % of said nanoparticles.