Heterogeneous composite bodies with isolated cermet regions formed by high temperature, rapid consolidation
AssigneePowdermet, Inc.
InventorsMark Grogan, Brian Doud, Andrew Sherman
Life of this patent
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Abstract
A heterogeneous composite consisting of near-nano ceramic clusters dispersed within a ductile matrix. The composite is formed through the high temperature compaction of a starting powder consisting of a core of ceramic nanoparticles held together with metallic binder. This core is clad with a ductile metal such that when the final powder is consolidated, the ductile metal forms a tough, near-zero contiguity matrix. The material is consolidated using any means that will maintain its heterogeneous structure.
Claims19
A heterogeneous body comprised of a plurality of ceramic-metallic composites;
- each of said ceramic-metallic composites includes a ceramic-rich cermet region coated with a metal coating about an outer surface of said ceramic-rich cermet region;
- said ceramic-rich cermet region comprises a plurality of ceramic particles that are bonded together by a metallic binder;
- a majority of said ceramic-rich cermet regions remain intact and are spaced from one another in a metal matrix material;
- a plurality of said ceramic-rich cermet regions are spaced from one another in said heterogeneous body;
- a plurality of said ceramic-rich cermet regions in said heterogeneous body are not uniformly distributed in said heterogeneous body;
- a content of metal in said metal coating greater than a content of metal of said metallic binder.
A method for making a heterogeneous body having a surface, and wherein said heterogeneous body comprises a plurality of ceramic-metallic composites bonded together, said method comprising:
- a. providing said plurality of ceramic-metallic composites;
- each of said ceramic-metallic composites including a ceramic-rich cermet region coated with a metal coating about the outer surface of said ceramic-rich cermet region;
- said ceramic-rich cermet region comprises a plurality of ceramic particles that are bonded together by a metallic binder;
- and,
- b. binding together said plurality of ceramic-metallic composites by a compaction method to form said heterogeneous body;
- said compaction method occurring at a temperature and for a time period such that said metal coating of ceramic-metallic composites bonds with said metal coating of adjacently positioned ceramic-metallic composites while said ceramic-rich cermet region of said ceramic-metallic composites remains substantially intact;
- a plurality of said ceramic-rich cermet regions are spaced from one another in said heterogeneous body after said binding step;
- and
- wherein said ceramic-metallic composites remain intact after formation of said heterogeneous body and a plurality of said ceramic-metallic composites ceramic-rich cermet regions are spaced from one another in said heterogeneous body;
- and
- wherein said ceramic-rich cermet regions in said heterogeneous body are not uniformly distributed in said heterogeneous body.
Dependencies are inferred from the claim text.