# US 2013/0156633 A1 · Aluminum composite and method of making same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2013/0156633 A1 - Document ID: US20130156633A1 - Status: Published application - Kind: A1 - Application number: 13/542,143 - Filed: 2012-07-05 - Published: 2013-06-20 - Earliest claimed: 2000-03-15 - Assignees: Aluminastic Corporation - Inventors: Matthew E. Blankenhorn; William F. Clifford, SR. - Web page: https://patentgrep.com/patent/US20130156633A1 ## CPC - C22C 21/00: Alloys based on aluminium - C22B 9/16: Remelting metals (liquating C22B9/02) - C22B 21/06: refining {(electrolytic refining C25C; C22B21/0046, C22B21/0061 take precedence)} - C22B 4/02: Light metals {(C22B4/005 takes precedence)} - C22C: ALLOYS (treatment of alloys C21D, C22F) - C22B: PRODUCTION AND REFINING OF METALS (electrolytic C25); PRETREATMENT OF RAW MATERIALS ## Abstract The present invention includes a method of making aluminum composite compositions and to an aluminum composite composition for creating a heat-treatable material that is harder, tougher, and lighter per volume than standard aluminum. ## Claims ### Claim 1 A molten aluminum composite precursor comprising: (a) molten aluminum and (b) carbon present in said molten aluminum in an amount in the range of about 0.08% and %10.0 by weight and homogeneously dispersed in solution throughout said molten aluminum; and wherein an electric current is being passed through said molten aluminum so as to cause a change in grain structure as compared to aluminum. ### Claim 2 (depends on 1) A molten aluminum composite precursor according to claim 1 wherein said electric current is sufficient to cause a change in the grain structure of said aluminum once solidified. Method Based Upon Carbon Homogeneously Dispersed Throughout Using Organic Compounds Or Carbonaceous Materials and No Specified Atmosphere With Change in grain structure ### Claim 3 A method for incorporating carbon homogeneously into an aluminum feedstock for forming a hardened aluminum product, which comprises the steps of: (a) providing a molten aluminum feedstock; (b) mixing a material selected from the group consisting of organic compounds and carbonaceous materials with said molten aluminum while running electric current through said molten aluminum; and (c) recovering said hardened aluminum product with carbon homogeneously dispersed in solution throughout whereby said aluminum product has a grain structure altered as compared to aluminum. ### Claim 4 (depends on 3) A method according to claim 3 wherein said material comprises a material selected from the group consisting of powdered carbon, charcoal, activated carbon, polyethylene, polypropylene, polystyrene, thermally decomposable organic polymers, and mixtures thereof. ### Claim 5 (depends on 3) A method according to claim 3 wherein said mixing is carried out under an inert atmosphere. ### Claim 6 (depends on 3) A method according to claim 3 wherein said carbon is present in an amount in the range of between about 0.08 and about 10.0 weight-percent. ### Claim 7 (depends on 3) A method according to claim 3 wherein said hardened aluminum product has a density less than that of 99.5% pure aluminum. ### Claim 8 (depends on 3) A method according to claim 3 wherein said hardened aluminum product has a hardness greater than that of 99.5% pure aluminum. Method Based Upon Carbon Homogeneously Dispersed Throughout Using Organic Compounds Or Carbonaceous Materials and No Specified Atmosphere With Formation of Carbon Ions ### Claim 9 A method for incorporating carbon homogeneously into an aluminum feedstock for forming a hardened aluminum product, which comprises the steps of: (a) providing a molten aluminum feedstock; (b) mixing a material selected from the group consisting of organic compounds and carbonaceous materials with said molten aluminum while running electric current through said molten aluminum so as to generate carbon ions ; and (c) recovering said hardened aluminum product with carbon homogeneously dispersed throughout. ### Claim 10 (depends on 9) A method according to claim 9 wherein said material comprises a material selected from the group consisting of powdered carbon, charcoal, activated carbon, polyethylene, polypropylene, polystyrene, thermally decomposable organic polymers, and mixtures thereof. ### Claim 11 (depends on 9) A method according to claim 9 wherein said mixing is carried out under an inert atmosphere. ### Claim 12 (depends on 9) A method according to claim 9 wherein said carbon is present in an amount in the range of between about 0.08 and about 10.0 weight-percent. ### Claim 13 (depends on 9) A method according to claim 9 wherein said hardened aluminum product has a density less than that of 99.5% pure aluminum. ### Claim 14 (depends on 9) A method according to claim 9 wherein said hardened aluminum product has a hardness greater than that of 99.5% pure aluminum. Method Based Upon Carbon Homogeneously Dispersed Throughout Using Organic Compounds Or Carbonaceous Materials and No Specified Atmosphere With Formation of Carbides ### Claim 15 A method for incorporating carbon homogeneously into an aluminum feedstock for forming a hardened aluminum product, which comprises the steps of: (a) providing a molten aluminum feedstock; (b) mixing a material selected from the group consisting of organic compounds and carbonaceous materials with said molten aluminum while running electric current through said molten aluminum so as to form carbides; and (c) recovering said hardened aluminum product with carbon homogeneously dispersed throughout. ### Claim 16 (depends on 15) A method according to claim 15 wherein said material comprises a material selected from the group consisting of powdered carbon, charcoal, activated carbon, polyethylene, polypropylene, polystyrene, thermally decomposable organic polymers, and mixtures thereof. ### Claim 17 (depends on 15) A method according to claim 15 wherein said mixing is carried out under an inert atmosphere. ### Claim 18 (depends on 15) A method according to claim 15 wherein said carbon is present in an amount in the range of between about 0.08 and about 10.0 weight-percent. ### Claim 19 (depends on 15) A method according to claim 15 wherein said hardened aluminum product has a density less than that of 99.5% pure aluminum. ### Claim 20 (depends on 15) A method according to claim 15 wherein said hardened aluminum product has a hardness greater than that of 99.5% pure aluminum.