Nano-structured refractory metals, metal carbides, and coatings and parts fabricated therefrom

A method for forming a refractory metal carbide coating, the method comprising the steps of:

• providing a refractory metal nanoparticle mixture including a solvent and a plurality of refractory metal nanoparticles, each of the plurality of refractory metal nanoparticles being surrounded by a layer of surfactant molecules;
• disposing the refractory metal nanoparticle mixture on a surface to be coated;
• heating the refractory metal nanoparticle mixture to a first temperature to evaporate the solvent and leave the plurality of refractory metal nanoparticles surrounded by surfactant molecules on the surface;
• and
• heating the refractory metal nanoparticles and the surfactant molecules to a second temperature to decompose the surfactant molecules and to react the plurality of refractory metal nanoparticles with carbon from the decomposed surfactant to provide a refractory metal carbide coating on the surface.

A method for forming a refractory metal carbide component, the method comprising the steps of:

• providing a refractory metal nanoparticle mixture in a mold, the mixture including a solvent and a plurality of refractory metal nanoparticles, each of the plurality of refractory metal nanoparticles being surrounded by a layer of surfactant molecules;
• disposing the refractory metal nanoparticle mixture in a mold;
• heating the refractory metal nanoparticle mixture to a first temperature to evaporate the solvent and leave the plurality of refractory metal nanoparticles surrounded by surfactant molecules in the mold;
• and
• heating the refractory metal nanoparticles and the surfactant molecules to a second temperature to decompose the surfactant molecules and to react the plurality of refractory metal nanoparticles with carbon from the decomposed surfactant to provide a refractory metal carbide component.