Gas atomization synthesis of refractory or intermetallic compounds and supersaturated solid solutions

A method of dispersion strengthening a metallic material, comprising:

• forming a melt comprising a metal or alloy under an inert gas atmosphere,
• atomizing said melt with an atomizing gas mixture to produce atomized particulates, said atomizing gas mixture comprising a carrier gas and a reactive gas that is reactive when dissolved in solid solution in said metallic material to form dispersoids therein, the temperature of said melt and the ratio of said carrier gas to said reactive gas being selected to provide a superequilibrium concentration of an atomic specie of said reactive gas in solid solution in said atomized particles to a depth below surface of said atomized particles upon solidification thereof,
• solidifying the atomized particles to retain the superequilibrium concentration of the atomic specie therein, and
• heating the atomized particles to a temperature to react said atomic specie of said reactive gas in solid solution with the solidified metal or alloy particles to form dispersoids therein.

A method of making dispersion strengthened aluminum particles, comprising:

• forming a melt comprising aluminum under an inert gas atmosphere,
• atomizing said melt with an atomizing gas mixture comprising an inert gas and nitrogen so as to produce atomized particles, the temperature of said melt and the ratio of said inert gas to nitrogen gas being effective to provide a superequilibrium concentration of atomic nitrogen in solid solution in said atomized particles to a depth below the surface of said atomized particles upon solidification,
• solidifying the atomized particles to retain the superequilibrium concentration of nitrogen therein, and
• heating the atomized particles to a temperature to react said atomic nitrogen in solid solution with said aluminum to form dispersoids therein.

A method of making a dispersion strengthened article, comprising:

• forming a melt comprising a metal or alloy under an inert gas atmosphere,
• atomizing said melt with an atomizing gas mixture to produce atomized particles, said atomizing gas comprising a carrier gas and a reactive gas that is reactive when dissolved in solid solution in said metallic material to form dispersoids therein, the temperature of said melt and the ratio of said carrier gas to said reactive gas being selected to provide a superequilibrium concentration of an atomic specie of said reactive gas in solid solution in said atomized particles to a depth below a surface of said atomized particles upon solidification,
• solidifying the atomized particles to retain the superequilibrium concentration of the atomic specie therein,
• forming an article from said atomized particles, and
• heating the solidified particles during or after formation of said article to a temperature to react said specie with said metallic material to form dispersoids therein.

A method of making a dispersion strengthened aluminum article, comprising:

• forming a melt comprising aluminum under an inert gas atmosphere,
• atomizing said melt with an atomizing gas mixture comprising a carrier gas and nitrogen so as to produce atomized particles, the temperature of said melt and the ratio of said carrier gas to said nitrogen gas being selected to provide a superequilibrium concentration of atomic nitrogen in solid solution in said atomized particles to a depth below the surface of said atomized particles upon solidification,
• solidifying the atomized particles to retain the superequilibrium concentration of nitrogen therein,
• forming an article from said atomized particles, and
• heating the solidified particles during or after formation of said article to a temperature to react said atomic nitrogen with said aluminum to form aluminum nitride dispersoids in said aluminum.