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AssigneeUtron Kinetics, LLC
InventorsKarthik Nagarathnam, Donald Trostle, Dennis Massey
Estimating the term…
New net shape strength retaining high temperature alloy parts are formed from fine metallurgical powders by mechanically blending the powders and placing them in die, placing a piston in the die, extending the piston into a driving chamber, filling the chamber with CH4 and air and compressing the powders with the filling pressure. Igniting gas in the chamber drives the piston into the cavity, producing pressures of about 85 to 150 tsi, compacting the powders into a near net shape alloy part, ready for sintering at 2300° C. without shrinking. The alloy parts are Re, Mo—Re, W—Re, Re—Hf—HfC, Re—Ta—Hf—HfC, Re—Mo—Hf—HfC, Mo—Re—Ta, Mo—Re-f-HfC, W—Re—Hf—HfC, W—Re—Ta—Hf—HfC or W—Re—Mo—Hf alloys.
A method of manufacturing high operating temperature Re containing composite near net shape parts comprising providing a combustion driven compaction press with a piston, a materials cavity and a male die and a chamber on opposite ends of the piston,
A method of forming high operating temperature near net shape Re containing composite near net shape parts comprising providing a press with a forming die cavity, a driving chamber and a piston and a male die extending between the chamber and the cavity, mechanically blending mixtures of RE containing metallurgical powders having sizes of about −635 mesh to about −200 mesh, placing the blended powders in the die cavity of the press, filling the chamber of the press with combustible material, and an oxidant, moving the piston in a direction of the cavity by the filling of the chamber, thereby pre-compressing the blended powders in the cavity by the filling of the chamber and the moving of the piston, igniting and combusting the combustible material with the oxidant, rapidly expanding the chamber with products of the combustion, driving the piston into the cavity and compacting and forming the mixed and compressed powders into a near net shape Re containing composite green part having 72-85% theoretical density, and sintering the formed Re containing composite near net shape part for a prolonged period of approximately three or more hours at a high temperature of about 2300° C. in a hydrogen controlled environment and producing a sintered part having 98% or more theoretical density, strength of 135 ksi ductility of 30% or more and hardness of 315 VHN or greater with a polycrystallic microstructure and average grain size of <64 microns.
Dependencies are inferred from the claim text.