US3449115A - Methods of making alloy powders and the corresponding powders - Google Patents
Methods of making alloy powders and the corresponding powders Download PDFInfo
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- US3449115A US3449115A US540216A US3449115DA US3449115A US 3449115 A US3449115 A US 3449115A US 540216 A US540216 A US 540216A US 3449115D A US3449115D A US 3449115DA US 3449115 A US3449115 A US 3449115A
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- 239000000843 powder Substances 0.000 title description 84
- 229910045601 alloy Inorganic materials 0.000 title description 30
- 239000000956 alloy Substances 0.000 title description 30
- 238000000034 method Methods 0.000 title description 16
- 239000000203 mixture Substances 0.000 description 60
- 229910052751 metal Inorganic materials 0.000 description 54
- 239000002184 metal Substances 0.000 description 52
- 238000007865 diluting Methods 0.000 description 37
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 description 30
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 28
- 239000000126 substance Substances 0.000 description 28
- 239000000047 product Substances 0.000 description 27
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 26
- 239000001257 hydrogen Substances 0.000 description 26
- 229910052739 hydrogen Inorganic materials 0.000 description 26
- 239000012298 atmosphere Substances 0.000 description 25
- NLXLAEXVIDQMFP-UHFFFAOYSA-N Ammonia chloride Chemical compound [NH4+].[Cl-] NLXLAEXVIDQMFP-UHFFFAOYSA-N 0.000 description 24
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 22
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 22
- 239000011651 chromium Substances 0.000 description 22
- 229910052804 chromium Inorganic materials 0.000 description 21
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 20
- 150000002739 metals Chemical class 0.000 description 18
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 15
- 150000001875 compounds Chemical class 0.000 description 14
- 229910052742 iron Inorganic materials 0.000 description 14
- ZCYVEMRRCGMTRW-UHFFFAOYSA-N 7553-56-2 Chemical compound [I] ZCYVEMRRCGMTRW-UHFFFAOYSA-N 0.000 description 12
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 12
- 235000019270 ammonium chloride Nutrition 0.000 description 12
- 239000011630 iodine Substances 0.000 description 12
- 229910052740 iodine Inorganic materials 0.000 description 12
- 229910052759 nickel Inorganic materials 0.000 description 12
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 10
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 10
- 229910052749 magnesium Inorganic materials 0.000 description 10
- 239000011777 magnesium Substances 0.000 description 10
- QTBSBXVTEAMEQO-UHFFFAOYSA-N Acetic acid Chemical compound CC(O)=O QTBSBXVTEAMEQO-UHFFFAOYSA-N 0.000 description 9
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 9
- 229910052782 aluminium Inorganic materials 0.000 description 9
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 9
- 238000009792 diffusion process Methods 0.000 description 9
- 229910017604 nitric acid Inorganic materials 0.000 description 9
- 239000000243 solution Substances 0.000 description 9
- 238000005406 washing Methods 0.000 description 9
- MUBZPKHOEPUJKR-UHFFFAOYSA-N Oxalic acid Chemical compound OC(=O)C(O)=O MUBZPKHOEPUJKR-UHFFFAOYSA-N 0.000 description 8
- DOLZKNFSRCEOFV-UHFFFAOYSA-L nickel(2+);oxalate Chemical compound [Ni+2].[O-]C(=O)C([O-])=O DOLZKNFSRCEOFV-UHFFFAOYSA-L 0.000 description 8
- 150000002736 metal compounds Chemical class 0.000 description 7
- ZOKXTWBITQBERF-UHFFFAOYSA-N Molybdenum Chemical compound [Mo] ZOKXTWBITQBERF-UHFFFAOYSA-N 0.000 description 6
- 238000005119 centrifugation Methods 0.000 description 6
- JKQOBWVOAYFWKG-UHFFFAOYSA-N molybdenum trioxide Chemical compound O=[Mo](=O)=O JKQOBWVOAYFWKG-UHFFFAOYSA-N 0.000 description 6
- 229910052757 nitrogen Inorganic materials 0.000 description 6
- 229910000990 Ni alloy Inorganic materials 0.000 description 5
- 229910052786 argon Inorganic materials 0.000 description 5
- 239000000395 magnesium oxide Substances 0.000 description 5
- 229910052750 molybdenum Inorganic materials 0.000 description 5
- 239000011733 molybdenum Substances 0.000 description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 229910000640 Fe alloy Inorganic materials 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- 230000015572 biosynthetic process Effects 0.000 description 4
- -1 chromium nitrides Chemical class 0.000 description 4
- 229910017052 cobalt Inorganic materials 0.000 description 4
- 239000010941 cobalt Substances 0.000 description 4
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 150000002431 hydrogen Chemical class 0.000 description 4
- 238000011065 in-situ storage Methods 0.000 description 4
- 239000002244 precipitate Substances 0.000 description 4
- 238000002360 preparation method Methods 0.000 description 4
- 239000010703 silicon Substances 0.000 description 4
- 229910052710 silicon Inorganic materials 0.000 description 4
- ZSLUVFAKFWKJRC-IGMARMGPSA-N 232Th Chemical compound [232Th] ZSLUVFAKFWKJRC-IGMARMGPSA-N 0.000 description 3
- WKBOTKDWSSQWDR-UHFFFAOYSA-N Bromine atom Chemical compound [Br] WKBOTKDWSSQWDR-UHFFFAOYSA-N 0.000 description 3
- 229910000599 Cr alloy Inorganic materials 0.000 description 3
- 229910052776 Thorium Inorganic materials 0.000 description 3
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 3
- 239000002253 acid Substances 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- GDTBXPJZTBHREO-UHFFFAOYSA-N bromine Substances BrBr GDTBXPJZTBHREO-UHFFFAOYSA-N 0.000 description 3
- 229910052794 bromium Inorganic materials 0.000 description 3
- 238000001354 calcination Methods 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 238000000975 co-precipitation Methods 0.000 description 3
- 238000004581 coalescence Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 230000008030 elimination Effects 0.000 description 3
- 238000003379 elimination reaction Methods 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 229910000765 intermetallic Inorganic materials 0.000 description 3
- 238000004519 manufacturing process Methods 0.000 description 3
- 238000002156 mixing Methods 0.000 description 3
- 239000002245 particle Substances 0.000 description 3
- 239000010936 titanium Substances 0.000 description 3
- 229910052719 titanium Inorganic materials 0.000 description 3
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 2
- 229910021586 Nickel(II) chloride Inorganic materials 0.000 description 2
- 239000012300 argon atmosphere Substances 0.000 description 2
- QVQLCTNNEUAWMS-UHFFFAOYSA-N barium oxide Chemical compound [Ba]=O QVQLCTNNEUAWMS-UHFFFAOYSA-N 0.000 description 2
- BRPQOXSCLDDYGP-UHFFFAOYSA-N calcium oxide Chemical compound [O-2].[Ca+2] BRPQOXSCLDDYGP-UHFFFAOYSA-N 0.000 description 2
- 239000000292 calcium oxide Substances 0.000 description 2
- ODINCKMPIJJUCX-UHFFFAOYSA-N calcium oxide Inorganic materials [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 2
- 238000010790 dilution Methods 0.000 description 2
- 239000012895 dilution Substances 0.000 description 2
- 239000012153 distilled water Substances 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 229940062993 ferrous oxalate Drugs 0.000 description 2
- 239000007789 gas Substances 0.000 description 2
- 238000010348 incorporation Methods 0.000 description 2
- FBAFATDZDUQKNH-UHFFFAOYSA-M iron chloride Chemical compound [Cl-].[Fe] FBAFATDZDUQKNH-UHFFFAOYSA-M 0.000 description 2
- OWZIYWAUNZMLRT-UHFFFAOYSA-L iron(2+);oxalate Chemical compound [Fe+2].[O-]C(=O)C([O-])=O OWZIYWAUNZMLRT-UHFFFAOYSA-L 0.000 description 2
- 239000007788 liquid Substances 0.000 description 2
- 229910052748 manganese Inorganic materials 0.000 description 2
- 239000011572 manganese Substances 0.000 description 2
- 229910052752 metalloid Inorganic materials 0.000 description 2
- 150000002738 metalloids Chemical class 0.000 description 2
- QMMRZOWCJAIUJA-UHFFFAOYSA-L nickel dichloride Chemical compound Cl[Ni]Cl QMMRZOWCJAIUJA-UHFFFAOYSA-L 0.000 description 2
- 150000003891 oxalate salts Chemical class 0.000 description 2
- 235000006408 oxalic acid Nutrition 0.000 description 2
- 239000003973 paint Substances 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 239000012255 powdered metal Substances 0.000 description 2
- 238000001556 precipitation Methods 0.000 description 2
- 239000011369 resultant mixture Substances 0.000 description 2
- 229910052715 tantalum Inorganic materials 0.000 description 2
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 2
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 2
- 229910052721 tungsten Inorganic materials 0.000 description 2
- 239000010937 tungsten Substances 0.000 description 2
- 229910052720 vanadium Inorganic materials 0.000 description 2
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 2
- 229910000838 Al alloy Inorganic materials 0.000 description 1
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- UXVMQQNJUSDDNG-UHFFFAOYSA-L Calcium chloride Chemical compound [Cl-].[Cl-].[Ca+2] UXVMQQNJUSDDNG-UHFFFAOYSA-L 0.000 description 1
- 239000004215 Carbon black (E152) Substances 0.000 description 1
- BVKZGUZCCUSVTD-UHFFFAOYSA-L Carbonate Chemical compound [O-]C([O-])=O BVKZGUZCCUSVTD-UHFFFAOYSA-L 0.000 description 1
- 229910000531 Co alloy Inorganic materials 0.000 description 1
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 1
- BDAGIHXWWSANSR-UHFFFAOYSA-M Formate Chemical compound [O-]C=O BDAGIHXWWSANSR-UHFFFAOYSA-M 0.000 description 1
- 229910001182 Mo alloy Inorganic materials 0.000 description 1
- 239000006230 acetylene black Substances 0.000 description 1
- 238000007259 addition reaction Methods 0.000 description 1
- QRRWWGNBSQSBAM-UHFFFAOYSA-N alumane;chromium Chemical compound [AlH3].[Cr] QRRWWGNBSQSBAM-UHFFFAOYSA-N 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- SWLVFNYSXGMGBS-UHFFFAOYSA-N ammonium bromide Chemical compound [NH4+].[Br-] SWLVFNYSXGMGBS-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 239000001110 calcium chloride Substances 0.000 description 1
- 229910001628 calcium chloride Inorganic materials 0.000 description 1
- QXDMQSPYEZFLGF-UHFFFAOYSA-L calcium oxalate Chemical compound [Ca+2].[O-]C(=O)C([O-])=O QXDMQSPYEZFLGF-UHFFFAOYSA-L 0.000 description 1
- 150000004649 carbonic acid derivatives Chemical class 0.000 description 1
- 238000009388 chemical precipitation Methods 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 239000003638 chemical reducing agent Substances 0.000 description 1
- 239000013065 commercial product Substances 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- VEPSWGHMGZQCIN-UHFFFAOYSA-H ferric oxalate Chemical compound [Fe+3].[Fe+3].[O-]C(=O)C([O-])=O.[O-]C(=O)C([O-])=O.[O-]C(=O)C([O-])=O VEPSWGHMGZQCIN-UHFFFAOYSA-H 0.000 description 1
- 125000001475 halogen functional group Chemical group 0.000 description 1
- 229930195733 hydrocarbon Natural products 0.000 description 1
- 150000002430 hydrocarbons Chemical class 0.000 description 1
- 229910052738 indium Inorganic materials 0.000 description 1
- 239000011872 intimate mixture Substances 0.000 description 1
- 230000002045 lasting effect Effects 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 229910000753 refractory alloy Inorganic materials 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 230000002311 subsequent effect Effects 0.000 description 1
- 229910000048 titanium hydride Inorganic materials 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/16—Making metallic powder or suspensions thereof using chemical processes
- B22F9/18—Making metallic powder or suspensions thereof using chemical processes with reduction of metal compounds
- B22F9/20—Making metallic powder or suspensions thereof using chemical processes with reduction of metal compounds starting from solid metal compounds
- B22F9/22—Making metallic powder or suspensions thereof using chemical processes with reduction of metal compounds starting from solid metal compounds using gaseous reductors
Definitions
- This invention is directed to a method of preparing an ultra-fine alloy powder by preparing a mixture of a powder of a reducible metal compound and of an inert diluting powder, then reducing the metal compound in the presence of the inert diluting powder, after which a powder of a difierent metal is mixed into the reduced mixture and the resultant mixture is heated in a hydrogenated and halogenated atmosphere to cause diffusion of one of the metals into the other to form the desired alloy powder.
- the present invention consists chiefly in heating, in a hydrogenated and'halogenated containing atmosphere, a mixture of at least two powders of two different metals, respectively, and of an inert diluting powder, at least one of said two metal powders having been obtained by the action of a reducing agent upon at least one metal compound (oxide, oxalate, formiate and carbonate, in particular) which is reducible and which can be obtained, in particular by chemical precipitation or by crushing, in the state of an ultra-fine powder (of sub-micron grain size and preferably of a grain size lower than about 0.1 micron), said compound being intimately mixed, in the state of powder (in particular of ultra-fine powder), with a diluting powder of a grain size at most equal to that of the compound powder, which permits, provided there is a suflicient percentage of inert diluting powder to avoid risk of coalescence of the metallic grains thus kept out of contact with one another by the grains of said inert diluting substance, of performing complete reduction, advantageously
- alloys which may be obtained in the form of ultra-fine powders by such a method may be cited in particular the alloys containing at least two metals of the group consisting of iron, nickel, cobalt, molybdenum and tungsten.
- the inert diluting substance it may advantapossibly barium oxide, the inert diluting powder being as above stated, of a grain size at most equal and preferably lower than that. of the metallic powder compound.
- the proportion of inert diluting powder must, as above stated, he suflicient to keep away from one another the grains of the metallic compound, thus preventing coalescence of the metallic grains formed by reduction, which generally leads to adopting a proportion of inert diluting substance .such that, after reduction, the proportion in volume of the inert diluting substance is at least 25% of the total volume.
- Every grain of the alloy to be obtained may then contain.
- At least one metal obtained by reduction and at least one other metal obtained in the form of a powder either alone or mixed with a diluting substance.
- the first embodiment will first be examined. A distinction will be made between the case where the second mentioned metal is considerably more electropositive than the metal obtained by reduction, and the case where said second mentioned metal is of an electropositivity little different from that of the metal obtained H by reduction.
- the grains of the second mentioned metal will disappear, as grains, during the formation by thermal diffusion of the alloyed grains and, consequently, the grain size of the second metal must be sufficiently small to prevent the operation from lasting too much, without it being necessary to use, for this second metal, a grain size as small as that of the metal obtained by re duction.
- the metal obtained by reduction will be called acceptor and the other metal, the grains of which are to disappear, giver.
- a halogenated and hydrogenated atmosphere vapor is made to act in the hot state upon an intimate mixture of a powder of an acceptor metal (obtained as above indicated), a powder of at least one giver metal and an inert diluting powder.
- alloy grains are not so protected, elimination of the diluting substance is obtained in another suitable way, for instance magnettic separation, difference of density, action of a suitable acid in suitable dilution and temperature conditions.
- metals capable of acting as a giver metal in such a method of production of ultra-fine powders of alloys in particular stainless or refractory alloys, may be cited, in particular, chromium, aluminum, silicon, titanium, tantalum, thorium, manganese and vanadium.
- the reducible metallic compounds subjected to the reduction operation may be either compound of commercial origin directly incorporated in the mixture at the beginning of the operation or compounds precipitated or co-precipitated in situ by chemical reaction before incorporation of the inert diluting substance.
- inert diluting substance it is possible to use either a commercial product or a product elaborated in situ by precipitation or co-precipitation, for instance at the same time as the reducible metallic compound or compounds when the latter is or are elaborated in situ at the beginning of the operation.
- a suitable liquid such for instance as an alcohol, and in particular isopropyl alcohol, or a hydrocarbon, when it is desired to perform by the moist way the mixing and/ or the crushing of the metallic compounds and of the inert diluting substance,
- the amounts that are indicated correspond to the production of one kilogram of ultra-fine metallic powder.
- Example 1 Metallic powder of an alloy of nickel and chromium (20%) 2.5 kgs. of commercial nickel oxalate and 0.65 kg. of calcined magnesia are mixed in 7.5 liters of isopropyl alcohol, the mixture being mixed for five hours in a ball crusher in such manner as finally to obtain the desired grain size even if said grain size were initially greater after which the liquid is driven out from this mixture.
- the product thus obtained preliminarily spread into a thin layer, is calcined during six hours at 750 C.
- the mixture that is obtained is placed in a partly gastight nickel box and heated to 950 C. in a hydrogen atmosphere, for three hours.
- the diluting substance is eliminated by washing with diluted nitric acid (for instance nitric acid at 40 Baum added with an equal volume of water), after which the product is Washed in distilled water and centrifugated, and the powder that is obtained is dried at C.
- diluted nitric acid for instance nitric acid at 40 Baum added with an equal volume of water
- An alloy powder is thus obtained, having practically the desired composition and the grain size of which is below one micron.
- Example 2 Metallic powder of an alloy of iron (74% chromium (18%) and nickel (8%) In order to obtain a more perfect mixture there is performed in this case a co-precipitation of iron and nickel oxalates, by dissolving, in 6 liters of water at 20 C., 2.65 kgs. of hydrated iron chloride, (FeCl 4H O) and 0.32 kg. of hydrated nickel chloride (NiCl 6H O'). 1.8 kgs. of oxalic acid are dissolved in 12 liters of water at 28 C. The two solutions are suddenly mixed together. The whole is allowed to rest, then is washed and the precipitate is separated.
- FeCl 4H O hydrated iron chloride
- NiCl 6H O' hydrated nickel chloride
- the product obtained is then calcined in a slightly moist argon atmosphere for one hour at 650 C., then reduced by moist hydrogen for five hours at 1000 C.
- the product is then placed in a partly gastight iron box and heated for four hours at 850 C. in a hydrogenated atmosphere, after which it is washed in diluted nitric acid, then in pure water centrifugated and dried at 110 C.
- This example differs from the preceding one in that use is made of 22 g. of ammonium bromide instead of 22 g. of ammonium chloride and 11 g. of bromine instead of 11 g. of iodine.
- Example 3 Metallic powder of an alloy of iron (55% chromium (25%) and nickel (20%)
- in situ oxalates of iron and nickel, and also oxalate of calcium we dissolve, in 8 liters of water at 20 C., 1.97 kg. of hydrated iron chloride, 0.8 kg. of hydrated nickel chloride and 1.3 kg of calcium chloride.
- This precipitate is calcined in a slightly moist argon atmosphere during two hours at 650 C., which has for its effect in particular, to transform the iron and nickel oxalate into oxides reducible by hydrogen, and the calcium oxalate into calcium oxide, which is not reducible by hydrogen and will constitute the inert diluting substance.
- the product is placed in a partly gastight iron box and the whole is heated for four hours at 850 C. in a hydrogenated atmosphere of cracked ammonia.
- the product obtained is finally Washed, first With diluted nitric acid, then with pure water and centrifu-gated, after which it is heated at 110 C.
- non-oxidized alloy powder the composition of which is very approximately the desired one and of sub-micron grain size, which may be below 1 tenth of a micron for some portions of the product obtained.
- the percentage of nitrogen in the powder reaches 02 approximately (in the form of very fine chromium nitrides).
- Example 4 Metallic powder of iron 67% nickel (12% chromium (18%) and molybdenum (3% We mix, in 7.5 liters of isopropyl alcohol, 1.14 kgs. of commercial ferrous oxalate. 0.37 of commercial nickel oxalate, 0.045 kg. of 'molybdic anhydride and 0.7 kg. of calcined magnesia. This mixture is treated for six hours in a ball crusher. The product finally obtained is then centrifugated and calcined in an atmosphere of moist argon for two hours at 700 C.
- the product obtained is then placed in a partly gastight iron box which is heated for five hours in a hydrogen atmosphere at 950 C.
- the operation is concluded by washing first in diluted nitric acid, then in pure water and by centrifugating followed by drying at 110 C.
- Example 5 --Metallic powder of an alloy of cobalt (65%) chromium (30% and molybdenum (5%) We mix for six hours, in a ball crusher, 1.5. kgs. of commercial cobalt formimate, 0.075 kg. of molybdic anhydride, 0.5 kg. of calcined magnesia and 6.5 liters of isopropyl alcohol. 1
- the product thus obtained is calcined, having been preliminarily spread into a thin layer, for six hours in air at 800 C. We proceed to a reduction by means of hydrogen for five hours at 1000 C.
- the mixture thus formed is then placed in a partly gastight cobalt or nickel box and heated for six hours at We thus obtain a non-oxidized alloy powder of a composition very close to the desired one and the grain size of which is lower than 1 micron.
- Example 6 Metallic powder of an alloy of nickel (75%), chromium (21%), titanium (2%) and aluminum (2%) We mix for five hours, in a crusher, 2.42 kgs. of commercial nickel oxalate, 0.65 kg. of calcined magnesia, 7.5 liters of isopropyl alcohol after which we proceed to centrifugation then to calcination in air for six hours at 950 C.
- Example 7 Metalic powder of an alloy of nickel (97% and thorium (3%) We mix for five hours, in a ball crusher, 3.02 kgs. of commercial nickel oxalate, 0.775 kg. of calcined magnesia and 8.5 liters of isopropyl alcohol. Then the product is dried and calcined in air in the form of a thin layer for six hours at 750 C.
- This mixture is placed in a partly gastight nickel box which is heated for four hours at 900 C. in an argon and hydrogen atmosphere.
- Example 8 Metal powderof an alloy of molybdenum (63%) and silicon (37%) We mix for six hours, in a ball crusher, 0.945 kg. of commercial molybdic anhydride, 0.5 kg. of calcined magnesia and 4.5 liters of isopropyl alcohol, after which we proceed to a centrifugation.
- the reduction operation is then performed by means of hydrogen directly on the centrifugated product, for six hours at 1000 C. and we add to the product thus obtained 402 g. of silicon in the state of a fine powder, 25 g. of ammonium chloride and 5 g. of iodine.
- This mixture is placed in a partly gastight box and heated for four hours at 850 C.
- Magnesium in the form of filings 20 This preparation is introduced into a partly gastight chromized iron box which is heated for four hours at 1000" C. in a hydrogen atmosphere. During this heating, aluminum, which is substantially more electro-positive than chromium, is conveyed onto the particles of chromium into which it diffuses.
- magnesothermic chromium which is not separated from the magnesia mixed therewith for its preparation, the proportion being substantially those corresponding to 2Cr+3MgO. 1760 g. of this mixture contain approximately 850 g. of chromium and 910 g. of magnesia.
- Example 10 Powder of an alloy of chromium (85%) and aluminum (15%) dispersed in alumina In a screw mixer We mix for twenty minutes:
- G Magnesothermic chromium powder of a grain size equal to or lower than 1 micron 850
- Ammonium chloride 25 This preparation is placed in a partly gastight chromized iron box heated for four hours at 1000 C. in a hydrogen atmosphere. After cooling, the product is in the form of a grey powder which is a dispersion in alumina of particles of a chromium aluminum alloy in the proportions of 85-15%, these particles being homogeneous and of a diameter lower 1 micron.
- Metals capable of such a co-diffusion may According to a first solution, be obtained individually, as above indicated, in distinct mixtures with an inert diluting substance, or
- the first metal including its inert diluting substance is mixed with the second metal and to the mixture are added chemical bodies intended to create the hydrogenated and halogenated atmosphere necessary to co-diffusion.
- Example 11 Metallic powder of an alloy of nickel (60%), iron (20%) and molybdenum (20%) We mix, in 7.5 liters of isopropyl alcohol, 1.9 kg. of commercial nickel oxalate and 0.62 kg. of ferrous oxalate with 0.8 kg. of calcined magnesia and the mixture is treated for six hours in a ball crusher, after which it is centrifugated and the product obtained is calcined in the presence of slightly moist argon for two hours at 700 C. Then we proceed to reduction by hydrogen for six hours at 980 C.
- the product thus obtained is placed in a partly gastight nickel box after adding thereto 22 g. of ammonium chloride, 11 g. of iodine and 10 g. of magnesium in the form of filings.
- the diffusion treatment is performed in a hydrogenated atmosphere for six hours at 1100 C.
- the metals which constitute the alloy may then be obtained individually either in distinct mixtures with an inert diluting substance or together in the same mixture with an inert diluting substance.
- Example 12 Metallic powder of an alloy of iron and nickel (25%) We mix, in 7.5 liters of isopropyl alcohol, 2.83 kgs. of iron oxalate and 0.79 kg. of nickel oxalate (both of commercial origin) with 0.95 of calcined magnesia, the mixture being treated for eight hours in a ball crusher, then centrifugated.
- the mixture that is obtained is placed in a partly gastight iron box and heated for five hours at 950 C. in a hydrogenated atmosphere.
- the diluting substance is eliminated by washing in diluted acetic acid and cooled, then it is washed in pure water, centrifugated and dried in an oven at C.
- This incorporation of a metalloid may be performed either after the formation of the ultra-fine powder or during the diffusion treatment in the hydrogenated and halo genated atmosphere.
- Example 13 Metal powder of an alloy of iron (74.5%), nickel (25%) and carbon (0.5%)
- Example 12 differs from Example 12 merely by the presence of 0.5% of carbon instead of the corresponding amount of iron, the operation being conducted in the same manner as stated in this Example 12, with the only dilferonce that when ammonium chloride, iodine and magnesium are added, we add also 6 g. of acetylene black.
- hydrogenated atmosphere relative to the atmosphere surrounding the partly gastight treatment boxes includes pure hydrogen, mixtures of hydrogen with gases inert with respect to the powders to be treated and mixtures of hydrogen with gases having an action upon the powders to be treated (nitrogen for instance).
- the method of producing an ultra-fine alloy powder having a grain size not greater than about 1 micron which comprises, preparing a mixture of at least one powder of a reducible metal compound and of an inert diluting powder, reducing said reducible metal compound in the presence of said inert diluting powder, then adding to the reduced mixture at least one powder of a: different metal, then diffusing one of said metals into the other thereof by heating the resultant mixture in a hydrogenated and halogenated atmosphere, and removing said inert diluting powder from the resultant alloy powder.
- reducible compound ' is a body of the group consisting of oxides, oxalates, formiates and carbonates.
- the metal obtained by reduction is at least one metal of the group consisting of iron, nickel, cobalt, chromium, molybdenum, tungsten and alloys of at least two of said last mentioned metals.
- the other metal of the mixture is a metal of the group consisting of chromium, aluminum, silicon, titanium, tantalum, therium, manganese and vanadium.
Description
United States Patent I 3,449,115 7 METHODS OF MAKING ALLOY POWDERS AND THE CORRESPONDING POWDERS Philippe Marie Galmiche, Paris, and Andr Hivert, Pontoise, France, assignors to Ofiice National dEtudes et de Recherches Aerospatiales 0.N.E.R.A., Chatillon-sous-Bagneux, France, a body corporate of France a No Drawing. Filed Apr. 5, 1966, Ser. No. 540,216 Claims priority, application France, Apr. 8, 1965,
12 Int. Cl. B22f 9700,- C22c 27/00 US. Cl. 75-5 9 Claims ABSTRACT OF THE DISCLOSURE This invention is directed to a method of preparing an ultra-fine alloy powder by preparing a mixture of a powder of a reducible metal compound and of an inert diluting powder, then reducing the metal compound in the presence of the inert diluting powder, after which a powder of a difierent metal is mixed into the reduced mixture and the resultant mixture is heated in a hydrogenated and halogenated atmosphere to cause diffusion of one of the metals into the other to form the desired alloy powder.
the present time and, in particular, a powder of finer grain size and which does not ignite spontaneously in air, while'being of a cost acceptable from the industrial point of view.
The present invention consists chiefly in heating, in a hydrogenated and'halogenated containing atmosphere, a mixture of at least two powders of two different metals, respectively, and of an inert diluting powder, at least one of said two metal powders having been obtained by the action of a reducing agent upon at least one metal compound (oxide, oxalate, formiate and carbonate, in particular) which is reducible and which can be obtained, in particular by chemical precipitation or by crushing, in the state of an ultra-fine powder (of sub-micron grain size and preferably of a grain size lower than about 0.1 micron), said compound being intimately mixed, in the state of powder (in particular of ultra-fine powder), with a diluting powder of a grain size at most equal to that of the compound powder, which permits, provided there is a suflicient percentage of inert diluting powder to avoid risk of coalescence of the metallic grains thus kept out of contact with one another by the grains of said inert diluting substance, of performing complete reduction, advantageously by means of hydrogen, of said metal compound, at a temperature ranging advantageously from 900 to 1100 C., the inert diluting substance which has served to the production of the alloy powderwhich diluting substance may be the same as that having served to the reduction treatment) being subsequently eliminated through any suitable physical or chemical .means, in particular by being attacked by means of a suitable acid under dilution and temperature conditions avoiding a substantial attack of the metallic grains obtained by reduction.
- geously consist of magnesia or calcium oxide,
3,449,l l5 Patented June 10, 1969 Among the alloys which may be obtained in the form of ultra-fine powders by such a method may be cited in particular the alloys containing at least two metals of the group consisting of iron, nickel, cobalt, molybdenum and tungsten.
As for the inert diluting substance it may advantapossibly barium oxide, the inert diluting powder being as above stated, of a grain size at most equal and preferably lower than that. of the metallic powder compound.
The proportion of inert diluting powder must, as above stated, he suflicient to keep away from one another the grains of the metallic compound, thus preventing coalescence of the metallic grains formed by reduction, which generally leads to adopting a proportion of inert diluting substance .such that, after reduction, the proportion in volume of the inert diluting substance is at least 25% of the total volume.
Every grain of the alloy to be obtained may then contain.
Either, according to a first embodiment of the invention, at least one metal obtained by reduction and at least one other metal obtained in the form of a powder, either alone or mixed with a diluting substance.
Or, according to a second embodiment of the invention, only at least two metals both obtained by reduction, either simultaneously from a single mixture as the result of a single reduction operation or separately from two distinct mixtures.
In both cases, it will be of interest to use the powdered metal or metals obtained by reduction when it is, or they are, still mixed with the inert diluting substance used in their formation, the subsequent effect of this inert diluting substance being hereinafter explained.
The first embodiment will first be examined. A distinction will be made between the case where the second mentioned metal is considerably more electropositive than the metal obtained by reduction, and the case where said second mentioned metal is of an electropositivity little different from that of the metal obtained H by reduction.
In the first case, the grains of the second mentioned metal will disappear, as grains, during the formation by thermal diffusion of the alloyed grains and, consequently, the grain size of the second metal must be sufficiently small to prevent the operation from lasting too much, without it being necessary to use, for this second metal, a grain size as small as that of the metal obtained by re duction.
For the sake of clarity, in this first case the metal obtained by reduction will be called acceptor and the other metal, the grains of which are to disappear, giver.
In order to obtain such alloyed powders, advantageously a halogenated and hydrogenated atmosphere vapor is made to act in the hot state upon an intimate mixture of a powder of an acceptor metal (obtained as above indicated), a powder of at least one giver metal and an inert diluting powder.
Of course, it is possible to use for this purpose a wholly elaborated acceptor metal powder, that is to say a powder made of grains free from any inert diluting substance but I it seems advantageous in view of the fact that the giver Subsequently to proceed to the action of the halogenated and hydrogenated gaseous medium advantageously performed in partly gastight boxes placed in a hydrogen atmosphere inside a furnace and containing, preferably mixed together, the chemical bodies necessary for creating in said boxes the desired hydrogenated and halogenated atmosphere, hydrogen either coming from the atmosphere in the furnace or being generated in the boxes, and
Finally to eliminate the inert diluting substance which has permitted of avoiding coalescence of the metallic grains in two successive circumstances (first during the reduction of the acceptor metal compound, and then during the addition of giver metal), this elimination being advantageously obtained by attacking the mixture by means of an acid (for instance nitric acid) in the case where the metallic grains are protected against such an attack by the presence, on the surface thereof, of a superficial diffusion alloy containing a protective giver metal (for instance chromium).
If the alloy grains are not so protected, elimination of the diluting substance is obtained in another suitable way, for instance magnettic separation, difference of density, action of a suitable acid in suitable dilution and temperature conditions.
As metals capable of acting as a giver metal in such a method of production of ultra-fine powders of alloys, in particular stainless or refractory alloys, may be cited, in particular, chromium, aluminum, silicon, titanium, tantalum, thorium, manganese and vanadium. It should be pointed out that the reducible metallic compounds subjected to the reduction operation may be either compound of commercial origin directly incorporated in the mixture at the beginning of the operation or compounds precipitated or co-precipitated in situ by chemical reaction before incorporation of the inert diluting substance.
Likewise, concerning the inert diluting substance, it is possible to use either a commercial product or a product elaborated in situ by precipitation or co-precipitation, for instance at the same time as the reducible metallic compound or compounds when the latter is or are elaborated in situ at the beginning of the operation.
On the other hand, it will be of interest to make use I of one of the following steps:
To incorporte a suitable liquid, such for instance as an alcohol, and in particular isopropyl alcohol, or a hydrocarbon, when it is desired to perform by the moist way the mixing and/ or the crushing of the metallic compounds and of the inert diluting substance,
To calcine the mixture, before reduction by a hydrogen stream, of the starting metallic compounds, such a calcination having for its effect to reduce the consumption of hydrogen and being, if necessary, performed in a decarburazing atmosphere, and
More especially for the preparation of ultrafine powders, to incorporate magnesium filings to the mixture to be subjected to the addition reaction in hydrogenated and halogenated atmosphere, said filings being intended to catch the traces of oxygen that might remain in said mixture.
In order to illustrate the preceding description some examples will now be given relating to the first case (that is to say that where one or several of the metals is, or are, strongly electro-positive) of the first embodiment, it being well understood that in each of these examples it would be possible, if it were desired merely to obtain an ultrafine metallic powder containing only the acceptor metal or metals to proceed to the elimination of the inert diluting substance once the operation of reduction of the starting metallic compound is achieved.
In all the following examples, the amounts that are indicated correspond to the production of one kilogram of ultra-fine metallic powder.
Example 1.-Metallic powder of an alloy of nickel and chromium (20%) 2.5 kgs. of commercial nickel oxalate and 0.65 kg. of calcined magnesia are mixed in 7.5 liters of isopropyl alcohol, the mixture being mixed for five hours in a ball crusher in such manner as finally to obtain the desired grain size even if said grain size were initially greater after which the liquid is driven out from this mixture.
The product thus obtained, preliminarily spread into a thin layer, is calcined during six hours at 750 C.
It is then reduced by hydrogen for five hours at 950 C.
To the product thus obtained we add 220 g. of fine magnesothermic chromium (grain size from 1 to 10 microns), 21 g. of ammonium chloride, 11 g. of iodine and 25 g. of magnesium filings and these constituents are intimately mixed in a helical screw mixing machine.
The mixture that is obtained is placed in a partly gastight nickel box and heated to 950 C. in a hydrogen atmosphere, for three hours.
The diluting substance is eliminated by washing with diluted nitric acid (for instance nitric acid at 40 Baum added with an equal volume of water), after which the product is Washed in distilled water and centrifugated, and the powder that is obtained is dried at C.
An alloy powder is thus obtained, having practically the desired composition and the grain size of which is below one micron.
Example 2.Metallic powder of an alloy of iron (74% chromium (18%) and nickel (8%) In order to obtain a more perfect mixture there is performed in this case a co-precipitation of iron and nickel oxalates, by dissolving, in 6 liters of water at 20 C., 2.65 kgs. of hydrated iron chloride, (FeCl 4H O) and 0.32 kg. of hydrated nickel chloride (NiCl 6H O'). 1.8 kgs. of oxalic acid are dissolved in 12 liters of water at 28 C. The two solutions are suddenly mixed together. The whole is allowed to rest, then is washed and the precipitate is separated.
To the whole of the co-precipitate thus obtained we add 0.7 kg. of calcined magnesia and 7.5 liters of isopropyl alcohol and the mixture thus formed is passed to a ball crusher where it remains for five hours, after which it is centrifugated.
The product obtained is then calcined in a slightly moist argon atmosphere for one hour at 650 C., then reduced by moist hydrogen for five hours at 1000 C.
To the product resulting from this reduction there is added 198 g. of fine chromium, 22 g. of ammonium chloride, 11 g. of iodine and 25 g. of magnesium in the form of filings the mixture being stirred in a screw mixer.
The product is then placed in a partly gastight iron box and heated for four hours at 850 C. in a hydrogenated atmosphere, after which it is washed in diluted nitric acid, then in pure water centrifugated and dried at 110 C.
We thus obtain an alloy powder containing no oxide having approximately the desired composition and the grain size of which is lower than 1 micron.
Example 21:
This example differs from the preceding one in that use is made of 22 g. of ammonium bromide instead of 22 g. of ammonium chloride and 11 g. of bromine instead of 11 g. of iodine.
Example 3.'-Metallic powder of an alloy of iron (55% chromium (25%) and nickel (20%) For the same reasons as in Example 2 we form in situ oxalates of iron and nickel, and also oxalate of calcium and for this purpose we dissolve, in 8 liters of water at 20 C., 1.97 kg. of hydrated iron chloride, 0.8 kg. of hydrated nickel chloride and 1.3 kg of calcium chloride. We dissolve 3.2 kgs. of oxalic acid in 20 liters of water at 28 C. We suddenly mix the two solutions. Then they are allowed to rest, after which the whole is washed and the precipitate is separated by centrifugation.
' This precipitate is calcined in a slightly moist argon atmosphere during two hours at 650 C., which has for its effect in particular, to transform the iron and nickel oxalate into oxides reducible by hydrogen, and the calcium oxalate into calcium oxide, which is not reducible by hydrogen and will constitute the inert diluting substance.
We perform the reduction operation in a moist hydrogenated atmosphere for five hours at 1000 C.
To the product thus obtained we add 275 g. of fine chromium, 25 g. of ammonium chloride, 12 g. of iodine and 30 g. of magnesium in the state of filings.
The product is placed in a partly gastight iron box and the whole is heated for four hours at 850 C. in a hydrogenated atmosphere of cracked ammonia. The product obtained is finally Washed, first With diluted nitric acid, then with pure water and centrifu-gated, after which it is heated at 110 C.
We thus obtain a non-oxidized alloy powder the composition of which is very approximately the desired one and of sub-micron grain size, which may be below 1 tenth of a micron for some portions of the product obtained.
. The percentage of nitrogen in the powder reaches 02 approximately (in the form of very fine chromium nitrides).
' Example 4.-Metallic powder of iron 67% nickel (12% chromium (18%) and molybdenum (3% We mix, in 7.5 liters of isopropyl alcohol, 1.14 kgs. of commercial ferrous oxalate. 0.37 of commercial nickel oxalate, 0.045 kg. of 'molybdic anhydride and 0.7 kg. of calcined magnesia. This mixture is treated for six hours in a ball crusher. The product finally obtained is then centrifugated and calcined in an atmosphere of moist argon for two hours at 700 C.
Then we proceed to the reduction treatment by means of hydrogen for six hours at 980 C., after which we add to the product thus obtained 198 g. of fine chromium, 22 g. of ammonium chloride, 11 g. of iodine and 25 g. of magnesia in the form of filings, the whole being intimately mixed in a screw mixer.
The product obtained is then placed in a partly gastight iron box which is heated for five hours in a hydrogen atmosphere at 950 C.
The operation is concluded by washing first in diluted nitric acid, then in pure water and by centrifugating followed by drying at 110 C.
. We thus obtain a non-oxidized alloy powder having very approximately the desired composition and the grain size of which is below 1 micron. The percentage of nitrogen in the powder reaches approximately 0.15 (in the form of chromium nitrides).
Example 5.--Metallic powder of an alloy of cobalt (65%) chromium (30% and molybdenum (5%) We mix for six hours, in a ball crusher, 1.5. kgs. of commercial cobalt formimate, 0.075 kg. of molybdic anhydride, 0.5 kg. of calcined magnesia and 6.5 liters of isopropyl alcohol. 1
We centrifugate. The product thus obtained is calcined, having been preliminarily spread into a thin layer, for six hours in air at 800 C. We proceed to a reduction by means of hydrogen for five hours at 1000 C.
We add, to the whole of the product thus obtained, 350 g. of fine chromium, 35 g. of ammonium chloride, 15 g. of iodine and 30 g. of magnesium in the form of filings, the whole being passed through a screw mixer.
The mixture thus formed is then placed in a partly gastight cobalt or nickel box and heated for six hours at We thus obtain a non-oxidized alloy powder of a composition very close to the desired one and the grain size of which is lower than 1 micron.
Example 6.--Metallic powder of an alloy of nickel (75%), chromium (21%), titanium (2%) and aluminum (2%) We mix for five hours, in a crusher, 2.42 kgs. of commercial nickel oxalate, 0.65 kg. of calcined magnesia, 7.5 liters of isopropyl alcohol after which we proceed to centrifugation then to calcination in air for six hours at 950 C.
Then the reduction treatment by means of hydrogen is performed for five hours at 1000 C.
We add, to the product thus obtained, 240 g. of fine chromium, 30' g. of titanium hydride, 22 g. of aluminum in the powder state, 20 g. of bromine, 12 g. of iodine and 22 g. of magnesium in the state of filings.
We place this mixture in a partly gastight nickel box, which is heated for five hours at 950 C. in an argon and hydrogen atmosphere. After this we proceed as in the preceding cases, to a washing in diluted nitric acid, to a. washing in pure water, to centrifugation and to drying at C.
We thus obtain a non-oxidized alloy powder the composition of which is very close to the desired composition and the grain size of which is below one micron. The alloy powder that is formed is free from any trace of nitrogen.
Example 7.Metallic powder of an alloy of nickel (97% and thorium (3%) We mix for five hours, in a ball crusher, 3.02 kgs. of commercial nickel oxalate, 0.775 kg. of calcined magnesia and 8.5 liters of isopropyl alcohol. Then the product is dried and calcined in air in the form of a thin layer for six hours at 750 C.
The treatment of reduction by hydrogen is then performed for six hours at 1000 C. Then we add to the resulting product 45 g. of thorium in the form of a fine powder, 20 g. of bromine, 12 g. of iodine and 20 g. of magnesia in the form of filings.
This mixture is placed in a partly gastight nickel box which is heated for four hours at 900 C. in an argon and hydrogen atmosphere.
Then we proceed to washing in acetic acid while cooling to washing in pure water, to centrifugation and to drying at 110 C.
We thus obtain a non-oxidized alloy powder, the composition of which is very close to the desired composition and the grain size of which is below 1 micron. This powder is free from any trace of nitrogen.
Example 8.Metallic powderof an alloy of molybdenum (63%) and silicon (37%) We mix for six hours, in a ball crusher, 0.945 kg. of commercial molybdic anhydride, 0.5 kg. of calcined magnesia and 4.5 liters of isopropyl alcohol, after which we proceed to a centrifugation.
The reduction operation is then performed by means of hydrogen directly on the centrifugated product, for six hours at 1000 C. and we add to the product thus obtained 402 g. of silicon in the state of a fine powder, 25 g. of ammonium chloride and 5 g. of iodine.
This mixture is placed in a partly gastight box and heated for four hours at 850 C.
We then proceed to washing in diluted nitric acid followed by washing in pure water, centrifugation and drying at 110 C.
We thus obtain an alloy powder the composiation of which is very close to the desired composition and the grain size of which is below 1 micron.
Example .9.-Powder of an alloy of chromium (85%) and aluminum (15% In a mixer we heat for twenty minutes a mixture of:
Magnesothermic chromium powder of a grain size of about 1 micron 850 Aluminum in fine powder of the quality used as pigment for paint 155 Calcined magnesia 900 Ammonium chloride 25 Magnesium in the form of filings 20 This preparation is introduced into a partly gastight chromized iron box which is heated for four hours at 1000" C. in a hydrogen atmosphere. During this heating, aluminum, which is substantially more electro-positive than chromium, is conveyed onto the particles of chromium into which it diffuses.
After cooling, the product is washed with diluted nitric acid, then with distilled water and dried at 110 C.
We thus obtain a powder of the desired composition, all the grains of which are homogeneous and of a size equal to or lower than 1 micron.
In a modification, we might utilize magnesothermic chromium which is not separated from the magnesia mixed therewith for its preparation, the proportion being substantially those corresponding to 2Cr+3MgO. 1760 g. of this mixture contain approximately 850 g. of chromium and 910 g. of magnesia.
Example 10.-Powder of an alloy of chromium (85%) and aluminum (15%) dispersed in alumina In a screw mixer We mix for twenty minutes:
G. Magnesothermic chromium powder of a grain size equal to or lower than 1 micron 850 Aluminum in fine powder of the quality used as pigment for paint 155 Calcined alumina in the form of fine powder 850 Ammonium chloride 25 This preparation is placed in a partly gastight chromized iron box heated for four hours at 1000 C. in a hydrogen atmosphere. After cooling, the product is in the form of a grey powder which is a dispersion in alumina of particles of a chromium aluminum alloy in the proportions of 85-15%, these particles being homogeneous and of a diameter lower 1 micron.
We will now examine, still within the scope of the first embodiment of the invention (application to alloys every grain of which contains at least one metal obtained by reduction and at least one other metal obtained in the form of a powder either alone or mixed with an inert diluting substance), the case where this other metal has an electro-positivity little different from that of the meta] obtained by reduction.
In this case, there will be produced only, between the metallic elements placed in the presence of each other, a co-diffusion due to the action of hydrogenated and halogenated vapors which serve to convey each of the metals on all the others.
Metals capable of such a co-diffusion may According to a first solution, be obtained individually, as above indicated, in distinct mixtures with an inert diluting substance, or
According to a second solution, be obtained simultaneously, still as above indicated, in the same mixture with an inert diluting substance, or again according to a third solution be obtained in the form of an ultra-fine powder by other suitable methods.
We then utilize, in this second case of the first embodiment of the invention, to form the grains of alloy, at least one first metal obtained by the first of the second solution and at least one second metal obtained by the third solution.
The first metal, including its inert diluting substance is mixed with the second metal and to the mixture are added chemical bodies intended to create the hydrogenated and halogenated atmosphere necessary to co-diffusion.
We will now give an example of alloy grains corresponding to the second case above referred to.
Example 11.Metallic powder of an alloy of nickel (60%), iron (20%) and molybdenum (20%) We mix, in 7.5 liters of isopropyl alcohol, 1.9 kg. of commercial nickel oxalate and 0.62 kg. of ferrous oxalate with 0.8 kg. of calcined magnesia and the mixture is treated for six hours in a ball crusher, after which it is centrifugated and the product obtained is calcined in the presence of slightly moist argon for two hours at 700 C. Then we proceed to reduction by hydrogen for six hours at 980 C.
We add to the total product thus obtained 200 g. of commercial molybdenum powder of a grain size below 1 micron and we proceed to an intimate mixing in a screw mixer for about one hour.
The product thus obtained is placed in a partly gastight nickel box after adding thereto 22 g. of ammonium chloride, 11 g. of iodine and 10 g. of magnesium in the form of filings. The diffusion treatment is performed in a hydrogenated atmosphere for six hours at 1100 C. We wash with cooled acetic acid then with pure water. We centrifugate and dry the product at 110 C. We thus obtain an alloy powder of a composition very close to the desired composition and the grain size of which is below 1 micron.
We will now examine the second embodiment of the invention, according to which the metals which constitute every alloy grain are all obtained by a reduction.
In this case, it is necessary to make use of metals the electro-positivities of which are of the same order of magnitude and the formation of the alloyed grains results, as in the preceding case, from a co-diffusion due to the action of the hydrogenated and halogenated vapors.
The metals which constitute the alloy may then be obtained individually either in distinct mixtures with an inert diluting substance or together in the same mixture with an inert diluting substance.
We will now give an example of this second embodiment.
Example 12.Metallic powder of an alloy of iron and nickel (25%) We mix, in 7.5 liters of isopropyl alcohol, 2.83 kgs. of iron oxalate and 0.79 kg. of nickel oxalate (both of commercial origin) with 0.95 of calcined magnesia, the mixture being treated for eight hours in a ball crusher, then centrifugated.
We then proceed to calcination under argon for two hours at 700 C. and then to reduction by hydrogen for six hours at 1000 C.
We then add 22 g. of ammonium chloride, 11 g. of iodine and 12 g. of magnesium in the form of filings, the whole being passed through a screw mixer.
The mixture that is obtained is placed in a partly gastight iron box and heated for five hours at 950 C. in a hydrogenated atmosphere.
The diluting substance is eliminated by washing in diluted acetic acid and cooled, then it is washed in pure water, centrifugated and dried in an oven at C.
We thus obtain an alloy powder the composition of which is very close to the desired one and the grain size of which is below 1 micron.
It should be pointed out that whatever he the application of this invention it is always possible to incorporate at least a metalloid, such as carbon or nitrogen.
This incorporation of a metalloid may be performed either after the formation of the ultra-fine powder or during the diffusion treatment in the hydrogenated and halo genated atmosphere.
This is an example of this last case.
Example 13.Metallic powder of an alloy of iron (74.5%), nickel (25%) and carbon (0.5%)
This example differs from Example 12 merely by the presence of 0.5% of carbon instead of the corresponding amount of iron, the operation being conducted in the same manner as stated in this Example 12, with the only dilferonce that when ammonium chloride, iodine and magnesium are added, we add also 6 g. of acetylene black.
Finally, it should be pointed out that the term hydrogenated atmosphere relative to the atmosphere surrounding the partly gastight treatment boxes includes pure hydrogen, mixtures of hydrogen with gases inert with respect to the powders to be treated and mixtures of hydrogen with gases having an action upon the powders to be treated (nitrogen for instance).
What we claim is:
1. The method of producing an ultra-fine alloy powder having a grain size not greater than about 1 micron which comprises, preparing a mixture of at least one powder of a reducible metal compound and of an inert diluting powder, reducing said reducible metal compound in the presence of said inert diluting powder, then adding to the reduced mixture at least one powder of a: different metal, then diffusing one of said metals into the other thereof by heating the resultant mixture in a hydrogenated and halogenated atmosphere, and removing said inert diluting powder from the resultant alloy powder.
2. The method according to claim 1 wherein said reducible compound 'is a body of the group consisting of oxides, oxalates, formiates and carbonates.
3. The method according to claim 1 wherein said reducible compound is reduced by hydrogen.
4. The method according to claim 1 wherein said re- 10 ducing step is performed at a temperature ranging from 900 to 1100 C.
5. A method according to claim 1 wherein the metal obtained by reduction is at least one metal of the group consisting of iron, nickel, cobalt, chromium, molybdenum, tungsten and alloys of at least two of said last mentioned metals.
6 A method according to claim 1 wherein the other metal of the mixture is obtained by a process other than reduction of a reducible compound and is more electropositive than the metal obtained by reduction.
7. A method according to claim 8 wherein the other metal of the mixture is a metal of the group consisting of chromium, aluminum, silicon, titanium, tantalum, therium, manganese and vanadium.
8. The method of claim 1 wherein at least two powders of said reducible metals are present and are obtained by coprecipitation from a common solution of compounds of said metals.
9. The method of claim 8 wherein said inert diluting powder is also obtained by precipitation from the common solution containing the compounds of said reducible metals.
References Cited UNITED STATES PATENTS 2,816,048 12/1957 Galmiche l48-126 3,157,532 11/1964 Galmiche 117-100 L. DEWAYNE RUTLEDGE, Primary Examiner. W. W. STALLARD, Assistant Examiner.
U.S. Cl. X.R. 117-107; 148126
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US4933003A (en) * | 1989-07-18 | 1990-06-12 | The United States Of America As Represented By The Secretary Of The Army | Metal alloy formation by reduction of polyheterometallic complexes |
US5061313A (en) * | 1990-09-07 | 1991-10-29 | Northeastern University | Direct alloy synthesis from heteropolymetallic precursors |
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US20060102255A1 (en) * | 2004-11-12 | 2006-05-18 | General Electric Company | Article having a dispersion of ultrafine titanium boride particles in a titanium-base matrix |
US20070141374A1 (en) * | 2005-12-19 | 2007-06-21 | General Electric Company | Environmentally resistant disk |
US7833472B2 (en) | 2005-06-01 | 2010-11-16 | General Electric Company | Article prepared by depositing an alloying element on powder particles, and making the article from the particles |
US20130186238A1 (en) * | 2012-01-24 | 2013-07-25 | Denso Corporation | Manufacturing method of magnetic alloy powder |
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Publication number | Priority date | Publication date | Assignee | Title |
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US4802915A (en) * | 1988-04-25 | 1989-02-07 | Gte Products Corporation | Process for producing finely divided spherical metal powders containing an iron group metal and a readily oxidizable metal |
Citations (2)
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US2816048A (en) * | 1949-08-05 | 1957-12-10 | Onera (Off Nat Aerospatiale) | Process of forming superficial alloys of chromium on metal bodies |
US3157532A (en) * | 1956-03-14 | 1964-11-17 | Onera (Off Nat Aerospatiale) | Methods of treating metallic powders |
-
1965
- 1965-04-08 FR FR12506A patent/FR1443968A/en not_active Expired
-
1966
- 1966-04-01 GB GB14662/66A patent/GB1148165A/en not_active Expired
- 1966-04-05 US US540216A patent/US3449115A/en not_active Expired - Lifetime
- 1966-04-07 DE DE19661533344 patent/DE1533344B1/en not_active Withdrawn
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US2816048A (en) * | 1949-08-05 | 1957-12-10 | Onera (Off Nat Aerospatiale) | Process of forming superficial alloys of chromium on metal bodies |
US3157532A (en) * | 1956-03-14 | 1964-11-17 | Onera (Off Nat Aerospatiale) | Methods of treating metallic powders |
Cited By (29)
Publication number | Priority date | Publication date | Assignee | Title |
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US3535103A (en) * | 1968-04-10 | 1970-10-20 | Atomic Energy Commission | Method of making metal alloy powders |
US4040815A (en) * | 1975-02-07 | 1977-08-09 | Agence Nationale De Valorisation De La Recherche (Anvar) | Very finely divided lithium and process for manufacturing same |
US4933003A (en) * | 1989-07-18 | 1990-06-12 | The United States Of America As Represented By The Secretary Of The Army | Metal alloy formation by reduction of polyheterometallic complexes |
US5061313A (en) * | 1990-09-07 | 1991-10-29 | Northeastern University | Direct alloy synthesis from heteropolymetallic precursors |
US20020197339A1 (en) * | 2001-03-28 | 2002-12-26 | Usha Goswami | Method for extraction and purification of biologically useful molecules from a mangrove plant Salvadora persica L |
US10100386B2 (en) | 2002-06-14 | 2018-10-16 | General Electric Company | Method for preparing a metallic article having an other additive constituent, without any melting |
US20040208773A1 (en) * | 2002-06-14 | 2004-10-21 | General Electric Comapny | Method for preparing a metallic article having an other additive constituent, without any melting |
US20030230170A1 (en) * | 2002-06-14 | 2003-12-18 | Woodfield Andrew Philip | Method for fabricating a metallic article without any melting |
US7416697B2 (en) | 2002-06-14 | 2008-08-26 | General Electric Company | Method for preparing a metallic article having an other additive constituent, without any melting |
US20060057017A1 (en) * | 2002-06-14 | 2006-03-16 | General Electric Company | Method for producing a titanium metallic composition having titanium boride particles dispersed therein |
US7842231B2 (en) | 2002-06-14 | 2010-11-30 | General Electric Company | Method for producing a titanium metallic composition having titanium boride particles dispersed therein |
US7655182B2 (en) | 2002-06-14 | 2010-02-02 | General Electric Company | Method for fabricating a metallic article without any melting |
US20070269333A1 (en) * | 2002-06-14 | 2007-11-22 | General Electric Company | Method for fabricating a metallic article without any melting |
US7329381B2 (en) * | 2002-06-14 | 2008-02-12 | General Electric Company | Method for fabricating a metallic article without any melting |
US7410610B2 (en) | 2002-06-14 | 2008-08-12 | General Electric Company | Method for producing a titanium metallic composition having titanium boride particles dispersed therein |
US20080193319A1 (en) * | 2002-06-14 | 2008-08-14 | General Electric Company | Method for producing a titanium metallic composition having titanium boride particles dispersed therein |
US20050220656A1 (en) * | 2004-03-31 | 2005-10-06 | General Electric Company | Meltless preparation of martensitic steel articles having thermophysically melt incompatible alloying elements |
US7604680B2 (en) | 2004-03-31 | 2009-10-20 | General Electric Company | Producing nickel-base, cobalt-base, iron-base, iron-nickel-base, or iron-nickel-cobalt-base alloy articles by reduction of nonmetallic precursor compounds and melting |
US20050217426A1 (en) * | 2004-03-31 | 2005-10-06 | General Electric Company | Producing nickel-base, cobalt-base, iron-base, iron-nickel-base, or iron-nickel-cobalt-base alloy articles by reduction of nonmetallic precursor compounds and melting |
US7531021B2 (en) | 2004-11-12 | 2009-05-12 | General Electric Company | Article having a dispersion of ultrafine titanium boride particles in a titanium-base matrix |
US20090229411A1 (en) * | 2004-11-12 | 2009-09-17 | General Electric Company | Article having a dispersion of ultrafine titanium boride particles in a titanium-base matrix |
US20060102255A1 (en) * | 2004-11-12 | 2006-05-18 | General Electric Company | Article having a dispersion of ultrafine titanium boride particles in a titanium-base matrix |
US8562714B2 (en) | 2004-11-12 | 2013-10-22 | General Electric Company | Article having a dispersion of ultrafine titanium boride particles in a titanium-base matrix |
US10604452B2 (en) | 2004-11-12 | 2020-03-31 | General Electric Company | Article having a dispersion of ultrafine titanium boride particles in a titanium-base matrix |
US7833472B2 (en) | 2005-06-01 | 2010-11-16 | General Electric Company | Article prepared by depositing an alloying element on powder particles, and making the article from the particles |
US20070141374A1 (en) * | 2005-12-19 | 2007-06-21 | General Electric Company | Environmentally resistant disk |
US20130186238A1 (en) * | 2012-01-24 | 2013-07-25 | Denso Corporation | Manufacturing method of magnetic alloy powder |
US8911530B2 (en) * | 2012-01-24 | 2014-12-16 | Denso Corporation | Manufacturing method of magnetic alloy powder |
EP2814630A4 (en) * | 2012-02-15 | 2015-12-02 | Baker Hughes Inc | Method of making a metallic powder and powder compact and powder and powder compact made thereby |
Also Published As
Publication number | Publication date |
---|---|
DE1533344B1 (en) | 1970-10-29 |
FR1443968A (en) | 1966-07-01 |
GB1148165A (en) | 1969-04-10 |
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