Superdeformable/high strength metal alloys

Abstract

A method for forming superdeformable metal alloy preforms that have high strength alloy compositions by selecting metal powders which will define the desired alloy, mixing the selected metal powders, performing either one of cold pressing the metal powders or fast heating the metal powders to define a desired preform shape, and fast heating the metal powder preform shape so as to consolidate it to a desired form.

1 . A method for forming superdeformable metal alloy preforms that have high strength alloy compositions, the method comprising: 
 selecting metal powders which will define the desired alloy;    mixing the selected metal powders;    performing either one of cold pressing the metal powders or fast heating the metal powders to define a desired preform shape; and    fast heating the metal powder preform shape so as to consolidate it to a desired form.    
     
     
         2 . The method as recited in  claim 1 , wherein selecting the metal powders comprises selecting aluminum as a matrix material.  
     
     
         3 . The method as recited in  claim 1 , wherein selecting the metal powders comprises selecting aluminum as a matrix material and selecting at least one alloy metal from the group consisting of: 
 copper;    magnesium;    chromium;    titanium;    iron;    lithium;    nickel;    vanadium;    silicon;    manganese; and    zinc.    
     
     
         4 . The method as recited in  claim 1 , wherein selecting the metal powders comprises selecting iron as a matrix material.  
     
     
         5 . The method as recited in  claim 1 , wherein selecting the metal powders comprises selecting iron as a matrix material and selecting at least one alloy material from the group consisting of: 
 nickel;    manganese;    silicon;    chromium;    molybdenum;    vanadium;    cobalt;    carbon; and    metal carbides.    
     
     
         6 . The method as recited in  claim 1 , wherein selecting the metal powders comprises selecting metal powders having particle sizes between approximately 1 micron and approximately 100 microns.  
     
     
         7 . The method as recited in  claim 1 , wherein mixing the selected metal powders comprises blending the selected metal powders with agitation.  
     
     
         8 . The method as recited in  claim 1 , further comprising mechanically alloying surfaces of the metal powders.  
     
     
         9 . The method as recited in  claim 1 , further comprising mechanically alloying surfaces of the metal powders by performing at least one process selected from the group consisting of: 
 hammer milling;    ball milling; and    impact milling.    
     
     
         10 . The method as recited in  claim 1 , wherein fast heating the cold pressed metal powder preform shape or the heated metal powder preform shape so as to consolidate the preform shape comprises heating the metal powder preform shape to the desired consolidation temperature in the shortest time possible, with minimum hold time.  
     
     
         11 . The method as recited in  claim 1 , wherein the heated metal powder preform is consolidated under pressure.  
     
     
         12 . The method as recited in  claim 1 , wherein the heated metal powder preform is consolidated under pressure of between approximately 20,000 pounds per square inch and approximately 100,000 pounds per square inch.  
     
     
         13 . The method as recited in  claim 1 , wherein the heated metal powder preform is consolidated at a temperature between approximately 40% and 75% of the melting point of the matrix metal of the metal powders, with the metal powder preform under pressure of between approximately 20,000 pounds per square inch and approximately 100,000 pounds per square inch.  
     
     
         14 . A method for forming superdeformable metal alloys that have high strength alloy compositions, the method comprising: 
 selecting metal powders which will define the desired alloy;    mixing the selected metal powders;    performing either one of cold pressing the metal powders or fast heating the metal powders to define a desired preform shape;    fast heating the metal powder preform shape so as to consolidate it to a desired form;    fast heating the consolidated preform to prepare the consolidated preform for working;    working the consolidated preform to a desired shape; and    heat treating the worked product to define a metal alloy having the desired shape and properties.    
     
     
         15 . The method as recited in  claim 14 , wherein selecting the metal powders comprises selecting aluminum as a matrix material.  
     
     
         16 . The method as recited in  claim 14 , wherein selecting the metal powders comprises selecting aluminum as a matrix material and selecting at least one alloy metal from the group consisting of: 
 copper;    magnesium;    chromium;    titanium;    iron;    lithium;    nickel;    vanadium;    silicon;    manganese; and    zinc.    
     
     
         17 . The method as recited in  claim 14 , wherein selecting the metal powders comprises selecting iron as a matrix material.  
     
     
         18 . The method as recited in  claim 14 , wherein selecting the metal powders comprises selecting iron as a matrix material and selecting at least one alloy material from the group consisting of: 
 nickel;    manganese;    silicon;    chromium;    molybdenum;    vanadium;    cobalt;    carbon; and    metal carbides.    
     
     
         19 . The method as recited in  claim 14 , wherein selecting the metal powders comprises selecting metal powders having particle sizes between approximately 1 micron and approximately 100 microns.  
     
     
         20 . The method as recited in  claim 14 , wherein mixing the selected metal powders comprises blending the selected metal powders With agitation and milling the selected powders to obtain desired dispersion of the powders.  
     
     
         21 . The method as recited in  claim 14 , further comprising mechanically alloying surfaces of the metal powders.  
     
     
         22 . The method as recited in  claim 14 , further comprising mechanically alloying surfaces of the metal powders by performing at least one process selected from the group consisting of: 
 hammer milling;    ball milling; and    impact milling.    
     
     
         23 . The method as recited in  claim 14 , wherein fast heating the cold pressed metal powder preform shape or the heated metal powder preform shape so as to consolidate the preform shape comprises fast heating the metal powder preform shape to the desired consolidation temperature, with minimum hold time.  
     
     
         24 . The method as recited in  claim 14 , wherein the heated metal powder preform is consolidated under pressure.  
     
     
         25 . The method as recited in  claim 14 , wherein the heated metal powder preform is consolidated under pressure of between approximately 20,000 pounds per square inch and approximately 100,000 pounds per square inch.  
     
     
         26 . The method as recited in  claim 14 , wherein the heated metal powder preform is consolidated at a temperature between approximately 40% and 75% of the melting point of the matrix metal of the powdered metals, and at a pressure of between approximately 20,000 pounds per square inch and approximately 100,000 pounds per square inch.  
     
     
         27 . The method as recited in  claim 14 , wherein fast heating the consolidated preform to prepare the consolidated preform for working comprises fast heating the consolidated preform to the desired working temperature, with minimum hold time.  
     
     
         28 . The method as recited in  claim 14 , wherein working the consolidated preform to a desired shape comprises performing at least one process selected from the group consisting of: 
 extruding;    rolling;    forging; and    machining.    
     
     
         29 . The method as recited in  claim 14 , wherein heat treating the worked product to define a metal alloy having the desired shape and properties comprises heating the product at a temperature and for a time that provides diffusion of the alloying elements and the matrix metal to give the desired properties.  
     
     
         30 . A superdeformable metal alloy with high strength alloy composition formed by a method comprising: 
 selecting metal powders which will define the desired alloy;    mixing the selected metal powders; performing either one of cold pressing the metal powders or fast heating the metal powders to define a desired preform shape; and    fast heating the metal powder preform shape so as to consolidate it to a desired form.    
     
     
         31 . The method as recited in  claim 30 , wherein selecting the metal powders comprises selecting aluminum as a matrix material.  
     
     
         32 . The method as recited in  claim 30 , wherein selecting the metal powders comprises selecting aluminum as a matrix material and selecting at least one alloy metal from the group consisting of: 
 copper;    magnesium;    chromium;    titanium;    iron;    lithium;    nickel;    vanadium;    silicon;    manganese; and    zinc.    
     
     
         33 . The method as recited in  claim 30 , wherein selecting the metal powders comprises selecting iron as a matrix material.  
     
     
         34 . The method as recited in  claim 30 , wherein selecting the metal powders comprises selecting iron as a matrix material and selecting at least one alloy material from the group consisting of: 
 nickel;    manganese;    silicon;    chromium;    molybdenum;    vanadium;    cobalt;    carbon; and    metal carbides.    
     
     
         35 . The method as recited in  claim 30 , wherein selecting the metal powders comprises selecting metal powders having particle sizes between approximately 1 micron and approximately 100 microns.  
     
     
         36 . The method as recited in  claim 30 , wherein mixing the selected metal powders comprises blending the selected metal powders with agitation and milling the selected powders to obtain desired dispersion of the powders.  
     
     
         37 . The method as recited in  claim 30 , further comprising mechanically alloying surfaces of the metal powders.  
     
     
         38 . The method as recited in  claim 30 , further comprising mechanically alloying surfaces of the metal powders by performing at least one process selected from the group consisting of: 
 hammer milling;    ball milling; and    impact milling.    
     
     
         39 . The method as recited in  claim 30 , wherein fast heating the cold pressed metal powder preform shape or the heated metal powder preform shape so as to consolidate the preform shape comprises heating the metal powder preform shape to the desired consolidation temperature in the shortest time possible, with minimum hold time.  
     
     
         40 . The method as recited in  claim 30 , wherein the heated metal powder preform is consolidated under pressure.  
     
     
         41 . The method as recited in  claim 30 , wherein the heated metal powder preform is consolidated under pressure of between approximately 20,000 pounds per square inch and approximately 100,000 pounds per square inch.  
     
     
         42 . The method as recited in  claim 30 , wherein the heated metal powder preform is consolidated at a temperature between approximately 40% and 75% of the melting point of the matrix metal of the metal powders, with the metal powder preform under pressure of between approximately 20,000 pounds per square inch and approximately 100,000  
     
     
         43 . A superdeformable metal alloy with high strength alloy composition formed and worked by a method comprising: 
 selecting metal powders which will define the desired alloy;    mixing the selected metal powders;    performing either one of cold pressing the metal powders or fast heating the metal powders to define a desired preform shape;    fast heating the metal powder preform shape so as to consolidate it to a desired form;    fast heating the consolidated preform to prepare the consolidated preform for working;    working the consolidated preform to a desired shape; and    heat treating the worked product to define a metal alloy having the desired shape and properties.    
     
     
         44 . The method as recited in  claim 43 , wherein selecting the metal powders comprises selecting aluminum as a matrix material.  
     
     
         45 . The method as recited in  claim 43 , wherein selecting the metal powders comprises selecting aluminum as a matrix material and selecting at least one alloy metal from the group consisting of: 
 copper;    magnesium;    chromium;    titanium;    iron;    lithium;    nickel;    vanadium;    silicon;    manganese; and    zinc.    
     
     
         46 . The method as recited in  claim 43 , wherein selecting the metal powders comprises selecting iron as a matrix material.  
     
     
         47 . The method as recited in  claim 43 , wherein selecting the metal powders comprises selecting iron as a matrix material and selecting at least one alloy material from the group consisting of: 
 nickel;    manganese;    silicon;    chromium;    molybdenum;    vanadium;    cobalt;    carbon; and    metal carbides.    
     
     
         48 . The method as recited in  claim 43 , wherein selecting the metal powders comprises selecting metal powders having particle sizes between approximately 1 micron and approximately 100 microns.  
     
     
         49 . The method as recited in  claim 43 , wherein mixing the selected metal powders comprises blending the selected metal powders with agitation and milling the selected powders to obtain desired dispersion of the powders.  
     
     
         50 . The method as recited in  claim 43 , further comprising mechanically alloying surfaces of the metal powders.  
     
     
         51 . The method as recited in  claim 43 , further comprising mechanically alloying surfaces of the metal powders by performing at least one process selected from the group consisting of: 
 hammer milling;    ball milling; and    impact milling.    
     
     
         52 . The method as recited in  claim 43 , wherein fast heating the cold pressed metal powder preform shape or the heated metal powder preform shape so as to consolidate the preform shape comprises fast heating the metal powder preform shape to the desired consolidation temperature, with minimum hold time.  
     
     
         53 . The method as recited in  claim 43 , wherein the heated metal powder preform is consolidated under pressure.  
     
     
         54 . The method as recited in  claim 43 , wherein the heated metal powder preform is consolidated under pressure of between approximately 20,000 pounds per square inch and approximately 100,000 pounds per square inch.  
     
     
         55 . The method as recited in  claim 43 , wherein the heated metal powder preform is consolidated at a temperature between approximately 40% and 75% of the melting point of the matrix metal of the powdered metals, and at a pressure of between approximately 20,000 pounds per square inch and approximately 100,000 pounds per square inch.  
     
     
         56 . The method as recited in  claim 43 , wherein fast heating the consolidated preform to prepare the consolidated preform for working comprises fast heating the consolidated preform to the desired working temperature, with minimum hold time.  
     
     
         57 . The method as recited in  claim 43 , wherein working the consolidated preform to a desired shape comprises performing at least one process selected from the group consisting of: 
 extruding;    rolling;    forging; and    machining.    
     
     
         58 . The method as recited in  claim 43 , wherein heat treating the worked product to define a metal alloy having the desired shape and properties comprises heating the product at a temperature and for a time that provides diffusion of the alloying elements and the matrix metal to give the desired properties.  
     
     
         59 . A method for extruding materials, the method comprising: 
 forming a dummy block which has a surface which is complimentary in shape to at least one of a die and a mandrel, such that the dummy block fits into an extrusion container generally flush with the die; and    placing the dummy block behind a hot billet during an extrusion process, such that efficiency of the extrusion process is enhanced as the billet is extruded.    
     
     
         60 . The method as recited in  claim 59 , further comprising: 
 removing the dummy block from the container after an extrusion process; and    placing the dummy block behind another hot billet and reusing the dummy block in a subsequent extrusion process.    
     
     
         61 . A method for extruding a clad material, the method comprising: 
 forming a superdeformable metal alloy preform having a high strength alloy composition, according to the method comprising: 
 selecting metal powders which will define the desired alloy;  
 mixing the selected metal powders; and  
 cold pressing the mixed metal powders to define a desired preform shape; and  
   forming a cladding upon the superdeformable metal alloy preform according to the method comprising: 
 selecting metal powders which will define the desired cladding;  
 mixing the selected metal powders; and  
 cold pressing the mixed metal powder cladding against the preform to define a desired clad preform shape; and  
   fast heating the cold pressed clad preform shape so as to consolidate the metal powders and bond the cladding to the preform; and    heating and extruding the clad superdeformable metal alloy to a desired form.    
     
     
         62 . A method for forming a superdeformable metal alloy preform having a high strength alloy composition, the method comprising: 
 selecting metal powders which will define the desired alloy;    mixing the selected metal powders;    performing one of either cold pressing the mixed metal powders or fast heating the metal powders to define a desired preform shape;    fast heating the preform shape to a desired consolidation temperature;    applying mechanical pressure thereto at reduced atmospheric pressure, so as to consolidate the metal powders in a manner which mitigates an occurrence of voids therein.    
     
     
         63 . The method as recited in  claim 62 , further comprising substantially surrounding the heated preform shape with a ceramic grain prior to applying mechanical pressure thereto at a reduced atmospheric pressure.  
     
     
         64 . A method for forming a preform which facilitates working of metal, the method comprising: 
 selecting metal powders which will define a desired alloy;    mixing the selected metal powders;    performing one of either cold pressing the mixed metal powders or fast heating the metal powders to define a desired preform shape;    fast heating the metal powder preform shape so as to consolidate the metal powders; and    wherein the desired preform shape is generally similar to a desired shape of a final, worked product.    
     
     
         65 . The method as recited in  claim 64 , wherein the desired preform shape is selected from the group consisting of: 
 tubular;    L-channel;    I-beam; and    U-channel.    
     
     
         66 . A preform formed by the method comprising: 
 selecting metal powders which will define a desired alloy;    mixing the selected metal powders;    performing one of either cold pressing the mixed metal powders or fast heating the metal powders to define a desired preform shape; and    fast heating the metal powder preform shape so as to consolidate the metal powders;    wherein the desired preform shape is generally similar to a desired shape of a final, worked product.    
     
     
         67 . The preform as recited in  claim 66 , wherein the desired preform shape is selected from the group consisting of: 
 tubular;    L-channel;    I-beam; and    U-channel.    
     
     
         68 . A method for working metals, the method comprising: 
 forming a superdeformable/high strength metal alloy preform, according to the method comprising: 
 selecting powdered metals which will define the desired alloy;  
 mixing the selected powdered metals;  
 performing one of either cold pressing the mixed metal powders or fast heating the metal powders to define a desired preform shape; and  
 fast heating the cold pressed powdered metals so as to consolidate the powdered metals;  
   wherein the desired preform shape is generally similar to a desired shape of a final, worked product; and 
 working the preform to the desired final shape;  
   
     
     
         69 . The method as recited in  claim 68  wherein the desired preform shape is selected from the group consisting of: 
 tubular;  
 L-channel;  
 I-beam; and  
 U-channel.  
 
     
     
         70 . The method as recited in  claim 68 , wherein working the preform to the desired final shape comprises a least one process selected from the group consisting of: 
 extruding;    rolling; and    forging.    
     
     
         71 . A method for extruding metals, the method comprising: 
 forming a superdeformable metal alloy preform having a high strength alloy composition, according to the method comprising: 
 selecting metal powders which will define the desired alloy;  
 mixing the selected powdered metals;  
 performing one of either cold pressing the mixed metal powders or fast heating the metal powders in a to define a desired preform shape; and  
 fast heating the preform shape so as to consolidate the metal powders;  
   wherein the desired preform shape is generally similar to a desired shape of a final, worked product; and 
 extruding the preform to the desired final shape.  
   
     
     
         72 . The method as recited in  claim 71 , wherein the desired preform shape is selected from the group consisting of: 
 tubular;    L-channel;    I-beam; and    U-channel.    
     
     
         73 . A metal extrusion formed by the method comprising: 
 forming a superdeformable/high strength metal alloy preform, according to the method comprising: 
 selecting powdered metals which will define the desired alloy;  
 mixing the selected powdered metals;  
 performing one of either cold pressing the mixed metal powders or fast heating the metal powders to define a desired preform shape; and  
 fast heating the preform shape so as to consolidate the metal powders;  
   wherein the desired preform shape is generally similar to a desired shape of a final, worked product; and 
 extruding the preform to the desired final shape.  
   
     
     
         74 . The metal extrusion as recited in  claim 73 , wherein the desired preform shape is selected from the group consisting of: 
 tubular;    L-channel;    I-beam; and    U-channel.    
     
     
         75 . The metal extrusion as recited in  claim 1 , further comprising: 
 fast heating the preform shape to a consolidation temperature;    applying at least a partial vacuum to the heated preform shape while simultaneously applying mechanical pressure thereto, so as to increase the density thereof, and so as to mitigate an occurrence of voids therein.    
     
     
         76 . A method for forming metal, the method comprising: 
 combining at least two different metals such that they are less fully alloyed and such that they have less strength;    working the combined metals; and    more fully alloying the metals such that they are more fully alloyed have more strength.    
     
     
         77 . A metal alloy formed by a process comprising: 
 combining at least two different metals such that they are less fully alloyed and such that they have less strength;    working the combined metals; and    more fully alloying the metals such that they are more fully alloyed have more strength.    
     
     
         78 . A method for forming metal products, the method comprising combining at least two different metals such that they are not fully alloyed and may thus be more easily worked.  
     
     
         79 . A method for forming metal products, the method comprising combining at least two different metals such that they are not fully alloyed and may thus be more easily worked, wherein at least a portion of the forming is performed using the consolidation equipment described in U.S. Pat. No. 4,634,375.