Metal composites and methods for forming same

Abstract

A metal composite comprising a spinodal structure having at least one ductile phase and method of making same is disclosed. The metal composite is formed by forming an alloy comprising a positive heat of mixing in the liquid state; purifying the alloy; and forming a network structure of the alloy comprising at least one ductile sub-network.

1 . A method comprising: 
 forming an alloy;    purifying the alloy; and    forming a network structure of the alloy comprising at least one ductile sub-network structure.    
   
   
       2 . The method of  claim 1  wherein the alloy formed comprises a ratio of T g  to T 1  greater than or equal to about 0.35.  
   
   
       3 . The method of  claim 2 , wherein the alloy formed comprises a ratio of T g  to T 1  greater than or equal to about 0.49.  
   
   
       4 . The method of  claim 2 , wherein the alloy formed comprises a metal and a metalloid.  
   
   
       5 . The method of  claim 4 , wherein purifying the alloy comprises: 
 heating the alloy to form a molten alloy; and    contacting the molten alloy with a flux material.    
   
   
       6 . The method of  claim 2 , wherein forming a network structure comprises cooling the molten alloy.  
   
   
       7 . The method of  claim 6 , wherein cooling the molten alloy comprises undercooling the molten alloy.  
   
   
       8 . The method of  claim 7 , wherein the molten alloy is cooled to a ΔT of about 100° K to about 500° K  
   
   
       9 . The method of  claim 4 , wherein the alloy formed comprises a metal selected from the group consisting of Fe, Co, Cu, Ni, Pd, Pt, Mn, Al, Ti, Zr, Cr, W, and combinations thereof.  
   
   
       10 . The method of  claim 9 , wherein the alloy formed comprises a metal selected from the group consisting of Fe, Co, Ni, and combinations thereof.  
   
   
       11 . The method of  claim 10 , wherein the alloy formed comprises Ni.  
   
   
       12 . The method of  claim 10 , wherein the alloy formed comprises Co  
   
   
       13 . The method of  claim 10 , wherein the alloy formed comprises Fe.  
   
   
       14 . The method of  claim 4 , wherein the alloy formed comprises a metalloid selected from the group consisting of B, Si, C and combinations thereof.  
   
   
       15 . The method of  claim 4 , wherein the alloy formed further comprises a non-metal selected from the group consisting of Ge, P, S and combinations thereof.  
   
   
       16 . The method of  claim 14 , wherein the metalloid is C.  
   
   
       17 . The method of  claim 10 , wherein the alloy formed comprises an element selected from the group consisting of C, Si, and combinations thereof.  
   
   
       18 . The method of  claim 15 , wherein the alloy formed further comprises Ge.  
   
   
       19 . The method of  claim 5 , wherein the alloy is contacted with a flux material selected from the group consisting of B 2 0 3 , glass, calcium oxide, barium oxide, aluminum oxide, magnesium oxide, lithium oxide, and combinations thereof.  
   
   
       20 . The method of  claim 19 , wherein the alloy is contacted with a flux material selected from the group consisting B 2 O 3 , glass, and combinations thereof.  
   
   
       21 . The method of  claim 20 , wherein the alloy is contacted with B 2 O 3 .  
   
   
       22 . The method of  claim 20 , wherein the alloy is contacted with glass.  
   
   
       23 . The method of  claim 4 , further comprising heating the alloy and the flux material to a temperature greater than about 1,000° C.  
   
   
       24 . The method of  claim 1 , further comprising: 
 placing the alloy in a first portion of a vessel;    heating the first portion of the vessel under a vacuum causing the alloy to melt and flow into a second portion of the vessel; and    cooling the second portion of the vessel.    
   
   
       25 . The method of  claim 1 , wherein the network structure is formed having a solid phase λ of about 50 microns or less.  
   
   
       26 . The method of  claim 25 , wherein the network structure is formed having a solid phase k of about 10 microns or less.  
   
   
       27 . The method of  claim 26 , wherein the network structure is formed having a solid phase λ of about 300 nm or less.  
   
   
       28 . The method of  claim 27 , wherein the network structure is formed having a solid phase X of about 100 nm or less.  
   
   
       29 . The method of  claim 1 , wherein the alloy comprising a positive heat of mixing in a liquid state is one of a monotectic alloy, a eutectic alloy, and a peritectic alloy.  
   
   
       30 . The method of  claim 25 , wherein the spinodal structure is formed having a liquid phase k and a solid phase λ that are substantially equal.  
   
   
       31 . The method of  claim 30 , wherein the liquid phase k and a solid phase k that are substantially equal are at a location where crystallization is initiated.  
   
   
       32 . The method of  claim 1 , wherein the alloy is formed from at least 2 constituents comprising a positive heat of mixing in the liquid state.  
   
   
       33 . The method of  claim 32 , wherein the liquid state is metastable.  
   
   
       34 . The method of  claim 32 , wherein the liquid state is stable.  
   
   
       35 . A metal composite comprising a ductile spinodal structure.  
   
   
       36 . The metal composite of  claim 35 , wherein the spinodal structure comprises a coherent grain boundary.  
   
   
       37 . The metal composite of  claim 35 , wherein the composite is a bulk material.  
   
   
       38 . The metal composite of  claim 37 , wherein the spinodal structure has a liquid phase λ of about 50 microns or less.  
   
   
       39 . The metal composite of  claim 37 , wherein the spinodal structure has solid phase λ of about 50 microns or less.  
   
   
       40 . The metal composite of  claim 38 , wherein the spinodal structure has a liquid phase λ and a solid phase λ that are substantially equal.  
   
   
       41 . The metal composite of  claim 35 , further comprising a metal and a metalloid.  
   
   
       42 . The metal composite of  claim 41 , wherein the metal is selected from the group consisting of Fe, Co, Cu, Ni, Pd, Pt, Mn, Al, Ti, Zr, Cr, W, combinations thereof.  
   
   
       43 . The metal composite of  claim 42 , wherein the metal is selected from the group consisting of Fe, Co, Ni, and combinations thereof.  
   
   
       44 . The metal composite of  claim 43 , wherein the metal is Ni.  
   
   
       45 . The metal composite of  claim 43 , wherein the metal is Co.  
   
   
       46 . The metal composite of  claim 43 , wherein the metal is Fe.  
   
   
       47 . The metal composite of  claim 41 , wherein the metalloid is selected from the group consisting of B, Si, C and combinations thereof.  
   
   
       48 . The metal composite of  claim 41 , further comprising Ge, P, S, and combinations thereof.  
   
   
       49 . The metal composite of  claim 47 , wherein the metalloid is selected from the group consisting of C, Si, and combinations thereof.  
   
   
       50 . The metal composite of  claim 42 , further comprising Si.  
   
   
       51 . The metal composite of  claim 42 , further comprising C.  
   
   
       52 . The metal composite of  claim 42 , further comprising a ratio of T g  to T 1  greater than or equal to about 0.35.  
   
   
       53 . The metal composite of  claim 52 , further comprising a ratio of T g  to T i  greater than or equal to about 0.49.  
   
   
       54 . A metal article comprising the metal composite of  claim 34 .  
   
   
       55 . The metal article of  claim 54 , wherein the article has a spherical shape.  
   
   
       56 . The metal article of  claim 55 , wherein the spherical shape has a diameter of about 1 inch or less.  
   
   
       57 . The metal article of  claim 56 , wherein the spherical shape has a diameter of about 2 cm or less.  
   
   
       58 . The metal article of  claim 57 , wherein the spherical shape has a diameter of about 1 cm or less.  
   
   
       59 . The metal article of  claim 58 , wherein the spherical shape has a diameter of about 5 mm or less.  
   
   
       60 . The metal article of  claim 59 , wherein the spherical shape has a diameter of about 0.1 mm.  
   
   
       61 . The metal article of  claim 54 , wherein the article further comprises a eutectic structure.  
   
   
       62 . The metal article of  claim 54 , wherein the metal article is a nanostructure composite.  
   
   
       63 . A method of forming a metal composite comprising: 
 forming an alloy; purifying the alloy;    forming one or more spinodals; and    heating the one or more spinodals causing at least one of the one or more brittle spinodals to transform into one or more ductile phases.    
   
   
       64 . The method of  claim 63 , wherein forming one or more spinodals comprises forming one or more brittle spinodals.  
   
   
       65 . The method of  claim 63 , wherein the one or more ductile phases are interconnected.  
   
   
       66 . The method of  claim 65 , wherein the one or more ductile phases are partially interconnected.  
   
   
       67 . The method of  claim 65 , wherein the one or more ductile phases are substantially completely interconnected.  
   
   
       68 . The method of  claim 65 , wherein the one or more ductile phases are interconnected with brittle phases.  
   
   
       69 . The method of  claim 63 , wherein the one or more ductile phases are isolated clusters.