Method of fabricating metal compound through smelting with vaporization purification

Abstract

The present invention provides a method for mass producing any metal alloy. After melting a metal mixture, a mixture of heating, soaking and/or cooling is processed to obtain the alloy even with a trace element added. The metal alloy made by the present invention thus has a high purity and a low cost.

1 . A method of fabricating a metal compound through smelting with a vaporized purification, comprising steps of:
 (a) obtaining a mixed material to be melted to obtain a liquid state of at least one component of said mixed material;   (b) after melting said mixed material to a state selected from a group consisting of a pure liquid state and a liquid-solid-mixed state, controlling a ratio, a size and a type of an initial phase of said mixed material during a phase formation of a biphasic region to obtain an eutectic alloy; and   (c) after obtaining requested values of said ratio, said size and said type of said initial phase, controlling separating statuses of components of said initial phase having different vapor pressures during a vaporized purification to obtain a metal compound,   wherein said component is selected from a group consisting of an element and a compound.   
     
     
         2 . The method according to  claim 1 ,
 wherein said mixed material comprises at least one component having a relatively higher vapor pressure and another component having a relatively lower vapor pressure;   wherein said element is selected from a group consisting of a 1A group element, a 2A group element, a 3A group element, a 4A group element, a 5A group element, a transitional element and a rare earth element; and   wherein an element of said component is selected from a group consisting of a 1A group element, a 2A group element, a 3A group element, a 4A group element, a 5A group element, a transition a element and a rare earth element.   
     
     
         3 . The method according to  claim 1 ,
 wherein said metal compound is obtained through a reaction selected from a group consisting of a peritectic reaction and an eutectic reaction.   
     
     
         4 . The method according to  claim 1 ,
 wherein said metal compound is a mixture of at least a phase selected from a group consisting of a primary phase, an eutectic phase, and a plurality of a primary phase and an eutectic phase.   
     
     
         5 . The method according to  claim 1 ,
 wherein said melting in step (a), said phase formation in step (b) and said vaporized purification in step (c) are processed with a mixture of at least a gas selected from a group consisting of an 8A element gas, nitrogen (N 2 ), argon (Ar), sulfur hexafluoride (SF 6 ) and carbon dioxide (CO 2 ); and   wherein said gas is obtained as a gas selected from a group consisting of a reacting gas and a protecting gas.   
     
     
         6 . The method according to  claim 1 ,
 wherein an element vapored in said melting in step (a), in said phase formation in step (b) and in said vaporized purification in step (c) are processed to obtain a by-product; and   wherein said processing is selected from a group consisting of being collected to be fabricated into powder and being directed to be reacted with other element.   
     
     
         7 . The method according to  claim 1 ,
 wherein said melting in step (a), said phase formation in step (b) and said vaporized purification in step (c) are processed with an agitation to obtain a change;   wherein said agitation is selected from a group consisting of a manual agitation, a mechanical agitation and a gas agitation; and   wherein said change is selected from a group consisting of:
 (i) speeding up melting an element into said liquid state of said mixed material; 
 (ii) improving an uniformity of said mixed material in said liquid-solid-mixed state; and 
 (iii) changing a state of a forming phase to obtain a change in a ratio selected from a group consisting of a reaction ratio and a volatilization ratio. 
   
     
     
         8 . The method according to  claim 7 ,
 wherein at least a trace element is further added in said agitation; and   wherein said trace element is selected from a group consisting of a 1A element, a 2A element, a 3A element, a 4A element, a 5A element, a transitional element and a rare earth element.   
     
     
         9 . The method according to  claim 7 ,
 wherein at least a component selected from a group consisting of an element and a compound is further added to said forming phase in said agitation; and   wherein said component has a characteristic selected from a group consisting of a higher melting point than that of said forming phase and a lower vapor pressure than that of said forming phase.   
     
     
         10 . The method according to  claim 1 ,
 wherein said melting in step (a), said phase formation in step (b) and said vaporized purification in step (c) are obtained through a combination of processes   wherein said process is selected from a group consisting of heating, soaking and cooling; and   wherein each said process is processed under a time, a temperature and a speed.   
     
     
         11 . The method according to  claim 10   wherein said heating, said soaking and said cooling are processed with a mixture of at least a gas under an environment;   wherein said gas is selected from a group consisting of an 8A element gas, oxygen (O 2 ), carbon monoxide (CO), hydrogen (H 2 ) SF 6  and CO 2 ; and   wherein said gas is obtained as a gas selected from a group consisting of a reacting gas and a protecting gas.   
     
     
         12 . The method according to  claim 10   wherein said cooling is selected from a group consisting of a furnace cooling, an air cooling, a water cooling and an oil quenching.   
     
     
         13 . The method according to  claim 1 ,
 wherein an initial phase obtained after said vaporized purification comprises at least a metal compound.   
     
     
         14 . The method according to  claim 1 ,
 wherein another process is processed after said vaporized purification to obtain a change in a micro-structure;   wherein said another process is selected from a group consisting of heating, soaking and cooling; and   wherein said change is selected from a group consisting of a solid solution and a phase transformation.