Nanophase dispersion strengthened low cte alloy

Abstract

A metal matrix composite material of a low coefficient of thermal expansion (CTE) alloy strengthened by nanophase dispersed particles. The low CTE alloy can be an iron-nickel alloy or an iron-nickel-cobalt alloy. The nanophase particles can be a refractory oxide, carbide or nitride. Also disclosed is a method of making a metal matrix composite material in which the nanophase particles are combined with the low CTE alloy to form a metal matrix composite material having the nanophase particles dispersed therein.

1 . A metal matrix composite material comprising a low coefficient of thermal expansion (CTE) alloy strengthened by nanophase dispersed particles. 
     
     
         2 . The metal matrix composite material according to  claim 1 , wherein said allow alloy is selected from the group consisting of iron-nickel and iron-nickel-cobalt alloys strengthened by nanophase dispersed particles. 
     
     
         3 . The metal matrix composite material of  claim 2  wherein the low CTE iron-nickel alloy comprises 36 weight percent nickel, remainder iron. 
     
     
         4 . The metal matrix composite material of  claim 2  wherein the low CTE iron-nickel-cobalt alloys are selected from the group consisting of a 32 weight percent nickel, 5 weight percent cobalt, remainder iron alloy and a 26 weight percent nickel, 17 weight percent cobalt, remainder iron alloy. 
     
     
         5 . The metal matrix composite of  claim 2  wherein the nanophase dispersed particles comprise about 10 to 45 volume percent of the metal matrix composite, wherein the remainder of the metal matrix composite is the low CTE alloy. 
     
     
         6 . The metal matrix composite of  claim 2  wherein the nanophase dispersed particles comprise about 30 volume percent of the metal matrix composite, wherein the remainder of the metal matrix composite is the low CTE alloy. 
     
     
         7 . The metal matrix composite of  claim 2  wherein the nanophase dispersed particles have a grain size distribution of about 10 nm to 200 nm with the majority of the nanophase particles having a grain size less than about 100 nm. 
     
     
         8 . The metal matrix composite of  claim 2  wherein the nanophase dispersed particles are selected from the group consisting of refractory oxides, carbides and nitrides. 
     
     
         9 . The metal matrix composite of  claim 8  wherein the refractory oxide is selected from the group consisting of Al 2 O 3 , TiO 2 , Y 2 O 3 , HfO 2 , ZrO 2 , SiO 2 , Ta 2 O 5 , and ZrSiO 4 . 
     
     
         10 . The metal matrix composite of  claim 8  wherein the nitride is selected from the group consisting of TaN, TiN, ZrN, AlN, Si 3 N 4 , VN, CrN, NbN, and HfN. 
     
     
         11 . The metal matrix composite of  claim 8  wherein the carbide is devoid of free carbon and is selected from the group consisting of TiC, ZrC, HfC, VC, NbC, TaC, Cr 3 C 2 , MO 2 C, WC, and SiC. 
     
     
         12 . A method of making a metal matrix composite material, the method comprising the steps of:
 forming nanophase particles;   combining the nanophase particles with a low coefficient of thermal expansion (CTE) alloy to form a metal matrix composite material having the nanophase particles dispersed therein.   
     
     
         13 . The method of  claim 12  wherein the nanophase particles are selected from the group consisting of refractory oxides, carbides and nitrides and the low CTE alloy is selected from the group consisting of iron-nickel and iron-nickel-cobalt alloys. 
     
     
         14 . The method of  claim 12  wherein the step of combining comprises mixing powders of the nanophase particles with powders of the low CTE alloy to form a compact and then heating to a temperature sufficient to cause sintering of the low CTE alloy. 
     
     
         15 . The method of  claim 12  wherein the step of combining comprises mechanical alloying. 
     
     
         16 . The method of  claim 12  wherein the step of combining includes forming a porous compact of the nanophase particles and then infiltrating the compact with a liquefied low CTE alloy. 
     
     
         17 . The method of  claim 12  wherein the nanophase particles comprise about 10 to 45 volume percent of the metal matrix composite, wherein the remainder of the metal matrix composite is the low CTE alloy. 
     
     
         18 . The method of  claim 12  wherein the nanophase particles comprise about 30 volume percent of the metal matrix composite, wherein the remainder of the metal matrix composite is the low CTE alloy. 
     
     
         19 . The method of  claim 13  wherein the refractory oxide is selected from the group consisting of Al 2 O 3 , TiO 2 , Y 2 O 3 , HfO 2 , ZrO 2 , SiO 2 , Ta 2 O 5 , and ZrSiO 4 . 
     
     
         20 . The method of  claim 13  wherein the nitride is selected from the group consisting of TaN, TiN, ZrN, AlN, Si 3 N 4 , VN, CrN, NbN, and HfN. 
     
     
         21 . The method of  claim 13  wherein the carbide is devoid of free carbon and is selected from the group consisting of TiC, ZrC, HfC, VC, NbC, TaC, Cr 3 C 2 , Mo 2 C, WC, and SiC. 
     
     
         22 . The method of  claim 12  wherein the nanophase particles have a grain size distribution of about 10 nm to 200 nm with the majority of nanophase particles having a grain size less than about 100 nm. 
     
     
         23 . A method of making a metal matrix composite material of low coefficient of thermal expansion comprising the steps of:
 a) providing an iron-nickel alloy powder metal material of a low coefficient of thermal expansion;   b) providing refractory nanophase particles having a standard molar enthalpy of formation less than −300 kJ mol −1 ;   c) mixing said iron nickel allow and said refractory nanophase particles to yield a substantially uniform mixture wherein said refractory nanophase particles amount to 10-45% of said mixture by volume;   d) forming said mixture into a compact; and   e) then heating said mixture to a temperature sufficient to cause sintering of said iron-nickel alloy.   
     
     
         24 . The method of making a metal matrix composite material according to  claim 23 , wherein said iron-nickel alloy is 36 weight percent nickel and 64 weight percent iron. 
     
     
         25 . The method of making a metal matrix composite material according to  claim 23 , wherein said step of heating includes sintering said mixture in one of a vacuum and a inert atmosphere and causing densification of the mixture into said metal matrix composite material. 
     
     
         26 . The method of making a metal matrix composite material according to  claim 23 , wherein said steps further comprising consolidated said mixture by one of hot isostatic pressing or extrusion. 
     
     
         27 . The method of making a metal matrix composite material according to  claim 23 , wherein said refractory nanophase particles constitute about 30% of said mixture by volume. 
     
     
         28 . A metal matrix composite material having of low coefficient of thermal expansion comprising:
 an iron nickel alloy having a low coefficient of thermal expansion; and   refractory nanophase particles having a standard molar enthalpy of formation less than −300 kJ mol −1  dispersed substantially uniformly within said iron nickel alloy, wherein said refractory nanophase particles constitute between 10-45% by volume of said metal matrix composite material.   
     
     
         29 . The metal matrix composite material according to  claim 28 , wherein said iron-nickel alloy is 36 weight percent nickel and 64 weight percent iron. 
     
     
         30 . The metal matrix composite material according to  claim 29 , wherein said refractory nanophase particles constitute about 30% of said mixture by volume. 
     
     
         31 . The metal matrix composite material according to  claim 28 , wherein said refractory nanophase particles constitute about 30% of said mixture by volume. 
     
     
         32 . The metal matrix composite according to  claim 28  wherein said metal matrix composite has 
     
     
         33 . The metal matrix composite according to  claim 28 , wherein said nanophase particles have a grain size distribution in a range between 10-200 nanometers (nm). 
     
     
         34 . The metal matrix composite according to  claim 30 , wherein said nanophase particles have a grain size distribution in a range between 10-200 nanometers (nm). 
     
     
         36 . The metal matrix composite according to  claim 28 , wherein said metal matrix composite has a secant coefficient of thermal expansion less than or equal to 1.5 ppm/K over the temperature range between 4K to 330K. 
     
     
         37 . The metal matrix composite according to  claim 28 , wherein said metal matrix composite has a secant coefficient of thermal expansion less than or equal to 1.5 ppm/K over the temperature range between 4K to 330K and said nanophase particles have a grain size distribution in a range between 10-100 nanometers (nm). 
     
     
         38 . The metal matrix composite according to  claim 34 , wherein said metal matrix composite has a secant coefficient of thermal expansion less than or equal to 1.5 ppm/K over the temperature range between 4K to 330K.