Preparation of alloys by the armstrong method

Abstract

A method and apparatus for making alloys or ceramics by the subsurface injection of an equilibrium vapor of a boiling liquid of the ceramic or alloys constituents is disclosed. Various powders and products are disclosed.

1 . A powder made by the exothermic subsurface reduction of a mixed halide vapor comprising principally a titanium halide and an amount of a halide of at least one other element in a preselected atomic ratio with a liquid reductant metal comprising liquid alkali or alkaline earth metal or mixtures thereof, wherein the mixed halide vapor is generated by boiling a liquid mixture of halides until an equilibrium vapor is attained, and thereafter introducing the equilibrium vapor into the liquid reductant metal to form the powder comprising principally titanium and an amount of the at least one other element in the preselected atomic ratio. 
   
   
       2 . The powder of  claim 1 , wherein the at least one other element is B. 
   
   
       3 . The powder of  claim 2 , wherein the powder is a titanium alloy powder and the at least one other element further includes one or more elements selected from the group consisting of Al, Sb, Be, Ta, Zr, V, Nb, Mo, Ga, U, Re and Si. 
   
   
       4 . The powder of  claim 3 , wherein the titanium alloy powder includes Al and V. 
   
   
       5 . The powder of  claim 4 , wherein the alloy powder is substantially 6% Al and 4% V with the remainder substantially Ti. 
   
   
       6 . The powder of  claim 1 , wherein the liquid reductant metal is Na or Mg. 
   
   
       7 . The powder of  claim 1 , wherein the halide is a chloride. 
   
   
       8 . The powder of  claim 1 , wherein the liquid reductant metal is present in excess of the stoichiometric amount. 
   
   
       9 . The powder of  claim 8 , wherein the liquid reductant metal is present as a flowing stream. 
   
   
       10 . The powder of  claim 1 ; wherein the equilibrium vapor is introduced into the liquid reductant metal by subsurface injection at greater than sonic velocity. 
   
   
       11 . A solid produced from the powder of  claim 1 . 
   
   
       12 . An apparatus for producing a powder by the exothermic subsurface reduction of a mixed halide vapor comprising principally a titanium halide and an amount of a halide of at least one other element in a preselected atomic ratio with a liquid reductant metal comprising liquid alkali metal or alkaline earth metal or mixtures thereof, the apparatus comprising:
 a storage container for storing the liquid reductant metal,   halide containers for storing each of the titanium halide and the halide of the at least one other element in liquid form,   a boiler in communication with each of the halide containers, wherein the titanium halide and the halide of the at least one other element are transferred in a preselected atomic ratio to the boiler to form a liquid mixture of halides,   heating mechanism in heat exchange relationship with the boiler to generate an equilibrium vapor from the liquid mixture of halides,   a reactor in communication with the boiler and the storage container for the liquid reductant metal, wherein the liquid reductant metal is transferred from the storage container to the reactor, and   injection mechanism for subsurface injecting the equilibrium vapor from the boiler into the liquid reductant metal in the reactor to produce the powder in the preselected atomic ratios.   
   
   
       13 . The apparatus of  claim 12 , wherein the at least one other element is B. 
   
   
       14 . The apparatus of  claim 13 , wherein the powder is a titanium alloy powder and the at least one other element further includes one or more elements selected from the group consisting of Al, Sb, Be, Ta, Zr, V, Nb, Mo, Ga, U, Re and Si. 
   
   
       15 . The apparatus of  claim 14 , wherein the titanium alloy powder includes Al and V. 
   
   
       16 . The apparatus of  claim 15 , wherein the alloy powder is substantially 6% Al and 4% V with the remainder substantially Ti. 
   
   
       17 . The apparatus of  claim 12 , wherein the liquid reductant metal is Na or Mg. 
   
   
       18 . The apparatus of  claim 12 , wherein the halide is a chloride. 
   
   
       19 . The apparatus of  claim 12 , wherein the liquid reductant metal in the reactor is present in excess of the stoichiometric amount. 
   
   
       20 . The apparatus of  claim 19 , wherein the liquid reductant metal in the reactor is present as a flowing stream. 
   
   
       21 . The apparatus of  claim 12 , wherein the equilibrium vapor is injected into the liquid reductant metal at greater than sonic velocity.