US2011103994A1PendingUtilityA1

Method and apparatus for producing a lightweight metal alloy

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Assignee: AUTOMOTIVE PARTS AND ACCESSORY SYSTEMS R & D CT LTDPriority: Oct 29, 2009Filed: Aug 9, 2010Published: May 5, 2011
Est. expiryOct 29, 2029(~3.3 yrs left)· nominal 20-yr term from priority
Inventors:June-Sang SiakChan Hung ShekChi Yuen ChungWai-Lam Ralph IpTik Lam Cheung
B22F 3/1003B22F 1/00C22C 1/047B22F 2999/00C22C 21/00B22F 3/105B22F 2998/10
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Claims

Abstract

A method of forming a metal alloy from a powder composition comprising first particles in a range of approximately 20-90% by weight of the powder composition, the remainder of the powder composition comprising approximately 95% by weight of second particles and 5% by weight of third particles, wherein the method includes the step of using rapid thermal processing (RTP) to sinter the powder composition.

Claims

exact text as granted — not AI-modified
1 . A method of forming a metal alloy from a powder composition comprising first particles in a range of approximately 20-90% by weight of the powder composition, the remainder of the powder composition comprising approximately 95% by weight of second particles and 5% by weight of third particles, wherein the method includes the step of using rapid thermal processing (RTP) to sinter the powder composition. 
     
     
         2 . A method as claimed in  claim 1  wherein the first particles include an inter-metallic compound. 
     
     
         3 . A method as claimed in  claim 2  wherein the inter-metallic compound includes TiAl 3  particles. 
     
     
         4 . A method as claimed in  claim 1  wherein the second particles include Aluminium particles. 
     
     
         5 . A method as claimed in  claim 4  wherein the Aluminium particles include 6061 Aluminium particles. 
     
     
         6 . A method as claimed in  claim 1  wherein the third particles include Titanium particles. 
     
     
         7 . A method as claimed in  claim 1  wherein the step of using rapid thermal processing to sinter the powder composition includes heating the powder composition up to a temperature substantially within a range of 700-800° C. 
     
     
         8 . A method as claimed in  claim 7  wherein the step of using rapid thermal processing to sinter the powder composition includes heating the powder composition up to within the range of approximately 700-800° C. within a timeframe of between approximately 0-10 seconds. 
     
     
         9 . A method as claimed in  claim 7  wherein after initially heating the powder composition up to a sintering temperature within the range of approximately 750-800° C., the powder composition is maintained at that sintering temperature for at least around 60 seconds. 
     
     
         10 . A method as claimed in  claim 7  wherein after initially heating the powder composition up to a sintering temperature of approximately 700° C. the powder composition is maintained at that sintering temperature for at least around 90 seconds. 
     
     
         11 . A method as claimed in  claim 1  wherein sintering is ceased after approximately 4 minutes of sintering. 
     
     
         12 . A method as claimed in  claim 11  wherein after sintering is ceased, the sintered powder composition is rapidly cooled. 
     
     
         13 . A method as claimed in  claim 1  including the step of cold-pressing the powder composition in to a mould before sintering the powder composition using rapid thermal processing. 
     
     
         14 . A method as claimed in  claim 13  including a step of mixing the powder composition before cold-pressing the powder composition. 
     
     
         15 . A method as claimed in  claim 14  wherein the step of mixing the power composition includes rotatably mixing the powder composition for at least 12 hours before being cold-pressed. 
     
     
         16 . A method as claimed in  claim 3  wherein the TiAl 3  particles in the powder composition include diameters of approximately 50 μm before sintering. 
     
     
         17 . A method as claimed in  claim 3  wherein sintering of the powder composition by rapid thermal processing causes the TiAl 3  particles to fragment into smaller particles of approximately 10 μm in diameter. 
     
     
         18 . A method of forming a Vanadium-containing metal alloy from a powder composition comprising first particles in a range of approximately 20-90% by weight of the powder composition, the remainder of the powder composition comprising approximately 95% by weight of second particles and 5% by weight of third particles, wherein the method includes the step of using rapid thermal processing (RTP) to sinter the powder composition. 
     
     
         19 . A powder composition adapted for processing by the method steps of  claim 1  to form a metal alloy. 
     
     
         20 . A metal alloy formed in accordance with the method steps of  claim 1 . 
     
     
         21 . A metal alloy as claimed in  claim 20  including inter-metallic TiAl 3  particles of approximately 10 μm in diameter. 
     
     
         22 . An apparatus adapted for performing the method steps in accordance with  claim 1 . 
     
     
         23 . A metal alloy automotive component formed in accordance with the method of  claim 1 . 
     
     
         24 . A metal alloy implantable medical component formed in accordance with the method of  claim 18 .

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