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.

What is claimed is: 
     
         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 l  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 l  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 O 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 .- 41 . (canceled)