Atomized picoscale composition aluminum alloy and method thereof

Abstract

The invention is a process for manufacturing a nano aluminum/alumina metal matrix composite and composition produced therefrom. The process is characterized by providing an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5 m2/g, hot working the aluminum powder, and forming a superfine grained matrix aluminum alloy. Simultaneously there is formed in situ a substantially uniform distribution of nano particles of alumina. The alloy has a substantially linear property/temperature profile, such that physical properties such as strength are substantially maintained even at temperatures of 250° C. and above.

1 . A system for manufacturing a nano aluminum composite, the system comprising:
 an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5.0 m 2 /g, the aluminum powder having a d90 particle size of about 2.3 microns and a d10 particle size of about 0.6 microns;   a hot-working apparatus configured to hot work the aluminum powder at a temperature below the recrystallization temperature of the powder to form a superfine grained matrix aluminum alloy; and   a blending apparatus for blending the superfine grained matrix aluminum alloy with a ceramic particulate to form a powder mixture;   whereby the powder mixture comprises about 5 wt. % to about 40 wt. % of the ceramic particulate.   wherein said superfine grained matrix aluminum alloy has an average particle size of about 200 nm.   
     
     
         2 . The system according to  claim 1 , wherein the hot-working apparatus is configured to hot work at a temperature less than the melting point of said alloy. 
     
     
         3 . The system according to  claim 1 , wherein the aluminum powder has a d50 particle size of about 1.3 microns. 
     
     
         4 . The system according to  claim 1 , wherein the ceramic particulate is selected from the group consisting of silica, silicon carbide, boron carbide, boron nitride, titanium oxide, titanium diboride, and mixtures thereof. 
     
     
         5 . The system according to  claim 1 , wherein the system further comprises a sintering apparatus configured to sinter the powder mixture to form a billet. 
     
     
         6 . The system according to  claim 1 , wherein the natural layer of aluminum oxide on the aluminum powder has a thickness of between 3-7 nm. 
     
     
         7 . The system according to  claim 1 , wherein the system is free of an mechanical alloying apparatus. 
     
     
         8 . A system for manufacturing a nano aluminum composite, the system comprising:
 an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5.0 m 2 /g;   hot working apparatus configured to hot work the aluminum powder at a temperature below the recrystallization temperature of the powder, and forming thereby a superfine grained matrix aluminum alloy, and the hot working apparatus configured to redistribute the aluminum powder into uniformly dispersed nano particles of alumina throughout said alloy;   a blending apparatus configured to blend the superfine grained matrix aluminum alloy with a ceramic particulate to form a powder mixture, the ceramic particulate comprising boron carbide having a particle size distribution of 100% less than about 250 microns and the boron carbide is nuclear grade;   wherein said superfine grained matrix aluminum alloy has an average particle size of about 200 nm.   
     
     
         9 . The system according to  claim 8 , wherein the hot working is carried out at a temperature less than the melting point of said alloy. 
     
     
         10 . The system according to  claim 8 , whereby the powder mixture comprises about 5 wt. % to about 40 wt. % of the ceramic particulate. 
     
     
         11 . The system according to  claim 8 , wherein the natural layer of aluminum oxide has a thickness of between 3-7 nm. 
     
     
         12 . The system according to  claim 8 , wherein the system is free of an mechanical alloying apparatus. 
     
     
         13 . A system for manufacturing a nano aluminum composite, the system comprising:
 an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5.0 m 2 /g, the aluminum powder having a particle size of less than about 30 μm in diameter and the natural layer of aluminum oxide has a thickness of between 3-7 nm;   a hot working apparatus configured to hot work the aluminum powder at a temperature below the recrystallization temperature of the powder thereby forming a superfine grained matrix aluminum alloy; and   a blending apparatus configures to blend the superfine grained matrix aluminum alloy with a ceramic particulate to form a powder mixture, whereby the powder mixture comprises about 5 wt. % to about 40 wt. % of the ceramic particulate;   a sintering apparatus configured to sinter the powder mixture to form a billet;   wherein the hot working apparatus is configured such that the superfine grained matrix aluminum alloy has an average particle size of about 200 nm.   
     
     
         14 . The system according to  claim 13 , wherein the ceramic particulate is selected from the group consisting of silica, silicon carbide, boron carbide, boron nitride, titanium oxide, titanium diboride, and mixtures thereof. 
     
     
         15 . The system of  claim 14 , wherein the ceramic particulate is boron carbide having a particle size distribution of 100% less than about 250 microns and the boron carbide is nuclear grade. 
     
     
         16 . The system according to  claim 13 , wherein the hot working apparatus is configured such that the hot working is carried out at a temperature less than the melting point of said alloy. 
     
     
         17 . The system according to  claim 13 , wherein the system is free of an mechanical alloying apparatus.