Dispersoid Hardened Metallic Materials Solid-State Oxidation
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Solution Overview
Problem
The high cost and time-consuming processes associated with mechanically producing dispersoid hardened metallic materials, which are necessary for achieving the desired strength and hardness through the incorporation of dispersoids with particle sizes of 1 micron or less, have limited their widespread use.
Innovation Solution
A method involving the formation of a starting composition with a base metal component and a dispersoid forming component, where the dispersoid forming component is oxidized while in a solid state, using a fluidizing gas to create dispersoid hardened metallic materials with the desired particle size and distribution, reducing production time and costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical milling and blending is used to produce dispersoid hardened metallic materials, then dispersoids with desired particle size (1 micron or less) are achieved, but production time extends to days and cost becomes prohibitive
Solution Approach 1:
The patent changes the fundamental parameter of the production method from mechanical physical processes (milling and blending) to a chemical process (oxidation). By controlling oxidation parameters such as temperature, atmosphere composition, and time, dispersoids are formed in-situ within the metal matrix, achieving the desired particle size of 1 micron or less without extensive mechanical processing, thereby reducing production time from days to a fraction of that time.
2Manufacturing precision
If mechanical milling and blending is used to produce dispersoid hardened metallic materials, then dispersoids with desired particle size (1 micron or less) are achieved, but production cost becomes prohibitive
Solution Approach 1:
The patent changes the production method from mechanical milling to chemical oxidation, fundamentally altering the manufacturing parameters. The oxidation process uses controlled atmospheres and temperature treatments to form dispersoids in-situ, eliminating the need for extensive mechanical energy input and multiple processing steps, thereby significantly reducing production cost while maintaining the desired dispersoid particle size of 1 micron or less.
Solution Approach 2:
The patent replaces the mechanical system (milling and blending equipment, extensive mechanical processing) with a chemical system (oxidation process using controlled atmospheres and temperature treatment). This substitution eliminates the need for expensive mechanical energy input and complex mechanical processing equipment, reducing production cost while achieving the same dispersoid particle size control.
3Productivity
If dispersoid forming component is oxidized in solid state using fluidizing gas, then production time and cost are reduced, but process complexity is introduced
Solution Approach 1:
The patent utilizes phase transitions by fluidizing the powder mixture with a gas stream, transitioning the solid powder particles into a fluid-like state that enhances gas-surface contact. This fluidization allows efficient oxidation of the dispersoid forming component in the solid state while maintaining good heat and mass transfer, achieving fast production without requiring complex liquid or molten state processing equipment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method enables the economical production of dispersoid hardened metallic materials with dispersoids of 1 micron or less, enhancing their strength and hardness while minimizing production time and costs, allowing for their broader application.
Implementation Method 1
the dispersoid forming component is oxidized while in a solid state
Implementation Method 2
the starting powder is fluidized with a fluidizing gas for a period of time sufficient to oxidize the dispersoid forming component
Data Source
AI summary
Methods of forming dispersoid hardened metallic materials are provided. In an exemplary embodiment, a method of producing dispersoid hardened metallic materials includes forming a starting composition with a base metal component and a dispersoid forming component. The starting composition includes the base metal component in an amount from about 50 to about 99.999 weight percent and the dispersoid forming component in an amount from about 0.001 to about 1 weight percent, based on the total weight of the starting composition. A starting powder is formed from the starting composition, and the starting powder is fluidized with a fluidizing gas for a period of time sufficient to oxidize the dispersoid forming component to form the dispersoid hardened metallic material. The dispersoid forming component is oxidized while the starting powder is a solid.