Gold-Titanium Alloy Sintering via Powder Metallurgy
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Solution Overview
Problem
The production of gold-titanium alloys is challenging due to segregation of composition, coarse grain structures, high processing costs, and significant waste generation in traditional casting methods, which result in non-uniformity and high costs, especially given the high value of gold.
Innovation Solution
A novel approach involving the use of gold and titanium powders for sintering to form sintered articles, with deoxygenation processing to achieve uniformity, fine-grained microstructure, and reduced waste, utilizing methods like powder metallurgy or additive manufacturing to produce gold-titanium alloys with controlled composition and reduced oxygen content.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If casting methods are used to produce gold-titanium alloys, then the production process is simple, but chemical segregation and coarse grain structures occur resulting in non-uniform composition
Solution Approach 1:
The invention changes the fundamental processing parameters from liquid casting to powder metallurgy, operating at solid-state temperatures rather than high melting temperatures. This parameter change eliminates the capillarity-driven segregation that occurs during casting while enabling controlled sintering to achieve uniform composition throughout the alloy.
Solution Approach 2:
The invention replaces the thermal-melting mechanism of casting with a solid-state sintering mechanism. Instead of melting metals and relying on gravity and capillarity for mixing, the process uses controlled heating of powder compact to achieve diffusion bonding, eliminating the mechanical segregation problems inherent in casting.
2Ease of manufacture
If casting methods are used to produce gold-titanium alloys, then the production process is simple, but large columnar grains form resulting in coarse microstructure
Solution Approach 1:
The invention changes the temperature parameter regime from high-temperature melting (above gold's melting point of 1064°C) to lower-temperature solid-state sintering (typically 600-900°C). This parameter change prevents the formation of large columnar grains that characterizes casting, instead producing fine, equiaxed grains through controlled powder densification.
3Ease of manufacture
If traditional casting and machining methods are used, then production is straightforward, but significant waste is generated resulting in high processing costs
Solution Approach 1:
The invention segments the alloy production into powder formulation and sintering stages, allowing precise control of composition before manufacturing. This segmentation enables near-net-shape forming of complex geometries directly from powder, eliminating the need for extensive post-production machining and associated gold waste.
Solution Approach 2:
The invention changes from subtractive machining of solid ingots to additive/sintering-based fabrication from powder. This parameter change in the manufacturing approach allows complex parts to be formed with minimal material removal, dramatically reducing gold waste and processing costs.
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 low-cost, high-uniformity production of gold-titanium alloys with reduced waste and improved properties, such as hardness and density, by using powder metallurgy or additive manufacturing techniques, thereby addressing the challenges of traditional casting methods.
Implementation Method 1
The consolidated body can be at least partially sintered in vacuum or a reducing atmosphere to form a gold-titanium alloy sintered article
Implementation Method 2
The composite metal powder, the consolidated body, and/or the sintered article can be deoxygenated at a deoxygenation temperature under a hydrogen-containing atmosphere to reduce an oxygen content
Data Source
AI summary
A method of making a gold-titanium alloy can include preparing a powder mixture of gold source powder and titanium source powder. The method can also include consolidating the powder mixture to form a consolidated body. The consolidated body can be at least partially sintered in vacuum or a reducing atmosphere to for a gold-titanium alloy sintered article.Another example method of producing a gold-titanium alloy can include preparing a composite metal powder having composite granules including a gold source powder and a titanium source powder within the composite granules. The composite metal powder can be consolidated to form a consolidated body. The consolidated body can be at least partially sintered to form a sintered article. The method can also include deoxygenating at least one of the composite metal powder, the consolidated body, or the sintered article at a deoxygenation temperature under a hydrogen-containing atmosphere to reduce an oxygen content.