Graphene-in-Metal Covetic Composition With Homogeneous Carbon Loading
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Solution Overview
Problem
Existing methods for using powdered constituents in vacuum induction melting furnaces face challenges as the electromagnetic forces from induction coils eject powders, inhibiting effective mixing with other constituents, particularly in the production of covetic materials that require nanoscale carbon-metal composites.
Innovation Solution
A microwave plasma torch reactor is used to grow pristine graphene onto molten metal nanoscale particles, forming carbon-metal nanoscale-sized particles with non-polar covalent bonds, achieving homogeneous distribution of carbon in the metal lattice without aggregates or agglomerates, and producing covetic materials with high carbon loading up to 90 wt%.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If powdered constituents are used in vacuum induction melting furnaces, then carbon content and material properties can be enhanced, but electromagnetic forces from induction coils eject the powders, inhibiting effective mixing
Solution Approach 1:
The patent introduces a graphite crucible as an intermediary medium to contain and facilitate mixing of carbon powder with metal constituents. The graphite crucible acts as a container that prevents direct electromagnetic ejection of powders while enabling effective mixing, thus resolving the contradiction between achieving high carbon content and maintaining mixing effectiveness.
2Ease of manufacture
If conventional induction melting methods are used, then processing is simple, but carbon aggregates and agglomerates form, reducing material quality
Solution Approach 1:
The patent modifies the melting process parameters by using a graphite crucible and controlling heating rates to achieve uniform carbon distribution. The graphite crucible facilitates controlled carbon dissolution into the metal melt, preventing aggregation while maintaining processing simplicity. This parameter change enables both ease of manufacture and high manufacturing precision regarding carbon distribution.
3Quantity of substance
If high carbon loading is achieved, then covetic material properties are enhanced, but formation of aggregates and defects increases
Solution Approach 1:
The patent employs continuous stirring and controlled addition of carbon sources during the melting process to maintain homogeneous carbon distribution. This continuous action prevents local concentration gradients that lead to aggregates and defects, enabling high carbon loading (up to 90 wt%) while ensuring defect-free material quality through sustained uniform mixing.
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
The method enables the production of covetic materials with enhanced mechanical, thermal, and electrical properties, including increased melting points and surface tension, while ensuring homogeneous carbon distribution and absence of defects, overcoming the limitations of conventional techniques.
Implementation Method 1
a microwave plasma spray torch reactor configured to dissociate a hydrocarbon process gas into carbon atoms
Implementation Method 2
microwave energy source operatively coupled to the reaction chamber to provide power thereto
Implementation Method 3
single layer graphene (SLG) or few layer graphene (FLG) is grown from the carbon atoms onto the molten metal nanoscale-sized particles to form a plurality of carbon-metal nanoscale-sized particles
Implementation Method 4
PLASMA SPRAY SYSTEMS AND METHODS
Data Source
AI summary
Inventive techniques for forming unique compositions of matter are disclosed, as well as associated physical characteristics and properties of the materials. In particular, particles comprising a metal lattice are characterized by having carbon (preferably graphene) disposed within the crystalline lattice structure thereof. The carbon is at least partially disposed in interstitial sites of the metal lattice, and may be present in amounts ranging from about 15 wt % to about 90 wt % of the total particle mass, with about 15 wt % to about 60 wt % being disposed in the interstitial sites, e.g., between basal planes, of the metal lattice. The carbon, moreover, is substantially homogeneously dispersed throughout the resultant material, conveying unique and advantageous properties such as strength-to-weight ratio, density, mechanical toughness, sheer strength, flex strength, hardness, anti-corrosiveness, electrical and/or thermal conductivity, etc. as described herein. In some approaches, the graphene is pristine, and has corresponding physical characteristics as described herein.