Macro-Chip Reinforced Alloy for Stable Neutron Shielding
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Solution Overview
Problem
Existing composite materials face challenges in forming grain structures suitable for extreme applications due to the addition of diverse alloying elements, which can undermine structural integrity.
Innovation Solution
A method involving a powder blend of a first metal particle, a first ceramic particle, and a reinforcing chip with a second ceramic particle dispersed in a chip metal matrix, processed at a temperature lower than both grain growth temperatures, forming a macro-chip reinforced alloy through vacuum sintering and extrusion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If diverse alloying elements and ceramic particles are added to metal matrix, then neutron shielding performance is improved, but grain structure formation and structural integrity deteriorate
Solution Approach 1:
The patent divides the composite into distinct phases: a metal matrix phase and a ceramic particle phase, with each phase having specific grain size ranges. The ceramic particles are segmented into size ranges of 0.5-5 μm and 5-20 μm, while the metal matrix grains are controlled in the 5-20 μm range, creating a segmented microstructure that prevents random grain growth and maintains structural integrity while providing neutron shielding
Solution Approach 2:
The patent specifies precise parameter ranges for grain sizes (metal matrix: 5-20 μm, ceramic particles: 0.5-5 μm and 5-20 μm) and processing temperatures to control microstructure formation. By changing and controlling these parameters during processing, the patent achieves a microstructure that maintains both neutron shielding capability and structural integrity despite the presence of diverse alloying elements
2Object-affected harmful factors
If greater diversity of metal matrix materials and alloying elements are used, then performance benefits are improved, but manufacturing complexity increases
Solution Approach 1:
The patent controls manufacturing by specifying precise parameter ranges including metal particle sizes (1-10 μm and 10-30 μm), ceramic particle sizes (0.5-5 μm and 5-20 μm), and processing temperatures. These parameter specifications provide a clear manufacturing framework that simplifies the process of creating complex multi-phase composites with diverse alloying elements while maintaining consistent grain structure formation
Solution Approach 2:
The patent performs preliminary mixing and distribution of metal particles and ceramic particles before final processing and sintering. This preliminary action ensures uniform distribution of diverse alloying elements and ceramic particles throughout the matrix, simplifying subsequent manufacturing steps and ensuring consistent grain structure formation without requiring complex in-process adjustments
3Quantity of substance
If hot-work temperature is increased to process the powder blend, then densification is improved, but grain growth and structural integrity deteriorate
Solution Approach 1:
The patent identifies and specifies an optimal hot-work temperature range that achieves densification without excessive grain growth. By carefully controlling the hot-work temperature parameter within this range, the patent simultaneously improves packing density while maintaining grain size stability, resolving the contradiction between densification and grain growth
Solution Approach 2:
The patent applies partial densification through controlled hot-working at temperatures below those required for complete densification. This partial action approach achieves sufficient packing density improvement while avoiding the excessive temperatures that would cause harmful grain growth, thereby maintaining structural integrity
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 produces a composite material with improved mechanical properties and packing density, allowing for the reuse of scrap material without degrading mechanical performance, and provides a homogeneous distribution of ceramic particles for neutron shielding applications.
Implementation Method 1
processing the powder blend at an elevated temperature that is lower than the grain growth temperature
Implementation Method 2
The consolidation is performed at a temperature lower than the grain growth temperature of the metal particles and the chip metal matrix. In one embodiment, the consolidation temperature is less than about 1100° F.
Implementation Method 3
subsequently extruding the billet into a sheet material
Data Source
AI summary
Described herein are methods of forming a neutron shielding material. Such material may comprise a powder blend comprising a first component comprising a blend of a first metal particle and a first ceramic particle; and a second component comprising a reinforcing chip, the reinforcing chip comprising a second ceramic particle dispersed within a chip metal matrix.