Patent Application
20220288679
Metal compositions (e.g., compositions comprising metals or composites, such as stainless steel) are used in a variety of materials, from medical devices and tools, to food storage and building materials.
There is a need for metal compositions (e.g., compositions comprising single metals or alloys, such as stainless steel) having improved properties such as high tensile strength, high yield strength, hardness, and resistance to friction for applications in industry. The present disclosure encompasses, among other things, an insight that properties of metal compositions comprising certain additives can exhibit alternative properties relative to metal compositions lacking said additives. For example, in some embodiments, the present disclosure encompasses an insight that a metal composition comprising particles of a transition metal or transition metal oxide exhibits certain properties (e.g., improved strength, improved elasticity, improved lubricity, reduced flammability, reduced smoking when burning, improved char yield after burning, improved recovery rate of transition metal or transition metal oxide after burning, improved shielding ability from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields etc.)) relative to a metal composition without the particles of the transition metal or transition metal oxide. Moreover, the present disclosure also encompasses an insight that incorporation of particles of certain metals (e.g., transition metals or transition metal oxides) may cause the metal to exhibit unique properties (e.g., paramagnetic properties).
In some embodiments, the present disclosure provides a method of preparing a metal composition comprising particles of a transition metal or transition metal oxide, the method comprising: adding particles of the transition metal or transition metal oxide to a first molten mixture to provide a second molten mixture, such that the transition metal or transition metal oxide remains in particle form after cooling of the second molten mixture, wherein the metal composition exhibits at least one of improved strength, elongation, corrosion resistance, lubricity, reduced flammability, reduced smoking when burning, and improved char yield after burning, improved shielding ability from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields, etc.) relative to a metal composition without the particles of the transition metal or the transition metal oxide.
There is a need for metal compositions having improved properties such as improved tensile strength, yield strength, hardness, corrosion resistance, resistance to friction, and lubricity, elongation, reduced flammability, reduced smoking when burning, improved char yield after burning, and improved recovery rate of transition metal or transition metal oxide after burning, improved shielding ability from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields, etc.) for applications in industry. The present disclosure encompasses an insight that addition of particles of certain metals or metal oxides (for example, transition metals or transition metal oxides) into a metal composition comprising, can modulate certain properties (for example, tensile strength, yield strength, hardness, corrosion resistance, resistance to friction, lubricity, paramagnetism, elongation, reduced flammability, suppressed smoking when burning, improved char yield after burning, and high recovery rate of transition metal or transition metal oxide after burning, and/or improved shielding ability from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields, etc.)) of the metal composition relative to a metal composition comprising that lacks said particles.
Metal Compositions
In some embodiments, the present disclosure provides, among other things, a metal composition comprising particles (e.g., microparticles or nanoparticles) of a transition metal or transition metal oxide. Incorporation of particles of a transition metal or transition metal oxide can be used to modulate certain properties in compositions comprising stainless steel. In some embodiments, a metal composition comprising particles (e.g., microparticles, or nanoparticles) of a transition metal or transition metal oxide exhibit improved properties relative to a metal composition without the particles of the transition metal or transition metal oxide.
Metal compositions comprising particles of a transition metal or transition metal oxide described herein are understood to incorporate said particles intact, that is, the particles are not melted and mixed into molten metal during production, and remain as complete particles after finalizing the composition. For example, as illustrated in
As used herein, the term “about”, in reference to a number or percentage, is intended to include numbers that fall within a certain range around that number (where the number is real, i.e., does not go below 0% or above 100%). For example, the term about is intended to encompass ±0.2%, ±0.5%, ±1%, ±5%, or ±10% with respect to any indicated number.
Particles of a Transition Metal or Transition Metal Oxide
In some embodiments, a metal composition comprises particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1% to about 99% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1% to about 75% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1% to about 50% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1% to about 25% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1% to about 10% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1% to about 5% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1% to about 3% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a composition comprises about 0.1% to about 2% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1% to about 0.5% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 1% to about 6% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 1% to about 5% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 3% to about 6% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 4% to about 6% by weight of particles of a transition metal or transition metal oxide. In some embodiments, a metal composition comprises about 0.1%, about 0.2%, about 0.3%, about 0.4%, about 0.5%, about 0.6%, about 0.7%, about 0.8%, about 0.9%, about 1%, about 1.5%, about 2%, about 2.5%, about 3%, about 3.5%, about 4%, about 4.5%, 5%, about 5.5% or about 6% by weight of particles of a transition metal or transition metal oxide.
Particles described herein can be in the form of a microparticle or a nanoparticle. As used herein, a “microparticle” is a particle that is between 1 and 1000 μm in size. As used herein, a “nanoparticle” is a particle that is between 1 and 1000 nm in size. The particles of a transition metal or transition metal oxide can be used in solid compositions, as described herein.
In some embodiments, a transition metal or transition metal oxide is selected from Mn, Mo, Fe, Ti, Zn, Cu, Au, and Ag, or an oxide thereof. In some embodiments, a transition metal or transition metal oxide is selected from Mn, Mo, Zn, Cu, Au, and Ag, or an oxide thereof. In some embodiments, a transition metal is Mo, or an oxide thereof. In some embodiments, a transition metal is Zn, or an oxide thereof. In some embodiments, a transition metal is Cu, or an oxide thereof. In some embodiments, a transition metal is Au, or an oxide thereof. In some embodiments, a transition metal is Ag, or an oxide thereof. In some embodiments, a transition metal is Mn, or an oxide thereof.
In some embodiments, a transition metal or transition metal oxide comprises molybdenum, wherein the transition metal or transition metal oxide is or comprises an oxide of molybdenum. In some embodiments, the oxide of molybdenum is selected from MoO2, MoO3, Mo2O6, and H2MoO5. In some embodiments, the oxide of molybdenum is MoO2. In some embodiments, the oxide of molybdenum is MoO3. In some embodiments, the oxide of molybdenum is Mo2O6. In some embodiments, the oxide of molybdenum is H2MoO5.
In some embodiments, compositions described herein comprise particles of a second metal or second metal oxide. In some embodiments, a second metal is selected from Al, Sn, Cu, Zn, Cr, Mn, Au, Ti, Ag, and W.
In some embodiments, particles of a transition metal or transition metal oxide is of a size that is about 1 nanometer (nm) to about 1000 micrometers (μm). In some embodiments, a transition metal or transition metal oxide is about 99% pure.
In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 1 nm to about 1000 nm. In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 1 nm to about 100 nm. In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 10 nm to about 85 nm. In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 10 nm to about 50 nm. In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 20 nm to about 50 nm. In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 30 μm to about 50 nm. In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 40 nm to about 50 nm. In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 40 nm to about 45 nm. In some embodiments, particles of at least one transition metal or transition metal oxide are nanoparticles having a size of about 30 nm, about 31 nm, about 32 nm, about 33 nm, about 34 nm, about 35 nm, about 36 nm, about 37 nm, about 38 nm, about 39 nm, about 40 nm, about 41 nm, about 42 nm, about 43 nm, about 44 nm, about 45 nm, about 46 nm, about 47 nm, about 48 nm, about 49 nm, or about 50 nm.
In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 1 μm to about 1000 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 1 μm to about 100 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 10 μm to about 85 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 10 μm to about 50 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 20 μm to about 50 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 30 μm to about 50 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 40 μm to about 50 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 40 μm to about 45 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 40 μm to about 45 μm. In some embodiments, particles of at least one transition metal or transition metal oxide are microparticles having a size of about 1 μm, about 2 μm, about 3 μm, about 4 μm, about 5 μm, about 6 μm, about 7 μm, about 8 μm, about 9 μm, about 10 μm, about 11 μm, about 12 μm, about 13 μm, about 14 μm, about 15 μm, about 16 μm, about 17 μm, about 18 μm, about 19 μm, about 20 μm, about 21 μm, about 22 μm, about 23 μm, about 24 μm, about 25 μm, about 26 μm, about 27 μm, about 28 μm, about 29 μm, about 30 μm, about 31 μm, about 32 μm, about 33 μm, about 34 μm, about 35 μm, about 36 μm, about 37 μm, about 38 μm, about 39 μm, about 40 μm, about 41 μm, about 42 μm, about 43 μm, about 44 μm, about 45 μm, about 46 μm, about 47 μm, about 48 μm, about 49 μm, or about 50 μm.
Single Metals and Alloys of Metal Compositions
Metal compositions described herein comprise particles of a transition metal or transition metal oxide. Metal compositions described herein can be single metals, or combinations of metals (i.e., an alloy). An “alloy” refers to a metal that is mixed together with another substance, such as another metal or nonmetal component. It is understood that alloys are made by melting the substances and mixing them together, then letting them cool to form a solid material.
In some embodiments, a metal composition is a single metal composition comprising particles of a transition metal or transition metal oxide. In some embodiments, a single metal is selected from copper, silver, iron, chromium, aluminum, and tin. In some embodiments, a single metal is copper. In some embodiments, a single metal is silver. In some embodiments, a single metal is iron. In some embodiments, a single metal is chromium. In some embodiments, a single metal is aluminum. In some embodiments, a single metal is tin.
In some embodiments, a metal composition is an alloy metal comprising particles of a transition metal or transition metal oxide. In some embodiments an alloy metal is selected from stainless steel, bronze, and brass. In some embodiments, an alloy metal is stainless steel. In some embodiments, an alloy metal is bronze. In some embodiments, an alloy metal is brass.
Alloy metal can comprise combinations of single metals and additional elements, as seen in the table below:
Additional elements can be incorporated into an alloy during the melting and mixing stage. For example, in some embodiments, stainless steel is an iron-based alloy having about 11% by weight of chromium. Different types of stainless steel can incorporate additional elements, including carbon, nitrogen, aluminum, silicon, sulfur, titanium, nickel, copper, selenium, and molybdenum.
For example, with regard to stainless steel, there are different types of stainless steel depending on the crystalline structure of the alloy: austenitic, ferritic, martensitic, duplex, and precipitation hardening. In some embodiments, an alloy is a stainless steel. In some embodiments, a stainless steel is austenitic stainless steel. Austenitic stainless steel comprises a face-centered cubic crystal structure. In some embodiments, austenitic stainless steel is achieved by alloying steel with sufficient nickel and/or manganese and nitrogen. In some embodiments, an austenitic stainless steel is a 304-type stainless steel or a 316-type stainless steel.
In some embodiments, a stainless steel is duplex stainless steel. Duplex stainless steel is a two-phase stainless steel comprising an austenite (face-centered cubic lattice) and a ferrite (body centered cubic lattice) is roughly equal proportions.
In some embodiments, a 304-type stainless steel comprises about 10-20% by weight of chromium and about 5-10% by weight of nickel. In some embodiments, a 304-type stainless steel comprises about 15-20% by weight of chromium and about 5-10% by weight of nickel. In some embodiments, a 304-type stainless steel comprises about 18% by weight of chromium and about 8-10% by weight of nickel. In some embodiments, a 304-type stainless steel comprises about 18% by weight of chromium and about 8% by weight of nickel. In some embodiments, a 304-type stainless steel comprises about 18% by weight of chromium and about 10% by weight of nickel. In some embodiments, a metal composition is a 304-type stainless steel comprising about 5% by weight of particles of molybdenum. In some embodiments, a 304-type stainless steel comprising about 5% by weight of particles of molybdenum, wherein particles of molybdenum are about 45 μm in size.
In some embodiments, a 316-type stainless steel comprises about 16-18% by weight of chromium, about 10-12% by weight of nickel, and about 2-3% by weight of molybdenum, optionally with 1% by weight of silicon, phosphorous and/or sulfur. In some embodiments, a 316-type stainless steel comprises about 16% by weight of chromium, about 10% by weight of nickel, and about 2% by weight of molybdenum, optionally with 1% by weight of silicon, phosphorous and/or sulfur. In some embodiments, a metal composition is a 316-type stainless steel comprising about 5% by weight of particles of molybdenum. In some embodiments, a 316-type stainless steel comprising about 5% by weight of particles of molybdenum, wherein particles of molybdenum are about 45 μm in size.
It is to be understood that metal compositions described herein comprise a metal or alloy formed from a molten mixture, where these metals are distinct from particles of transition metals and transition metal oxides that make up metal compositions described herein. For example, a metal composition comprising an alloy and particles of transition metal or transition metal oxide is, in some embodiments, a stainless steel comprising particles of molybdenum. Methods of producing said metal compositions are described further herein.
Assessment and/or Characterization
As described herein, metal compositions comprising particles of a transition metal or transition metal oxide exhibit certain (e.g., improved) properties relative to a metal composition without the particles of the transition metal or transition metal oxide. That is, in some embodiments, metal compositions described herein exhibit certain unexpected and improved characteristics compared to previously provided metal compositions. For example, in some embodiments, metal compositions described herein exhibit one or more improved properties selected from increased yield strength, increased tensile strength, increased corrosion resistance, increased lubricity, increased elongation, and increased paramagentism.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibit improved yield strength. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits between about 1% and about 15% greater yield strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14%, or 15% greater yield strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits between about 1% and about 5% greater yield strength relative to a metal composition without the particles of the transition metal or transition metal oxide.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibit improved tensile strength relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising stainless steel and particles of a transition metal or transition metal oxide exhibits about 35% to about 95% greater tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising stainless steel and particles of a transition metal or transition metal oxide exhibits about 45% to about 95% greater tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising stainless steel and particles of a transition metal or transition metal oxide exhibits about 55% to about 95% greater tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising stainless steel and particles of a transition metal or transition metal oxide exhibits about 65% to about 95% greater tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising stainless steel and particles of a transition metal or transition metal oxide exhibits about 75% to about 95% greater tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising stainless steel and particles of a transition metal or transition metal oxide exhibits about 85% to about 95% greater tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising stainless steel and particles of a transition metal or transition metal oxide exhibits about 90% to about 95% greater tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising stainless steel and particles of a transition metal or transition metal oxide exhibits about 95% greater tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits improved corrosion resistance relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 1% to about 25% improved corrosion resistance relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 5% to about 25% improved corrosion resistance relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 10% to about 25% improved corrosion resistance relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 15% to about 25% improved corrosion resistance relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 20% to about 25% improved corrosion resistance relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 25% improved corrosion resistance relative to a metal composition without the particles of the transition metal or transition metal oxide.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits improved lubricity relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 1% to about 10% improved lubricity relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 5% to about 10% improved lubricity relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 10% improved lubricity relative to a metal composition without the particles of the transition metal or transition metal oxide.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits reduced flammability relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 1% to about 25% reduced flammability relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 5% to about 25% reduced flammability relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 10% to about 25% reduced flammability relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 15% to about 25% reduced flammability relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 20% to about 25% reduced flammability relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 25% reduced flammability relative to a metal composition without the particles of the transition metal or transition metal oxide.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits reduced smoking when burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 1% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 10% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 20% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 30% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 40% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 50% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 60% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 70% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 80% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 90% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits improved char yield after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 1% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 10% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 20% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 30% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 40% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 50% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 60% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 70% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 80% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 90% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits improved recovery of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 5% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 10% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 15% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 20% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 25% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 30% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 35% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 40% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 45% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 50% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 55% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 60% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 65% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 70% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 75% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 80% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 85% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 90% to about 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or the transition metal oxide.
In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits improved shielding ability from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields, etc.) relative to a metal composition without the particles of the transition metal or the transition metal oxide. As described herein, improved shielding ability refers to an improved resistance to failure or decomposition due to exposure to external forces, such as X-ray exposure, electromagnetic pulses, ionizing radiation, magnetic fields, and the like. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 1% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 10% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 20% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 30% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 40% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 50% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 60% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 70% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 80% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 90% to about 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide. In some embodiments, a metal composition comprising particles of a transition metal or transition metal oxide exhibits about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% improved shielding ability from external damaging forces relative to a metal composition without the particles of the transition metal or transition metal oxide.
Improved properties of metal compositions described herein can be assessed according to methods known to those of skill in the art. For example, in some embodiments, improved yield strength is assessed by testing according to one or more ASTM standards.
Improved properties of metal compositions described herein can be assessed according to methods known to those of skill in the art. For example, in some embodiments, improved tensile strength is assessed by testing according to one or more ASTM standards.
Improved properties of metal compositions described herein can be assessed according to methods known to those of skill in the art. For example, in some embodiments, improved corrosion resistance is assessed by testing according to one or more ASTM standards.
Improved properties of metal compositions described herein can be assessed according to methods known to those of skill in the art. For example, in some embodiments, improved lubricity is assessed by one or more ASTM standards.
Improved properties of metal compositions described herein can be assessed according to methods known to those of skill in the art. For example, in some embodiments, reduced flammability is assessed by oxygen index, O.I. (ASTM D 2863-70). See Moore et al. Journal of the Less-Common Metals, 54 (1977) 297-309, the entirety of which is herein incorporated by reference.
Improved properties of metal compositions described herein can be assessed according to methods known to those of skill in the art. For example, in some embodiments, reduced smoking when burning is assessed using the National Bureau of Standards (NBS) smoke chamber. See Moore et al. Journal of the Less-Common Metals, 54 (1977) 297-309, the entirety of which is herein incorporated by reference.
Improved properties of metal compositions described herein can be assessed according to methods known to those of skill in the art. For example, in some embodiments, improved char yield after burning is assessed using the method described in Moore et al. Journal of the Less-Common Metals, 54 (1977) 297-309, the entirety of which is herein incorporated by reference.
Improved properties of metal compositions described herein can be assessed according to methods known to those of skill in the art. For example, improved shielding ability from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields, etc.) is assessed by measuring the change of total radiation energy per unit volume deposited in silicon. In some embodiments, the absorbed energy density is expressed in rads(Si) (1 rad=100 ergs/gram). It is understood that shielding ability from external forces can be measured according to methods known to those of skill in the art. In some embodiments, shielding ability from external damaging forces is measured using the method described in “Radiation Effects on Electronics 101: Simple Concepts and New Challenges”, NASA.gov, available at https://nepp.nasa.gov/DocUploads/392333B0-7A48-4A04-A3A72B0B1DD73343/Rad_Effects_101_WebEx.pdf, the entirety of which is herein incorporated by reference.
As described herein, the present disclosure provides methods of manufacturing metal compositions comprising particles of a transition metal or transition metal oxide. In some embodiments, the present disclosure provides a method of preparing a metal composition comprising particles of a transition metal or transition metal oxide, the method comprising: adding particles of the transition metal or transition metal oxide to a first molten mixture to provide a second molten mixture, such that the transition metal or transition metal oxide remains in particle form after cooling of the second molten mixture, wherein the metal composition exhibits at least one of improved strength, elongation, corrosion resistance, and lubricity relative to a metal composition without particles of the transition metal or the transition metal oxide.
In some embodiments, a first molten mixture comprises one or more components selected from iron, chromium, nickel, molybdenum, copper, carbon, manganese, phosphorous, sulfur, silicon, nitrogen, titanium, niobium, zirconium, cerium, and combinations thereof. In some embodiments, a first molten mixture comprises iron, chromium, and nickel. In some embodiments, a first molten mixture comprises iron, chromium, nickel, and molybdenum.
In some embodiments, a first molten mixture is prepared in a furnace at a temperature of about 2500° F. to about 3000° F. In some embodiments, a first molten mixture is prepared in a furnace at a temperature of about 2750° F. to about 3000° F. In some embodiments, a first molten mixture is prepared in a furnace at a temperature of about 2975° F. to about 3000° F. In some embodiments, a first molten mixture is prepared in a furnace at a temperature of about 2550° F. to about 3650° F. In some embodiments, a first molten mixture is heated for a period of about 1 or 2 hours.
In some embodiments, particles of a transition metal or transition metal oxide are added to a first molten mixture at a time and temperature to prevent said particles from melting, and thereby becoming incorporated into the first molten mixture. For example, in some embodiments, particles of a transition metal or transition metal oxide are added to a first molten mixture (thereby providing a second molten mixture), which is then cast by pouring the second molten mixture into a mold to provide a semi-finished form. In some embodiments, particles of a transition metal or transition metal oxide are added to a molten mixture that has been removed from heat, but before said mixture has been cast into a semi-finished form. In some embodiments, particles of a transition metal or transition metal oxide are added to a molten mixture that has been cooled to a temperature sufficient to prevent said particles from melting.
In some embodiments, a semi-finished form is formed into a pre-treated melted product by at least one of rolling, forging, pressing, piercing, and drawing, the semi-finished form, and extruding the semi-finished form into at least one of plates, strips, sheets, rolls, bars, and wires.
In some embodiments, a pre-treated metal product is heat treated. In some embodiments, heat treating comprises at least one of annealing, quenching, and/or tempering a pre-treated metal product.
In some embodiments, a pre-treated metal product is descaled. In some embodiments, descaling comprises pickling and electrocleaning.
In some embodiments, a pre-treated metal product is cut (e.g., cut into a particular shape). In some embodiments, cutting comprises at least one of plasma arc, water jet, and mechanical cutting. In some embodiments, mechanical cutting comprises use of at least one of a guillotine knife, a circular knife, blanking, nibbling, or a high speed blade.
In some embodiments, a pre-treated metal product is finished (e.g., polished) to provide a smooth surface. In some embodiments, polishing makes a surface smooth, resulting in reduced friction of a surface. In some embodiments, using lubricants (for example, oil or grease) can reduce the friction between surfaces. In some embodiments, objects are rolled over the surface, and friction between the rolled object and surface can be reduced by using ball bearings.
In some embodiments, a pre-treated metal product is subjected to a metal hardening process comprising: heating, soaking and cooling the pre-treated metal product. In some embodiments, a hardening process described herein comprises strain hardening, solid solution strengthening, precipitation hardening, and quenching and tempering.
The present disclosure encompasses an insight that metal or stainless steel compositions described herein have a variety of uses, such as systems or methods in medical, aerospace, defense, construction, transportation, technology, consumer products, agriculture, automotive, and energy. In some embodiments, a metal or stainless steel composition described herein has uses in systems or methods in medical (for example, class I, II, III, or IV medical devices). In some embodiments, a metal or stainless steel composition described herein has uses in systems or methods in aerospace. In some embodiments, a metal or stainless steel composition described herein has uses in systems or methods in defense. In some embodiments, a metal or stainless steel composition described herein has uses in systems or methods in construction. In some embodiments, a metal or stainless steel composition described herein has uses in systems or methods in transportation. In some embodiments, a metal or stainless steel composition described herein has uses systems or methods in technology. In some embodiments, a metal or stainless steel composition described herein has uses systems or methods in consumer products. In some embodiments, a metal or stainless steel composition described herein has uses systems or methods in agriculture. In some embodiments, a metal or stainless steel composition described herein has uses systems or methods in automotive. In some embodiments, a metal or stainless steel composition described herein has uses systems or methods in energy. In some embodiments, a metal or stainless steel composition described herein has uses in shielding electronic devices, electric grid, electric generator, electric transformer, satellite, aerospace equipment from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields, etc.).
Embodiment 1. A metal composition comprising particles of a transition metal or transition metal oxide, characterized in that the composition exhibits improved strength relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 2. The metal composition of Embodiment 1, wherein the metal composition exhibits improved yield strength relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 3. The metal composition of Embodiment 1, wherein the metal composition exhibits improved tensile strength relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 4. The metal composition of Embodiment 1, wherein the metal composition exhibits improved corrosion resistance relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 5. The metal composition of Embodiment 1, wherein the metal composition exhibits improved lubricity relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 6. The metal composition of Embodiment 1, wherein the metal composition exhibits improved elongation relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 7. The metal composition of any one of Embodiments 1-6, wherein the improved yield strength is determined by one or more ASTM standards.
Embodiment 8. The metal composition of any one of Embodiments 1-6, wherein the improved tensile strength is determined by one or more ASTM standards.
Embodiment 9. The metal composition of any one of Embodiments 1-6, wherein the improved lubricity is determined by one or more ASTM standards.
Embodiment 10. The metal composition of any one of Embodiments 1-6, wherein the improved elongation is determined by one or more ASTM standards.
Embodiment 11. The metal composition of any one of Embodiments 1-6, wherein the improved corrosion resistance is determined by one or more ASTM standards.
Embodiment 12. The metal composition of any one of Embodiments 1-11, wherein the metal composition exhibits about 1% to about 15% greater yield strength relative to a composition without the particles of the transition metal or transition metal oxide.
Embodiment 13. The metal composition of any one of Embodiments 1-11, wherein the metal composition exhibits about 35% to about 95% greater tensile strength relative to a composition without the particles of the transition metal or transition metal oxide.
Embodiment 14. The metal composition of any one of Embodiments 1-11, wherein the metal composition exhibits about 1% to about 10% improved lubricity relative to a composition without the particles of the transition metal or transition metal oxide.
Embodiment 15. The metal composition of any one of Embodiments 1-11, wherein the metal composition exhibits about 1% to about 25% improved corrosion resistance relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 16. A metal composition comprising particles of a transition metal or transition metal oxide, characterized in that the composition exhibits reduced flammability relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 17. A metal composition comprising particles of a transition metal or transition metal oxide, characterized in that the composition exhibits reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 18. A metal composition comprising particles of a transition metal or transition metal oxide, characterized in that the composition exhibits improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 19. A metal comprising particles of a transition metal or transition metal oxide, characterized in that the composition exhibits improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or transition metal oxide
Embodiment 20. A metal composition comprising particles of a transition metal or transition metal oxide, characterized in that the composition exhibits improved shielding ability from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields, etc.) relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 21. The metal composition of Embodiment 16, wherein the composition exhibits about 1% to about 25% reduced flammability relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 22. The metal composition of Embodiment 17, wherein the composition exhibits about 5% to about 95% reduced smoking when burning relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 23. The metal composition of Embodiment 18, wherein the composition exhibits about 5% to about 95% improved char yield after burning relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 24. The metal composition of Embodiment 19, wherein the composition exhibits the composition exhibits about 5%, 10%, 15%, 20%, 25%, 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, 75%, 80%, 85%, 90%, or 95% improved recovery rate of a transition metal or transition metal oxide after burning relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 25. The metal composition of Embodiment 20, wherein the composition exhibits about 5% to about 95% improved shielding ability from external damaging forces (e.g., X-rays, electromagnetic pulses, ionizing radiation, magnetic fields, etc.) relative to a metal composition without the particles of the transition metal or transition metal oxide.
Embodiment 26. The metal composition of any one of Embodiments 1-25, wherein the particles of the transition metal or transition metal oxide are microparticles.
Embodiment 27. The metal composition of Embodiment 26, wherein the microparticles are from about 1 μm to about 1000 μm in size.
Embodiment 28. The metal composition of Embodiment 27, wherein the microparticles are from about 1 μm to about 50 μm in size.
Embodiment 29. The metal composition of any one of Embodiments 1-28, wherein the metal composition comprises about 1% to about 5% by weight of particles of the transition metal or transition metal oxide.
Embodiment 30. The metal composition of any one of Embodiments 1-29, wherein the transition metal or transition metal oxide is selected from Mo, Zn, Cu, Au, and Ag, or an oxide thereof.
Embodiment 31. The metal composition of any one of Embodiments 1-30, wherein the transition metal or transition metal oxide is or comprises molybdenum.
Embodiment 32. The metal composition of any one of Embodiments 1-30, wherein the transition metal or transition metal oxide is or comprises an oxide of molybdenum.
Embodiment 33. The metal composition of Embodiment 32, wherein the oxide of molybdenum is selected from MoO2, MoO3, Mo2O6, and H2MoO5.
Embodiment 34. The metal composition of any one of Embodiments 1-33, wherein the metal composition is a single metal composition comprising a single metal and particles of a transition metal or transition metal oxide.
Embodiment 35. The metal composition of Embodiment 34, wherein the single metal is selected from copper, silver, iron, chromium, aluminum, and tin.
Embodiment 36. The metal composition of any one of Embodiments 1-35, wherein the metal composition is an alloy metal composition comprising an alloy and particles of a transition metal or transition metal oxide.
Embodiment 37. The metal composition of Embodiment 36, wherein the alloy is selected from stainless steel, bronze, and brass.
Embodiment 38. The metal composition of Embodiment 37, wherein the alloy is a stainless steel.
Embodiment 39. The metal composition of Embodiment 38, wherein the stainless steel comprises chromium and iron.
Embodiment 40. The metal composition of Embodiments 38 or 39, wherein the stainless steel further comprises one or more components selected from nickel, molybdenum, copper, carbon, manganese, phosphorous, sulfur, silicon, nitrogen, titanium, niobium, zirconium, cerium, and combinations thereof.
Embodiment 41. The metal composition of any one of Embodiments 37-40, wherein the stainless steel is austenite stainless steel.
Embodiment 42. The metal composition of any one of Embodiments 37-41, wherein the stainless steel is 304-type or 316-type.
Embodiment 43. The metal composition of any one of Embodiments 37-42, wherein the stainless steel is 304-type.
Embodiment 44. The metal composition of any one of Embodiments 37-42, wherein the stainless steel is 316-type.
Embodiment 45. The metal composition of any one of Embodiments 37-42, wherein the stainless steel is duplex stainless steel.
Embodiment 46. A method of preparing a metal composition comprising particles of a transition metal or transition metal oxide, the method comprising:
adding particles of the transition metal or transition metal oxide to a first molten mixture to provide a second molten mixture, such that the transition metal or transition metal oxide remains in particle form after cooling of the second molten mixture,
wherein the metal composition exhibits at least one of improved strength, elongation, corrosion resistance, and lubricity relative to a metal composition without particles of the transition metal or the transition metal oxide.
Embodiment 47. The method of Embodiment 46, wherein the first molten mixture comprises one or more components selected from iron, chromium, nickel, molybdenum, copper, carbon, manganese, phosphorous, sulfur, silicon, nitrogen, titanium, niobium, zirconium, cerium, and combinations thereof.
Embodiment 48. The method of Embodiments 46 or 47, further comprising casting the second molten mixture into a semi-finished form by pouring the second molten mixture into a mold.
Embodiment 49. The method of Embodiment 48, further comprising forming a pre-treated metal product from the semi-finished form by at least one of rolling, forging, pressing, piercing, and drawing, the semi-finished form, and extruding the semi-finished form into at least one of plates, strips, sheets, rolls, bars, and wires.
Embodiment 50. The method of Embodiment 49, further comprising heat treating the pre-treated metal product in a controlled environment, wherein heat treating comprises at least one of annealing, quenching, and tempering the pre-treated metal product.
Embodiment 51. The method of Embodiment 49, further comprising descaling the pre-treated metal product, wherein descaling comprises pickling and electrocleaning.
Embodiment 52. The method of Embodiment 51, further comprising cutting the pre-treated metal product, wherein cutting comprises at least one of plasma arc, water jet, and mechanical cutting, and wherein mechanical cutting comprises using at least one of guillotine knives, circular knives, blanking, nibbling, and high speed blades.
Embodiment 53. The method of Embodiment 52, further comprising surface finishing the pre-treated metal product to provide a smooth surface.
Embodiment 54. The method of any one of Embodiments 46-53, wherein the first molten mixture is prepared in a furnace at a temperature of about 2500° F. to about 3000° F.
Embodiment 55. The method of any one of Embodiments 46-54, wherein the first molten mixture is heated for a period of about 1 to 2 hours.
Embodiment 56. The metal composition of any one of Embodiments 1-45, prepared according to the method of any one of Embodiments 46-55.
The present teachings include descriptions provided in the Examples that are not intended to limit the scope of any claim. Unless specifically presented in the past tense, inclusion in the Examples is not intended to imply that the experiments were actually performed. The following non-limiting examples are provided to further illustrate the present teachings. Those of skill in the art, in light of the present application, will appreciate that many changes can be made in the specific embodiments that are provided herein and still obtain a like or similar result without departing from the spirit and scope of the present teachings.
Four samples were prepared using two additives, A and B. Additive A was 4 μm unactivated molybdenum powder. Additive B was 45 μm unactivated molybdenum powder. Each sample was heated to about 2975-3000° F. in a furnace prior to addition of the Additives. Additives were added slowly with stirring to avoid the formation of a crust. The addition process took between 2 to 4 minutes. Once all material was added, the heats were tapped out, ladle pouring temperature was checked, and the molds were poured. Final chemistry samples were taken at the end of the pour. All molds were hot topped as standard. The results of the chemistry for the four samples are provided below:
Sample 1-316-Type Stainless Steel prepared with additive A
Sample 2-316-Type Stainless Steel prepared with additive B
Sample 3-304-Type Stainless Steel prepared with additive A
Sample 4-304-Type Stainless Steel prepared with additive B
For each sample, the following was poured: two each investment molds, two each sand molds, and one test coupon sample mold. Each investment mold produced three investment cast bars, nominally 0.5″×2.85″ (raw processed). Each sand mold produced two sand cast test bars, nominally 1″×6.6″ (raw processed). All castings were heat treated. Parameters of this heat treatment are heat to 2035° F.+15/−25° F., hold for 1 hour then nitrogen back flush. Initially, one bar of each type, from each heat, was machined to ASTM E8 standards for tensile testing. The results of this testing is shown below, along with hardness from the same test coupons. As a result of a “broke out of gauge” failure on one of the bars, as well as significantly lower elongation on two other bars, three tests were replicated.
This application claims priority to U.S. Provisional Application No. 63/159,862, filed Mar. 11, 2021, the entirety of which is incorporated herein by reference.
| Number | Date | Country | |
|---|---|---|---|
| 63159862 | Mar 2021 | US |
