Preparation of alloys by the armstrong method

Abstract

A method and apparatus for making alloys or ceramics by the subsurface injection of an equilibrium vapor of a boiling liquid of the ceramic or alloys constituents is disclosed. Various powders and products are disclosed.

1 - 31 . (canceled)  
   
   
       32 . An alloy or ceramic powder made by the exothermic subsurface reduction of a mixed halide vapor of the alloy or ceramic constituents with liquid alkali or alkaline earth metal or mixtures thereof, wherein a liquid mixture of halides of the alloy or ceramic constituents in a preselected atomic ratio is provided, boiling the liquid until an equilibrium with the vapor is attained, and thereafter introducing the equilibrium vapor into the liquid reductant metal to form an alloy or ceramic powder of the equilibrium vapor constituents in the preselected atomic ratio.  
   
   
       33 . The powder of  claim 32 , wherein the reductant metal is Na or Mg.  
   
   
       34 . The powder of  claim 33 , wherein the halide is a chloride.  
   
   
       35 . The powder of  claim 34 , wherein the alloy is principally Ti.  
   
   
       36 . The powder of  claim 35 , wherein the alloy is principally Ti and includes Al and V.  
   
   
       37 . The powder of  claim 36 , wherein the alloy is substantially 6% Al and 4% V with the remainder substantially Ti.  
   
   
       38 . The powder of  claim 32 , wherein the reductant metal is present in excess of the stoichiometric amount.  
   
   
       39 . The powder of  claim 38 , wherein the reductant metal is present as a flowing stream.  
   
   
       40 . The powder of  claim 32 , wherein the vapor is introduced into the liquid metal by subsurface injection at greater than sonic velocity.  
   
   
       41 . The powder of  claim 32 , wherein the ceramic is one or more of a nitride or a carbide or a boride mixture thereof.  
   
   
       42 . The powder of  claim 32 , wherein the alloy includes one or more of Ti, Al, Sb, Be, B, Ta, Zr, V, Nb, Mo, Ga, U, Re, or Si.  
   
   
       43 . A solid produced from the powder of  claim 32 .  
   
   
       44 . An alloy or ceramic powder made by the exothermic subsurface reduction of a mixed halide vapor of the alloy constituents with liquid alkali or alkaline earth metal or mixtures thereof, wherein a liquid mixture of halides of the alloy constituents in a preselected atomic ratio is provided, boiling the liquid until an equilibrium with the vapor is attained, and thereafter injecting the equilibrium vapor into the liquid reductant metal at greater than sonic velocity to form an alloy powder of the equilibrium vapor constituents in the preselected atomic ratio.  
   
   
       45 . The powder of  claim 44 , wherein the reductant metal is Na or Mg and the halide is chloride.  
   
   
       46 . The powder of  claim 44 , wherein the alloy is principally Ti.  
   
   
       47 . The powder of  claim 46 , wherein the alloy is principally Ti and includes Al and V.  
   
   
       48 . The powder of  claim 47 , wherein the alloy is substantially 6% Al and 4% V with the remainder substantially Ti.  
   
   
       49 . The powder of  claim 45 , wherein the reductant metal is present as a flowing stream.  
   
   
       50 . A solid produced from the powder of  claim 44.