Method for making a non-toxic dense material

Abstract

A composition having high density and low toxicity suitable for use as a shotgun pellet, a bullet or armor piercing projectile and a method for manufacturing such composition is described. This material and product are developed to economically address the toxicity problems inherent in lead shot and bullets. This composition, in its present embodiment, is also suitable for use in any product requiring high-density and low toxicity. One present embodiment maintains the magnetic properties of the projectile if desired.

1 . A method for manufacturing high-density materials, comprising:
 combining nickel with manganese and a tungsten composition to form a mixture;   shaping said mixture;   sintering said mixture for a time of between about 1 to about 60 minutes at a temperature of from about 1030° C. to about 1200° C. to produce a high-density low toxicity material.   
   
   
       2 . The method of  claim 1 , wherein said nickel, said manganese, and said tungsten are in powdered form. 
   
   
       3 . The method of  claim 1 , further comprising adding a sintering aid to said mixture. 
   
   
       4 . The method of  claim 3 , further comprising heating said mixture, prior to said sintering. 
   
   
       5 . The method of  claim 1 , further comprising adding a binder to said mixture. 
   
   
       6 - 10 . (canceled) 
   
   
       11 . The method of  claim 1 , wherein said tungsten composition consists of tungsten. 
   
   
       12 . The method of  claim 3 , wherein said sintering aid is selected from the group consisting of tin, bismuth, aluminum, carbon black, graphite, nano tubes, diamond, charcoal and hydro carbon. 
   
   
       13 . The method of  claim 1 , wherein said tungsten composition further comprises a material selected from the group consisting of Iron; Nickel; Manganese; Cobalt; Copper; Silver; Gold; Gallium; Germanium; Chromium; Vanadium; Niobium; Molybdenum. 
   
   
       14 . The method of  claim 1 , wherein said sintering occurs in a protective environment. 
   
   
       15 . The method of  claim 4 , wherein said heating further comprises heating in a protective environment. 
   
   
       16 . The method of  claim 5 , wherein the ratio of nickel to manganese in said mixture ranges from about 40% nickel to 60% manganese to about 60% nickel to about 40% manganese. 
   
   
       17 . A method for manufacturing high-density non-toxic materials, comprising:
 combining a carbon-based material, nickel, and manganese with a tungsten composition to form a tungsten-carbon mixture;   shaping said tungsten-carbon mixture;   sintering said tungsten-carbon mixture at a temperature in the range of about 1030° C. to about 1200° C. to produce a high-density low toxicity material.   
   
   
       18 . The method of  claim 17 , further comprising adding a sintering aid to said tungsten-carbon mixture. 
   
   
       19 . (canceled) 
   
   
       20 . The method of  claim 17 , wherein said sintering is performed in a protective atmosphere. 
   
   
       21 . The method of  claim 17 , wherein said sintering is done at about 1100° C. 
   
   
       22 . The method of  claim 17 , wherein said produced high-density low toxicity material is a generally round pellet. 
   
   
       23 . The method of  claim 17 , wherein said produced high-density low toxicity material is a generally round dimpled pellet. 
   
   
       24 . The method of  claim 17 , wherein said carbon-based material is graphite and said sintering step sinters said graphite to said tungsten composition. 
   
   
       25 - 46 . (canceled) 
   
   
       47 . The method of  claim 17 , further comprising selecting the hardness of said produced high-density low toxicity material by adjusting the temperature of said sintering step. 
   
   
       48 - 50 . (canceled) 
   
   
       51 . A method comprising:
 forming a mixture consisting essentially of nickel, manganese and a tungsten composition;   shaping said mixture;   sintering said mixture for a time of between about 1 to about 60 minutes at a temperature of from about 1030° C. to about 1200° C. to produce a high-density low toxicity material.