Hard and Super-hard Metal Alloys and Methods for Making the Same

Abstract

The present invention relates to Cu 33 Al 17 alloys and Cu 33 Al 17 -based bulk alloys and coatings that exhibit significantly increased hardness characteristics compared to traditional copper-aluminum alloys

What is claimed is: 
     
         1 . A method for producing Cu 33 Al 17  based alloys in bulk form comprising:
 mixing Cu powder and Al powder in sufficient amounts to form a blended copper-aluminum based mixture consisting essentially of: 77-80 wt. % Cu and 20-23 wt. % Al with the remainder consisting of one or more elements selected from the group consisting of: Zn, Sn, Ga, Ge and combinations thereof, or unavoidable impurities, and wherein the wt. % ratio of Cu to Al is between about 3:1 and 4:1;   cold pressing the blended copper-aluminum based mixture to form a copper-aluminum green body; and   sintering the pressed copper aluminum to form a uniform, single-phase Cu 33 Al 17  alloy.   
     
     
         2 . The method of  claim 1 , wherein the sintering step is followed by pressure driven consolidation. 
     
     
         3 . The method of  claim 1 , wherein the sintering step is replaced by a pressure driven consolidation step wherein the green body is hot pressed to form a uniform, single-phase Cu 33 Al 17  alloy. 
     
     
         4 . The method of  claim 1 , wherein the copper-aluminum based mixture consists of: 77-80 wt. % Cu and 20-23 wt. % Al. 
     
     
         5 . The method of  claim 1 , wherein the copper-aluminum based mixture consists essentially: 77.4-79.2 wt. % Cu and 20.7-22.6 wt. % Al. 
     
     
         6 . The method of  claim 1  wherein the copper-aluminum based mixture consists of: 77.4-79.2 wt. % Cu and 20.7-22.6 wt. % Al. 
     
     
         7 . The method of  claim 1 , wherein the copper-aluminum based mixture consists essentially: 77.43-79.28 wt. % Cu and 20.72-22.57 wt. % Al. 
     
     
         8 . The method of  claim 1 , wherein the copper-aluminum based mixture consists of: 77.43-79.28 wt. % Cu and 20.72-22.57 wt. % Al. 
     
     
         9 . The method of  claim 1 , wherein the copper-aluminum based mixture consists essentially: 78.4-79.3 wt. % Cu and 20.72-21.56 wt. % Al. 
     
     
         10 . The method of  claim 1 , wherein the copper-aluminum based mixture consists of: 78.4-79.3 wt. % Cu and 20.72-21.56 wt. % Al. 
     
     
         11 . The method of  claim 1 , wherein Cu and Al are mixed in a wt. % ratio of between about 3.4:1 to 3.9:1, Cu to Al. 
     
     
         12 . The method of  claim 1 , wherein Cu and Al are mixed in a wt. % ratio of between about 3.43:1 and 3.83:1, Cu to Al. 
     
     
         13 . The method of  claim 1 , wherein mixture consists essentially of: 77.4-79.2 wt. % Cu and 20.72-22.57 wt. % Al with the remainder consisting of one or more elements selected from the group consisting of: Zn, Sn, Ga, Ge, and combinations thereof. 
     
     
         14 . The method of  claim 1 , wherein mixture consists essentially of: 77.4-79.2 wt. % Cu and 20.72-22.57 wt. % Al with the remainder consisting: Sn, wherein the wt. % ratio of Cu to Al is between about 3.4:1 and 3:9:1. 
     
     
         15 . The method of  claim 1 , wherein the copper-aluminum green body is sintered at a temperature of between about 500-650° C. 
     
     
         16 . A product made according to the method of  claim 1 . 
     
     
         17 . A Cu 33 Al 17  based bulk alloy consisting essentially of: 77-82 wt. % Cu and 18-23 wt. % Al with the remainder consisting of one or more elements selected from the group consisting of: Zn, Sn, Ga, Ge and combinations thereof, and wherein the wt. % ratio of Cu to Al is between about 3:1 and 4.6:1; 
     
     
         18 . The alloy of  claim 17 , wherein the alloy consists essentially of: 77.4-79.2 wt. % Cu and 18-23 wt. % Al with the remainder consisting of one or more elements selected from the group consisting of: Zn, Sn, Ga, Ge and combinations thereof, and wherein the wt. % ratio of Cu to Al is between about 3:4 and 3.9:1. 
     
     
         19 . The alloy of  claim 17 , wherein the alloy consists essentially of: 78.4-79.3 wt. % Cu and 20.72-21.56 wt. % Al with the remainder consisting of one or more elements selected from the group consisting of: Zn, Sn, Ga, Ge and combinations thereof. 
     
     
         20 . The Cu 33 Al 17  based alloy of  claim 17 , wherein the alloy consists essentially of 77-80 wt. % Cu and 20-23 wt. % Al. 
     
     
         21 . The Cu 33 Al 17  based alloy of  claim 17 , wherein the alloy consists essentially of 77.4-79.2 wt. % Cu and 20.7-22.6 wt. % Al. 
     
     
         22 . The Cu 33 Al 17  based alloy of  claim 17 , wherein the alloy consists essentially of 78.4-79.3 wt. % Cu and 20.72-21.56 wt. % Al. 
     
     
         23 . The Cu 33 Al 17  based alloy of  claim 17 , wherein the alloy consists of 77-80 wt. % Cu and 20-23 wt. % Al. 
     
     
         24 . The Cu 33 Al 17  based alloy of  claim 17 , wherein the alloy consists of 78.4-79.3 wt. % Cu and 20.72-21.56 wt. % Al.