A method for the manufacture of an efficient steel deoxidizer aluminum matrix composite material

Abstract

A method of manufacture to provide an efficient and economical steel deoxidizer aluminum matrix composite material that is near fully dense, free of brittle intermetallic compounds and allows for deep penetration of aluminum into molten steel thus cutting unnecessary losses of this valuable metal to parasitic oxidation reactions with slag and atmosphere.

What is claimed is: 
     
         1 . A method for the manufacture of a steel deoxidizer aluminum matrix composite material comprising the steps of:
 forming a porous free-standing preform, wherein the free-standing preform is comprised of aluminum and an iron-rich component;   applying a quantity of heat to the free-standing preform to raise the temperature of the free-standing preform above the melting point of aluminum and below the melting point of the iron-rich component; and   applying a quantity of pressure to densify the free-standing preform to a near full density and to allow for the aluminum in the free-standing preform to solidify.   
     
     
         2 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 1 , wherein the iron-rich component is steel. 
     
     
         3 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 1 , wherein aluminum is present in the range of ten to fifty percent of the composite material by weight. 
     
     
         4 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 3 , wherein aluminum is thirty percent of the composite material by weight. 
     
     
         5 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 1 , wherein the free-standing preform is formed by a process selected from the group consisting of: mechanical pressing, briquetting, a container, an inorganic binder, and any combination thereof. 
     
     
         6 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 1 , wherein the quantity of heat applied to the free-standing preform is sufficient to raise its temperature over six hundred sixty one degrees Celsius. 
     
     
         7 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 1 , wherein the quantity of heat applied to the free-standing preform is through a process selected from the group consisting of: induction heating, electrical resistance furnace heating, and organic fuel burner furnace heating, and any combination thereof. 
     
     
         8 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 1 , wherein the quantity of external pressure applied to the free-standing preform is sufficient for a molten aluminum component to fill porosity and gaps between the iron-rich components. 
     
     
         9 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 1 , wherein the quantity of external pressure to densify the preform is applied by means of pressing in a closed die. 
     
     
         10 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 1 , wherein the iron-rich component is selected from the group consisting of: ferromanganese, and a mixture of steel and ferromanganese. 
     
     
         11 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 10 , wherein the free-standing preform is bound and supported by a process selected from the group consisting of: mechanical pressing, inorganic binder, a steel container, and any combination thereof. 
     
     
         12 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 11 , wherein the quantity of heat to the free-standing preform applied is through a process selected from the group consisting of: induction heating, electrical resistance furnace heating, and organic fuel burner furnace heating, and any combination thereof. 
     
     
         13 . A method for the manufacture of a steel deoxidizer and inclusion modifier aluminum matrix composite material comprising the steps of:
 forming a porous free-standing preform, wherein the free-standing preform is comprised of a plurality of fines of aluminum and a plurality of fines selected from the group consisting of: steel, ferromanganese, silicocalcium, calcium carbide, rare earth metals, any ferroalloy other than ferromanganese, and any combination thereof;   applying a quantity of heat to the free-standing preform to raise the temperature of the free-standing preform above the melting point of aluminum and below the melting point of other components of the free-standing preform; and   applying a quantity of pressure to densify the free-standing preform to a near full density and to allow for the aluminum in the free-standing preform to solidify.   
     
     
         14 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 13 , wherein aluminum is present in the range of ten to fifty percent of the composite material by weight. 
     
     
         15 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 13 , wherein aluminum is thirty percent of the composite material by weight. 
     
     
         16 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 13 , wherein the free-standing preform is formed by a process selected from the group consisting of: mechanical pressing, briquetting, a container, an inorganic binder, and any combination thereof. 
     
     
         17 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 13 , wherein the quantity of heat applied to the free-standing preform is sufficient to raise its temperature over six hundred sixty one degrees Celsius. 
     
     
         18 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 13 , wherein the quantity of heat to the free-standing preform applied is through a process selected from the group consisting of: induction heating, electrical resistance furnace heating, and organic fuel burner furnace heating, and any combination thereof. 
     
     
         19 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 13 , wherein the quantity of external pressure applied to the free-standing preform is sufficient for a molten aluminum component to fill porosity and gaps between the iron-rich components. 
     
     
         20 . The method for the manufacture of a steel deoxidizer aluminum matrix composite material of  claim 13 , wherein the quantity of external pressure to densify the preform is applied by means of pressing in a closed die.