System and method for using metal-wrapped carbon-containing powders in a vacuum induction melting furnace

Abstract

A vacuum induction melting (VIM) furnace and method of using. A VIM is configured for use with metal-containing carbon powders. In operation, the metal-containing carbon powders are formed into a pellet so as to minimize or eliminate ejection of material during introduction of the pellet into the VIM processor. The VIM processor may be substituted or used in combination with a vacuum arc melt processing apparatus, an electron beam melt furnace, an ion plating furnace, a plasma flame source, a smelter, a traditional metal-metal melt furnace, or any equivalent. Pelletizing can be accomplished through use of a press or through application of any pelletizing technique and/or use of any apparatus that is able to generate pellets that have sufficient mass to avoid ejection from a VIM processor.

What is claimed is: 
     
         1 . A vacuum induction melting furnace system, comprising:
 a vacuum induction melting processor configured to melt a metal-containing powder and/or metal-containing pellets.   
     
     
         2 . The vacuum induction melting furnace system as recited in  claim 1 , comprising a pelletizer configured to form the metal-containing pellets. 
     
     
         3 . The vacuum induction melting furnace system as recited in  claim 1 , wherein the metal-containing powder and/or metal-containing pellets include a metal-decorated carbon powder. 
     
     
         4 . The vacuum induction melting furnace system as recited in  claim 3 , comprising a plasma reactor for forming the metal-decorated carbon powder. 
     
     
         5 . The vacuum induction melting furnace system as recited in  claim 4 , comprising a gas-solid separator for separating a gas from the metal-decorated carbon powder formed by the plasma reactor. 
     
     
         6 . The vacuum induction melting furnace system as recited in  claim 1 , comprising a mold configured to receive the melted metal-containing powder and/or metal-containing pellets. 
     
     
         7 . A material formed using the vacuum induction melting furnace system as recited in  claim 1 . 
     
     
         8 . The material as recited in  claim 7 , wherein the material includes an alloy comprising nickel, iron, chromium, and carbon. 
     
     
         9 . A method, comprising:
 melting at least one metal with a carbon-containing material in a vacuum induction melting processor for creating a melt of the at least one metal and the carbon-containing material; and   forming the melt into a component.   
     
     
         10 . The method as recited in  claim 9 , wherein the carbon-containing material includes pellets of a metal-decorated carbon powder. 
     
     
         11 . The method as recited in  claim 10 , comprising using a pelletizer to form the metal-decorated carbon powder into the pellets. 
     
     
         12 . The method as recited in  claim 9 , wherein the carbon-containing material includes a metal-decorated carbon powder. 
     
     
         13 . The method as recited in  claim 12 , comprising forming the metal-decorated carbon powder using a plasma reactor. 
     
     
         14 . The method as recited in  claim 9 , wherein forming the melt into a component includes placing the melt in a mold. 
     
     
         15 . The method as recited in  claim 9 , wherein the at least one metal includes one or more metals selected from the group consisting of nickel, iron, and chromium. 
     
     
         16 . The method as recited in  claim 9 , wherein the at least one metal includes nickel, iron, and chromium. 
     
     
         17 . A material formed using the method as recited in  claim 9 . 
     
     
         18 . The material as recited in  claim 17 , wherein the material includes an alloy comprising nickel, iron, chromium, and carbon. 
     
     
         19 . The material as recited in  claim 17 , wherein at least some of the carbon in the material is characterized by having a structure comprising one or more coherent, planar layers. 
     
     
         20 . The material as recited in  claim 17 , wherein the material is characterized by one or more characteristics selected from the group consisting of:
 at least some of the carbon is interlaced interstitially between basal planes of a metal lattice of the material;   the carbon is substantially devoid of defects;   a lack of carbon aggregate(s) and/or carbon agglomerate(s) at grain boundaries thereof; and   the carbon is present in the metal lattice in an amount of at least about 15 wt %.