A New Semi-Solid Forming Process For Fabrication of High Volume Fraction (>15 vol%) Metal/metal Carbide Nanocomposites

49 A New Semi-Solid Forming Process For Fabrication of High Volume Fraction (>15 vol%) Metal/metal Carbide Nanocomposites--Nanopowder Enterprises, Inc., 120 Centennial Avenue, Piscataway, NJ 08854-3900; (908) 885-5909 Dr. Ganesh Skandan, Principal Investigator Dr. Gary S. Tompa, Business Official DOE Grant No. DE-FG02-97ER82441 Amount: $75,000 Presently, there is no commercially viable forming process for the production of high volume fraction carbide containing components for high strength and wear resistant applications. This project is to develop a new method for semi-solid forming of high volume fraction (30-70 vol%) carbide containing alloys at a relatively low temperature (~1100 ¿C). The process relies upon the formation of low melting point multi-component liquid, containing a high volume fraction of nanostructured M6C carbides. No special methods are required to obtain a carbide/metal slurry with equiaxed grains, as is required in the case of conventional semi-solid forming methods. Expensive intermediate steps such as electromagnetic stirring are completely avoided; and, presently available die and tooling materials can be used to ¿mushy form¿ these materials. In Phase I, the feasibility will be demonstrated of forming simple symmetrical shapes from pre-sintered powder compacts of iron-base alloys by making molds using ceramic materials. The process can be adapted to a variety of nickel- and cobalt-base alloys as well. In Phase II, the process will be optimized by careful selection of mold materials and alloy systems for desired end products. Commercial Applications and Other Benefits as described by the awardee: The semi-solid forming approach would enable the fabrication of high performance parts for the aerospace, automotive and tooling industries.