Abstract: An aluminum casting alloy consisting of, by weight, of 7.0-13.0% copper, 0.4-1.2% manganese, 0.21-0.40% vanadium, 0.31-0.70% zirconium; impurities limited to: less than to 0.6% Si, less than 0.8% Fe, less than 0.2% zinc, less than 0.1% Mn, less than 0.2% Ni, and the remainder being essentially aluminum. There is an absence of titanium, cobalt, molybdenum, tungsten, chromium, boron, tantalum, and niobium. The alloy has, at room temperature, a UTS of about 61 ksi, a YS of about 49 ksi, a tensile elongation of about 6%, and tensile modulus elasticity of about 11.5 MSi, a compressive yield strength of about 53 ksi, a compressive modulus of elasticity of about 18 MSi; high temperature physical properties at 500.degree. F., after 1000 hours exposure to 500.degree. F., comprise a tensile strength of 33 ksi or greater, a tensile yield strength of 23 ksi or greater, a tensile elongation of about 9%, and tensile modulus of elasticity of 10 msi.

Abstract: A method of determining the location and history of metallic nitride and/or oxynitride inclusions in metallic melts. The method includes the steps of labeling metallic nitride and/or oxynitride inclusions by making a coreduced metallic-hafnium sponge from a mixture of hafnium chloride and the chloride of a metal, reducing the mixed chlorides with magnesium, nitriding the hafnium-labeled metallic-hafnium sponge, and seeding the sponge to be melted with hafnium-labeled nitride inclusions. The ingots are neutron activated and the hafnium is located by radiometric means. Hafnium possesses exactly the proper metallurgical and radiochemical properties for this use.

Abstract: In a process and an apparatus for stably and continuously producing a solid-liquid metal mixture in which non-dendritic primary solid particles are dispersed into the remaining liquid matrix, molten metal is charged into a clearance between a wall member and a rotating agitator composed of a cylindrical drum having a horizontally rotational axis.

Abstract: Apparatus for producing metal alloys in semi-liquid or paste-like state, constituted by a plurality of modular elements (1a--1b--1c, and so forth), each of which is formed by an elongated hollow body with two mutually opposite open faces, transversely to which through-tubes 8--8a--8b are inserted, which tubes can be connected with an external source of controlled-circulation coolant liquid, such as a diathermic liquid, or air mixed with atomized water.

Abstract: A magnetic metallic glass alloy exhibits, in combination, high saturation induction and high Curie temperature. The alloy has a composition described by the formula Fe.sub.a Co.sub.b Ni.sub.c B.sub.d Si.sub.e C.sub.f, where "a"-"f" are in atom percent, "a" ranges from about 75 to about 81, "b" ranges from 0 to about 6, "c" ranges from about 2 to about 6, "d" ranges from about 11 to about 16, "e" ranges from 0 to about 4, and "f" ranges from 0 to about 4, with the provisos that (i) the sum of "b" and "c" may not be greater than about 8, (ii) "d" may not be greater than about 14 when "b" is zero (iii) "e" may be zero only when "b" is greater than zero, and (iv) "f" is zero when "e" is zero. This alloy is suitable for use in large magnetic cores used in various applications requiring high magnetization rates, and in the cores of line frequency power distribution transformers, airborne transformers, current transformers, ground fault interrupters, switch-mode power supplies, and the like.

Abstract: A method for providing improved castability in a gamma titanium aluminide is taught. The method involves adding inclusions of boron to the titanium aluminide containing chromium and tantalum. Boron additions are made in concentrations between 0.5 to 2 atomic percent. Fine gain equiaxed microstructure is formed from solidified melt. Property improvements are also achieved.

Abstract: A container for adding to a liquid metal of known density and melting point an additive metal of lower density. The container comprises a tube portion of defined cross-section formed of a metal having a melting point higher than the melting point of the liquid metal and which can alloy with the liquid metal without being a source of pollution, and an insert comprising the additive metal placed within the tube portion. The tube portion has at least one end portion constricted so as to leave a passage with a cross-section smaller than the defined cross-section of the tube, the ratio of the passage cross-section to the tube cross-section being from 1:10 to 1:1000. The container overall has a density greater than the density of the liquid metal, so that it sinks when placed within a bath of the liquid metal. This invention finds application in modifying aluminum-silicon alloys with sodium, and additive metal which is lighter than and floats on a bath of liquid aluminum-silicon alloy.

Abstract: A manufacturing method of aluminum-lithium alloy by atmospheric melting in which oxidation of lithium is minimized through improvement of degassing system under normal atmospheric melting method without using separate hermetically sealing device for isolating from atmosphere upon melting of alloy material.The method is carried out in that aluminum and other alloy elements except metal lithium are melted in atmosphere, and primary degassing process is executed in a state that surface of the molten metal is covered with a flux such as LiCl or LiF, and then metal lithium ingot covered with aluminum is added to molten metal and secondary degassing process is executed with bubbling inert gas and thereafter tertiary degassing process is executed by flowing inert gas such as argon through hermetically sealed pouring path of molten metal.

Abstract: A known "spark cup process" may be operated without the spark cup if the violent fluctuations in the melt surface with which the electric arc is struck are accommodated so as to allow the electric arc to be maintained substantially continuously. Controlling the dynamic profile of the melt surface without a spark cup allows continuous operation of the electric arc which generates enough plasma to permit addition of as much as 1000 lb/hr of a spray of superheated feed material to a flowing stream of melt which assimilates the feed material.

Abstract: The present invention provides an amorphous alloy having superior mechanical strength, corrosion resistance for formability, at a relatively low cost. The amorphous alloy is a composition represented by the general formula: Al.sub.100-x-y M.sub.x Ln.sub.y wherein M is at least one element selected from the group consisting of Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zr, Nb, Mo, Hf, Ta and W; Ln is at least one element selected from the group consisting of Y, La, Ce, Nd, Sm, Gd, Tb, Dy, Ho and Yb or misch metal (Mm) which is a combination of rare earth elements; and x and y are, in atomic percentages: 0<x.ltoreq.55 and 30.ltoreq.y.ltoreq.90, preferably 0<x.ltoreq.40 and 35.ltoreq.y.ltoreq.80, and more preferably 5<x.ltoreq.40 and 35.ltoreq.y.ltoreq.70, with the proviso that 100-x-y.gtoreq.5 the alloy having at least 50% (by volume) of an amorphous phase.

Abstract: Disclosed herein is a wear-resistance alloy comprising 10 to 40 wt % of Zn, 3 to 10 wt % of Al, 0.1 to 4 wt % of Cr and the balance Cu.

Abstract: The present invention relates to the formation of whisker reinforced metal matrix composites in which complex boride or carbide whiskers having an aspect ratio of greater than 10:1 are distributed throughout a metal, metal alloy, or intermetallic matrix. Exemplary complex boride whiskers include TiNbB, TiTaB, TiVB, NbHfB, and TiNbMoB. Exemplary complex carbide whiskers include TiNbC, TiVC, TiZrC, TiHfC, and TiTaC. A method for the in-situ formation of complex boride and complex carbide whiskers within metallic matrices is disclosed which involves reacting a mixture of individual complex ceramic-forming constituents in the presence of a metal to precipitate the desired complex ceramic whiskers in a metal matrix.

Abstract: An amalgam and a method of preparing an amalgam for bonding two articles together, which includes mixing a composition of a liquid metal and a metal powder to thoroughly wet the metal powder with the liquid metal, and thereafter mixing a composition with a pestle element for mechanically amalgamating the composition. Other additives may be provided such as ductile metals, additives containing oxides, ceramics, or other non-metallic compounds, and volatile constituents. The amalgamated composition can then wet surfaces to be bonded and harden at or near room temperature.

Abstract: A method for the manufacture of copper base alloys having improved resistance to thermally induced softening is provided. The alloy composition is selected so that the alloy undergoes either a peritectic or eutectic transformation during cooling. The solidification rate is controlled so that the second phase forms as a uniform dispersion of a relatively small dispersoid. The dispersoid inhibits recrystallization resulting in an alloy less susceptible to softening at elevated temperatures.

Abstract: A method for making a light metal-rare earth metal alloy comprises adding a pellet to a bath of molten light metal, said pellet consisting essentially of a mixture of light metal powder and rare earth metal-containing compound. Such pellets, which are made under pressures of about 9 ksi or more, are preferably added to molten baths of aluminum, magnesium or combinations thereof. The light metal powders and rare earth metal-containing compounds that are mixed together to form said pellets are preferably substantially similar in terms of median particle size. This method is suitable for aluminothermically reducing scandium oxide to make aluminum-scandium alloy therefrom.

Abstract: A method of producing a thixotropic material is provided which consists of deforming a fully solidified metal or metal alloy below its temperature of recrystallization by cold or warm working such as extrusion or rolling. The deformed material is then caused to recrystallize by heating and the temperature is either further raised or subsequently raised above the solidus of the material so that the recrystallized structure partially melts to provide discrete particles which spheroidize in the liquid matrix to provide a material which behaves thixotropically. The flow characteristics of the material are such that lower forming loads are required and weaker non-metallic die materials may be used.

Abstract: Alloys of uranium and tungsten and a method for making the alloys. The amount of tungsten present in the alloys is from about 4 wt % to about 35 wt %. Tungsten particles are dispersed throughout the uranium and a small amount of tungsten is dissolved in the uranium.

Abstract: A matrix-bonded carbide-containing material of high hardness is prepared using a mixture containing a matrix alloy having a composition in weight percent of from about 15 to about 45 percent chromium, from 0 to about 3 percent silicon, from about 2 to about 6 percent boron, from about 3 to about 11 percent titanium (either as metal or as a compound), balance iron and impurities, and a mass of tungsten carbide particles, the tungsten carbide particles preferably being present in an amount of from about 15 to about 60 percent by weight of the total mixture and the matrix alloy preferably being present in an amount of from about 85 to about 40 percent by weight of the total mixture. The matrix alloy is melted to produce a flowable mixture having a liquid phase and solid tungsten carbide particles, and thereafter solidified. During melting, the tungsten carbide particle size is reduced by interaction with the liquid phase.

Abstract: A metal matrix composite material containing discontinuous particles in a metallic matrix is prepared by forming a mixture of the molten alloy and the particles in a closed reactor, removing oxygen from the interior of the reactor, statically pressurizing the interior of the reactor with nitrogen gas, mixing the mixture of the molten alloy and particles in the presence of the static nitrogen gas to wet the molten matrix to the particles, and evacuating the interior of the reactor in a stepwise manner. The nitrogen gas aids in wetting the metallic alloy to the particles by forming aluminum nitride at the particle-molten matrix interface, so that a lower contact angle of the alloy to the particle results. Oxygen that may be present in the sealed reactor is gettered by the aluminum, and the nitrogen is removed by stepwise evacuation, thereby minimizing the introduction of gas into, and retention of gas within, the melt.

Abstract: The improved friction facing has a porous, resilient fused metallic matrix with a second metal having a lower boiling point being infused into and alloyed with the matrix.

Abstract: An electrically conductive composite material is formed by dispersing in a matrix metal the other metal which is not solid soluble with the matrix metal. The other metal is finely divided to an extent of not excessively lowering the conductivity and is mixed in the matrix metal in a particle amount with which respective particles keep a mutual distance effective to strengthen the composite material, whereby the material is sufficiently improved in the mechanical strength and wear resistance and remarkably reduced in the high temperature deformation. Such conductive composite material can be obtained through a melt atomization.

Abstract: Normally reject sponge metal fines, especially those produced by the crushing and screening of a regulus of zirconium and/or hafnium metal sponge, are added to the initial reduction charge of the metal tetrachloride and magnesium metal, and the so-modified charge is then passed through the conventional reduction and vacuum distillation steps to produce a regulus of the metal that has the reject fines incorporated therein by sintering.

Abstract: A chromium additive of the formula: Cr.sub.x C.sub.y O.sub.z where 0.04.ltoreq.y.ltoreq.0.35, and 0.03.ltoreq.z.ltoreq.0.30 for x=1, said additive having an X ray diffraction peak at d=3.32 .ANG. (2.theta.=26.8.degree.).

Abstract: A semi-solid metal-forming process for producing an article of a hypoeutectic aluminum-silicon alloy comprises heating a solid billet of the alloy to a temperature intermediate the liquidus temperature and the solidus temperature at a rate not greater than 30.degree. C. per minute, preferably not greater than 20.degree. C. per minute, to form a semi-solid body of the alloy while inhibiting the formation of free silicon particles therein. The semi-solid body comprises a primary spheroidal phase dispersed in a eutectic-derived liquid phase and is conducive to forming at low pressure. In one apsect of this invention, a billet having a quiescently cast microstructure characterized by primary dendrite particles in a eutectic matrix is heated at the slow rate and maintained at the intermediate temperature for a time sufficient to transform the dendrite phase into the desired spheroidal phase.

Abstract: A method for providing a multicomponent alloy for hydrogen storage and for a hydride electrode. The steps involved in the method include: providing a quantity of elements A, B, C, . . . , where said elements are selected from the group consisting of Mg, Ti, V, Cr, Mn, Fe, Co, Ni, Al, Y, Zr, Nb, Pd, Mo, Ca, Si, C, Cu, Ta, and rare earth elements, the quantity of the elements including nickel and at least two other elements from said group; apportioning the quantity of the elements in order to form a composition A.sub.a B.sub.b C.sub.c . . . such that the composition A.sub.a B.sub.b C.sub.c . . . contains 5 to 65 mole percent of nickel and further such that the composition A.sub.a B.sub.b C.sub.c . . . has, when in the form of a multicomponent alloy, a heat of hydride formation that is in a range of between -3.5 and -9.0 kcal/mold H; and, finally, melting the composition A.sub.a B.sub.b C.sub.c . . . in order to form the desired multicomponent alloy.

Abstract: Alloys such as U-6Nb are prepared by forming a stacked sandwich array of uraniun sheets and niobium powder disposed in layers between the sheets, heating the array in a vacuum induction melting furnace to a temperature such as to melt the uranium, holding the resulting mixture at a temperature above the melting point of uranium until the niobium dissolves in the uranium, and casting the uranium-niobium solution. Compositional uniformity in the alloy product is enabled by use of the sandwich structure of uranium sheets and niobium powder.

Abstract: Disclosed is a method of forming a vanadium-rich, multi-component reversible, electrochemical hydrogen storage alloy directly from a vanadium-reductant alloy without first obtaining pure vanadium. In one exemplification the vanadium-reductant alloy is a vanadium-aluminum alloy of low oxygen content, while in another exemplification the vanadium-reductant alloy is refined by electron beam evaporation, and in a third exemplification the vanadium-reductant alloy contains further reductants that reduce the oxygen content without adding impurities to the alloy. The vanadium-reductant alloy is directly used as a precursor in forming the electrochemical hydrogen storage alloy.

Abstract: A method of making high melting point alloys. The reactive and non-reactive charge materials are separately refined as initial alloys, generally as an alloy of a base element selected from the iron group of the Periodic Table, such as nickel, and at least one metallic element other than the base element. At least one first initial alloy and at least one second initial alloy are provided. The metallic elements other than the base element in the first initial alloys are relatively non-reactive in the molten state, whereas the metallic elements in the second initial alloys are relatively reactive in the molten state. Amounts of the first and second initial alloys are selected to yield a predetermined composition of the high melting point alloy upon melting. The selected amounts are melted to form a molten mixture having the predetermined composition, and then the molten mixture is solidified.

Abstract: A method is taught for the in-situ precipitation of second phase materials, such as ceramic or intermetallic particles, in a substantial volume fraction of solvent metal matrix. The invention involves the propagating reaction of the second phase-forming constituents in a solvent metal medium to provide a porous composite of finely-dispersed second phase particles in the metal matrix. Exemplary materials include titanium carbide or titanium diboride in an aluminum matrix.

Abstract: A method for the densification of a shaped nickel base single crystal alloy article utilizing a pre-HIP, an improved hot isostatic pressing (HIP) step, and post-HIP solution heat treatment to enhance removal of casting porosity in a finished article.

Abstract: Self-supporting bodies are produced by reactive infiltration of a parent metal into a boron nitride material typically resulting in a body comprising a boron-containing compound, a nitrogen-containing compound and metal. The mass to be infiltrated may contain one or more inert fillers admixed with the boron nitride, to produce a composite by reactive infiltration, which composite comprises a matrix which embeds the filler material. The matrix, in a composite body containing filler material, comprises one or more of metal, a boron-containing compound and a nitrogen-containing compound. The relative amounts of reactants and process conditions may by altered or controlled to yield a body containing varying volume percents of ceramic, metal and/or porosity. The mass to be infiltrated can be contained within a refractory vessel having a venting means included therein.

Abstract: Alloys of uranium and tungsten and a method for making the alloys. The amount of tungsten present in the alloys is from about 4 wt % to about 35 wt %. Tungsten particles are dispersed throughout the uranium and a small amount of tungsten is dissolved in the uranium.

Abstract: This invention relates to a process for making in-situ precipitated second phase in an intermetallic matrix, which composite is rapidly solidified to form a product. The invention also relates to a rapidly solidified product comprising a second phase in both a stable particulate form and a metastable flake form dispersed in an intermetallic matrix.

Abstract: A method is taught for the in-situ precipitation of second phase materials, such as ceramic or intermetallic particles, in a metallic matrix. By means of the Direct Addition Process, metal-second phase composites having highly superior properties may be obtained. Compacts of second phase-forming constituents and solvent metal are directly added to a molten metal bath to precipitate the second phase in-situ. Exemplary materials include titanium diboride or titanium carbide in an aluminum matrix.

Abstract: A method is taught for the formation of intermetallic-second phase composite materials. The method involves the formation of a first metal-second phase composite comprising a relatively high loading of discrete, second phase particles distributed throughout a metal matrix, dilution of the first composite into an additional amount of metal to form a second composite comprising a lower loading of second phase particles within an intermediate metal matrix, and introduction of the second composite into another metal which is reactive with the intermediate metal matrix of the composite to form an intermetallic. A final intermetallic-second phase composite is thereby formed comprising a dispersion of discrete second phase particles throughout a final intermetallic matrix. The final intermetallic matrix may comprise a wide variety of intermetallic materials, with particular emphasis drawn to the aluminides and silicides. Exemplary intermetallics include Ti.sub.3 Al, TiAl, TiAl.sub.3, Ni.sub.3 Al, NiAl, Nb.sub.

Abstract: The present invention relates to the formation of whisker reinforced metal matrix composites in which complex boride or carbide whiskers are distributed throughout a metal, metal alloy, or intermetallic matrix. Exemplary complex boride whiskers include TiNbB, TiTaB, TiVB, NbHfB, and TiNbMoB. Exemplary complex carbide whiskers include TiNbC, TiVC, TiZrC, TiHfC, and TiTaC. A method for the in-situ formation of complex boride and complex carbide whiskers within metallic matrices is disclosed which involves reacting a mixture of individual complex ceramic-forming constituents in the presence of a metal to precipitate the desired complex ceramic whiskers in a metal matrix.

Abstract: This invention relates to a metallic-second phase composites comprising a matrix of titanium aluminide with discrete titanium silicide particles dispersed therein. The second phase dispersoid is stabilized during the process of in-situ formation by the presence of zirconium.

Abstract: A method and an apparatus for the manufacture of non-allergy creating objects, especially objects of metal for direct contact with the skin of a human body, for instance jewelery, watches, glasses etc. whereby completely pure metals, especially precious metals like gold, silver, platinum, palladium, rodium etc. are alloyed with optimum pure zinc, copper, aluminum, nickel or chrome, and whereby any and all treatments both in hot and cold stage are made without access of air and without any contact with extraneous substances like salts or acids. Preferably all melting and heating is made under a protective gas.

Abstract: Homogeneous and refined microstructure powders and the method of making them from, for example, liquid metal immiscible systems or very limited solid solubility systems. At least two metals are melted and then rapidly solidified to yield a solid with a segregated, non-uniform microstructure. The resulting rapidly-solidified solid is then reduced to a powder and subjected to high-energy milling for a time sufficient to reduce the segregation to the desired level of uniformity.

Abstract: Highly uniform alloy targets are prepared by melting together predetermined amounts of terbium iron and cobalt with an additional element selected from platinum, chromium, nickel, palladium, tantalum, hafnium or mixtures thereof in an argon atmosphere and casting the thus formed melt into a mold.

Abstract: The present invention provides a rapidly dissolving additive for molten metal, wherein it contains 2 to 50% by weight of a component A, which consists of an alkali metal aluminium fluoride and/or an alkali metal aluminium fluoride-containing salt mixture, and 50 to 98% by weight of a component B, which consists of at least one alloying metal, the alloying metal being different from the base metal to be allied, the components A and B being present intimately mixed.The present invention also provides a process for the production of this additive.

Abstract: An improved aluminum-titanium master alloy is provided. Such alloy contains a small be effective amount of, in weight percent, any two or more elements selected from the group consisting of carbon about 0.003 up to 0.1, sulfur about 0.03 up to 2, phosphorus about 0.03 up to 2, nitrogen about 0.03 up to 2, and boron about 0.01 up to 0.4, titanium 2 to 15, and the balance aluminum. After melting, the master alloy is superheated to about 1200.degree. C.-1300.degree. C. to put the element into solution, then the alloy is cast in a workable form. The master alloy in final form is substantially free of carbides, sulfides, phosphides, nitrides, or borides greater than about 5 microns in diameter. The alloy of this invention is used to refine aluminum products that may be rolled into thin sheet, foil, or fine wire and the like. Such grain refined products are also substantially free of carbides, sulfides, phosphides, nitrides, or borides.

Abstract: An easy method and apparatus to eliminate casting defects from composite materials of hypereutectic Al-Si alloys and improve their properties. The product composite materials with primary silicon crystals of several microns have fine homogeneous microstructures and mechanical properties comparable to similar materials produced by the conventional powder metallurgy technology. Highly wear-resistant composite materials, in which the hypereutectic Al-Si alloy and strengthening material are homogeneously mixed, can be obtained with ease. The hypereutectic Al-Si alloy and strengthening material are homogeneously mixed by stirring blades rotated at low speed. The obtained molten composite alloy rotated at high speed about a horizontal shaft in a heat-resistant vessel. The rotor rotating and stirring at high speed spatters the molten composite alloy material to break up the crystallizing out primary silicon crystals.

Abstract: A method for preparing cast composite materials of nonmetallic carbide particles in a metallic matrix, wherein the particles are roasted and then mixed into a molten metallic alloy to wet the molten metal to the particles, and the particles and metal are sheared past each other to promote wetting of the particles by the metal. The particles are roasted in air or other source of oxygen to remove the carbon from the near-surface region of the particles and to produce an oxide surface diffusion barrier, resulting in a reduction of carbide formation in the molten matrix. The mixing occurs while minimizing the introduction of gas into the mixture, and while minimizing the retention of gas at the particle-liquid interface. Mixing is done at a maximum temperature whereat the particles do not substantially chemically degrade in the molten metal during the time required for processing, and casting is done at a temperature sufficiently high that there is no solid metal present in the melt.

Abstract: The nuclear radiation metallic absorber contains a metallic copper alloy containing 0.05 to 50% of boron in weight, compared to the total alloy weight, preferably 0.05 to 10% boron in weight, compared to the total alloy weight. Moreover it may contain additional elements such as neutron absorbing elements, mechanical, physical and technological properties reinforcing elements, fibres or anti-corrosion elements.It may more specifically be used for neutron and .gamma. and X radiation absorption.

Abstract: Disclosed is a process for the preparation of chalcogenide alloys, particularly selenium tellurium alloys, of high purify wherein there is provided a solution mixture of the aforementioned compounds; and thereafter this mixture is subjected to a simultaneous oxidation reaction.

Abstract: A process for controlling fractionation in selenium alloys comprising providing pellets of an alloy comprising amorphous selenium and an alloying component selected from the group consisting of tellurium, arsenic, and mixtures thereof, the particles having an average particle size between about 300 micrometers and about 3,000 micrometers, exposing the pellets to an ambient temperature of between about 114.degree. C. and about 190.degree. C. until an exotherm occurs in the pellets resulting in substantially complete crystallization between about 104.degree. C. and about 180.degree. C., grinding the pellets into fresh powder having an average particle size of less than about 200 micrometers, and compressing the fresh powder into fresh pellets having an average weight between about 50 mg and about 1000 mg. The resulting fresh pellets may be heated in a vacuum chamber to vacuum deposit the alloy onto a substrate.

Abstract: The present invention is directed to a process for the synthesis of a compositionally graded substantially amorphous metal alloy comprising:(a) combining a bulk hydrogen storage material with an A-containing material to obtain a mixture thereof;(b) sealing the mixture in a mechanical milling device under an inert atmosphere; and(c) milling the mixture.Alloys produced by this process are useful for the efficient cyclic storage and release of hydrogen in large quantities without becoming embrittled, inactivated or corroded.

Abstract: A process for producing a blend of maraging steel alloys and an oxidizable metal comprises forming an aqueous solution or iron, cobalt, nickel and molybdenum in a predetermined ratio. Thereafter, a reducible solid material containing the metals is produced from the solution. The solid material is reduced to metallic powder particles which are entrained in a carrier gas and fed into a high temperature zone to form droplets which are cooled to form essentially spherical shaped metal alloy particles. These particles are combined with a predetermined amount of at least one easily oxidizable metal selected from the group consisting of aluminum, titanium and vanadium to form a relative uniform blend of the spherical shaped particles and the readily oxidizable metal.

Abstract: Composite materials and methods for making such materials are disclosed in which dispersed ceramic particles are at chemical equilibrium with a base metal matrix, thereby permitting such materials to be remelted and subsequently cast or otherwise processed to form net weight parts and other finished (or semi-finished) articles while maintaining the microstructure and mechanical properties (e.g. wear resistance or hardness) of the original composite. The composite materials of the present invention are composed of ceramic particles in a base metal matrix. The ceramics are preferably carbides of titanium, zirconium, tungsten, molybdenum or other refractory metals. The base metal can be iron, nickel, cobalt, chromium or other high temperature metal and alloys thereof. For ferrous matrices, alloys suitable for use as the base metal include cast iron, carbon steels, stainless steels and iron-based superalloys.