Abstract: The present invention relates to a method of producing nanophase WC/TiC/Co composite powder by means of a mechano-chemical process comprising a combination of mechanical and chemical methods. For this purpose, the present invention provides a method of producing nanophase WC/TiC/Co composite powder, said method comprising as follows: a process of producing an initial powder by means of spray-drying from water-soluble salts containing W, Ti, and Co; a process of heating to remove the salts and moisture contained in the initial powder after spray-drying; a process of mechanically ball-milling to grind oxide powder after removing the salts and moisture therefrom, and to homogeneously mix the powder with an addition of carbon; and a process of heating the powder after milling, for reduction and carburization, in an atmosphere of reductive gas or non-oxidative gas.

Abstract: A method and structure for forming magnetic alloy nanoparticles includes forming a metal salt solution with a reducing agent and stabilizing ligands, introducing an organometallic compound into the metal salt solution to form a mixture, heating the mixture to a temperature between 260° and 300° C., and adding a flocculent to cause the magnetic alloy nanoparticles to precipitate out of the mixture without permanent agglomeration. The deposition of the alkane dispersion of FePt alloy particles, followed by the annealing results in the formation of a shiny FePt nanocrystalline thin film with coercivity ranging from 500 Oe to 6500 Oe.

Abstract: A polyisocyanate-based polymer having dispersed therein a metal salt, obtained by reacting an organic polyisocyanate with an aqueous composition of a metal salt. The polymer comprises the metal salt in an amount of from at least 10 weight percent based on total weight of the dry salt with the weight of the polyisocyanate-based polymer including salt therein. The polymer on calcination provides a metal-containing powder having an average particle size of 1 micrometer or less. Such metal-containing powders are of value in the preparation of industrial catalysts, ceramics, electronic components, or as fillers in plastics, paints, or cosmetics.

Abstract: Fine aluminum powders are prepared by decomposing alane-adducts in organic solvents under an inert atmosphere to provide highly uniform particles and believed particularly effective as fuels and additives, in pyrotechnics, and in energetic materials. Effective adduct species are trialkyl amines and tetramethylethylenediamine, ethers and other aromatic amines. Effective production is obtained at atmospheric pressure and at temperatures as low as 50° C. with xylene solvent. Toluene, dioxane, and tetramethylethylenediamine were also effective solvents. Aliphatic solvents and other aromatic and polar solvents are believed effective. Titanium catalyst was provided as a halide, amide, and alkoxide; and it is believed that the corresponding compounds of zirconium, hafnium, vanadium, niobium, and tantalum are effective as catalysts. Particle size was controlled by varying catalyst concentration and by varying the concentration of an adducting species.

Abstract: The method of the invention is based on the unique electron-carrying function of a photocatalytic unit such as the photosynthesis system I (PSI) reaction center of the protein-chlorophyll complex isolated from chloroplasts. The method employs a photo-biomolecular metal deposition technique for precisely controlled nucleation and growth of metallic clusters/particles, e.g., platinum, palladium, and their alloys, etc., as well as for thin-film formation above the surface of a solid substrate. The photochemically mediated technique offers numerous advantages over traditional deposition methods including quantitative atom deposition control, high energy efficiency, and mild operating condition requirements.

Abstract: Methods and apparatus for preparing gaseous compositions comprising a metal carbonyl, preferably at ppm concentration, are disclosed. The methods comprise placing metal, preferably in the form of filings, of the metal carbonyl to be produced into a first test vessel at a first temperature, and then pressurizing the first test vessel with a gas comprising carbon monoxide from a carbon monoxide source vessel. The contents of the first vessel are then heated to a second temperature and at a rate sufficient to initiate metal carbonyl formation, thereby forming a gas composition comprising a metal carbonyl. The reaction is then quenched by transferring some of the gas composition comprising a metal carbonyl from the first test vessel to a second test vessel which is at a third temperature, the third temperature being lower than the second temperature. Finally, the gas composition is diluted in the second test vessel with an inert gas (preferably argon) from an inert gas source container.

Abstract: A process for preparing uniform, agglomerate free, submicron/nanosize ceramic powders from a polymeric foam comprising metal cations homogeneously incorporated within a foam cell structure of the polymeric foam. The polymeric foam is heated to remove any solvent, and calcined at a temperature of about 400.degree. C. to about 1400.degree. C. for about 1 minute to about 96 hours to produce the desired ceramic or metal powder.

Abstract: A process for manufacturing of metal powder from a halogen containing chemical compound of the metal. The process involves thermal treatment of the compound within a closed reactor and in non-oxidizing atmosphere so as to induce decomposition of the compound and formation therefrom of a metal halide and a reduction agent capable to reduce the metal halide to elemental metal which can be collected in the form of fine powder. By variation of condition of the thermal treatment like temperature, pressure, duration and by choosing particular type of the compound it is possible to control the size and purity of the powder as well the powder particles shape.

Abstract: Fine aluminum powders are prepared by decomposing alane-adducts in organic olvents under an inert atmosphere to provide highly uniform particles and believed particularly effective as fuels and additives, in pyrotechnics, and in energetic materials. Effective adduct species are trialkyl amines and tetramethylethylenediamine, ethers and other aromatic amines. Effective production is obtained at atmospheric pressure and at temperatures as low as 50.degree. C. with xylene solvent. Toluene, dioxane, and tetramethylethylenediamine were also effective solvents. Aliphatic solvents and other aromatic and polar solvents are believed effective. Titanium catalyst was provided as a halide, amide, and alkoxide; and it is believed that the corresponding compounds of zirconium, hafnium, vanadium, niobium, and tantalum are effective as catalysts. Particle size was controlled by varying catalyst concentration and by varying the concentration of an adducting species.

Abstract: The present invention relates to a powder of unagglomerated metallic particles. More particularly, the present invention relates to a powder of unagglomerated metallic particles having an average diameter of about 1-100 nm and the process for making the same. Additionally, the powder of unagglomerated metallic particles can be formed into a lyophilized form which upon reconstitution maintains the average diameter of between about 1-100 nm wherein the particles remain unagglomerated.

Abstract: Finely divided phosphorus-containing iron is prepared by reacting iron pentacarbonyl with a volatile phosphorus compound, in particular PH.sub.3, in the gas phase. The resulting phosphorus-containing iron powders and iron whiskers have a particularly low content of extraneous elements.

Abstract: Methods for the manufacture of nanostructured metals, metal carbides, and metal alloys are presented, such metals including nanostructured aluminum, chromium, iron, molybdenum, vanadium, and steel. Preferably, the nanostructured steel is of the M50 type, and comprises iron, molybdenum, chromium, vanadium and carbon. Synthesis of M50 steel further comprising nanostructured aluminum, aluminum oxide, or aluminum nitride is also described. In accordance with an important feature of this invention, the grain size of the metals and metal alloys is in the nanometer range. In accordance with the method of the present invention, the nanostructured metals, metal carbides, and metal alloys are prepared via chemical synthesis from aluminum, iron, molybdenum, chromium and vanadium starting materials. Decomposition of metal precursors or co-precipitation or precipitation of metal precursors is followed by consolidation of the resulting nanostructured powders.

Abstract: A process for producing nanoscale powders, and the powders so produced. The process comprises mixing an emulsion comprising all of the elements of the desired powder composition and a combustible fuel, and then combusting that emulsion to produce a powder. Powders with a median particle size of less than 50 nm have been made by this process. The process is suitable for the production of many types of powders, including particles and nanowhiskers of simple, doped, and polymetallic powders.

Abstract: A novel zerovalent zinc species and an organozinc reagent are disclosed. The zerovalent zinc species is directly produced by reaction of a reducing agent on a zinc salt, preferably Zn(CN).sub.2. The organozinc regent results from the reaction of the zerovalent zinc species and an organic compound having one or more stable anionic leaving groups. These organozinc reagents include a wide spectrum of functional groups in the organic radical, and are useful in a variety of reactions schemes.

Abstract: This process provides a method of fabricating porous aluminide articles. First the process consists of plating a preform with nickel and aluminum to create a metal-plated structure. The plating of nickel consists of electrodeposition or gaseous plating. The plating of aluminum consists of gaseous deposition of an organometallic-aluminum compound. The preform has either an open felt, woven fabric or a reticulated foam shape. Reactive sintering the metal-plated structure leaves an open nickel-aluminum structure having porosity and excellent strength and oxidation properties above 400.degree. C.

Abstract: Fine aluminum powders are prepared by decomposing alane-adducts in organic solvents under an inert atmosphere to provide highly uniform particles selectably sized from about 65 nm to about 500 nm and believed particularly effective as fuels and additives, in pyrotechnics, and in energetic materials including composites, super thermite, and other explosives. Effective adduct species are trialkyl amines and tetramethylethylenediamine, ethers and other aromatic amines being believed effective. Effective production is obtained at atmospheric pressure and at temperatures as low as 50.degree. C. with xylene solvent. Increased production rate is achieved at higher temperatures. Toluene, dioxane, and tetramethylethylenediamine were also effective solvents. Aliphatic solvents and other aromatic and polar solvents are believed effective.

Abstract: One or more metal salts of at least one of Co, Ni and/or Fe is dissolved/suspended in water. To the solution/suspension is added at least one hard constituent powder to form a slurry. The solvent is evaporated, preferably by spray drying, and the resultant powder is heat treated in a reducing atmosphere. As a result, a coated hard constituent powder is obtained which, after addition of a pressing agent, can be compacted and sintered according to standard practice. In addition to or instead of said salt of Co, Ni and/or Fe, a soluble salt of Mo and/or W can be used.

Abstract: The surface of material containing a hydrogen storage alloy are treated with an organometallic compound to provide the alloy with corrosion resistance.

Abstract: A method is described for the liquid phase synthesis of particles. The particles are composed of silicon or germanium and are optionally produced at sizes such that the particles exhibit quantum size effects. The particles are produced from an organometallic (tetra-organosilicon or tetra-organogermanium) precursors which is dissolved in a solvent that transmits a wavelength of light that photolyzes the precursor. The reaction is carried out under an inert atmosphere. A passivating agent is added to arrest particle growth and impart solubility to the particle. Optionally, a dopant is incorporated into the particle in the course of production so as to modify the electronic properties of the semiconductor particle.

Abstract: Sononochemistry permits extremely rapid cooling to produce nanoscale particles. If magnetic, these particles are valuable for magnetic recording media, manufacture of permanent magnets, and other uses. In the present invention, we sonicate neat metal carbonyl to produce particles which we separate, generally magnetically, from the metal carbonyl, thereby making the production process as simple as possible and continuous.

Abstract: Sonochemistry permits extremely rapid cooling to form nanoscale amorphous metal particles. If magnetic, these particles are valuable for magnetic recording media, manufacture of permanent magnets, and other uses. The nanoscale particles agglomerate, however, which limits their utility for these magnetic applications. To keep the particles isolated, we extract the particles from the n-alkane reaction solvent in a polar solvent and cast the extracted particles with a polymer, such as polyvinylpyrrolidone.

Abstract: Nanostructured metal powders and films are made by dissolving or wetting a metal precursor in an alcoholic solvent. The resulting mixture is then heated to reduce the metal precursor to a metal precipitate. The precipitated metal may be isolated, for example, by filtration.

Abstract: A centrifugal plasma arc furnace is used to vitrify contaminated soils and other waste materials. An assessment of the characteristics of the waste is performed prior to introducing the waste into the furnace. Based on the assessment, a predetermined amount of iron is added to each batch of waste. The waste is melted in an oxidizing atmosphere into a slag. The added iron is oxidized into Fe.sub.3 O.sub.4. Time of exposure to oxygen is controlled so that the iron does not oxidize into Fe.sub.2 O.sub.3. Slag in the furnace remains relatively non-viscous and consequently it pours out of the furnace readily. Cooled and solidified slag produced by the furnace is very resistant to groundwater leaching. The slag can be safely buried in the earth without fear of contaminating groundwater.

Abstract: Process for preparing high purity metal powder by reacting one or more volatile alkoxide compounds with a reducing gas.

Abstract: A process for producing nano size powders comprising the steps of mixing an aqueous continuous phase comprising at least one metal cation salt with a hydrophilic organic polymeric disperse phase, forming a metal cation salt/polymer gel, and heat treating the gel at a temperature sufficient to drive off water and organics within the gel, leaving as a residue a nanometer particle-size powder.

Abstract: The material of the present invention is a mixture of catalytically active material and carrier materials, which may be catalytically active themselves. Hence, the material of the present invention provides a catalyst particle that has catalytically active material throughout its bulk volume as well as on its surface. The presence of the catalytically active material throughout the bulk volume is achieved by chemical combination of catalytically active materials with carrier materials prior to or simultaneously with crystallite formation.

Abstract: Sonochemistry permits extremely rapid cooling from the melt which is necessary for forming amorphous metals. Sonochemistry also functions at an extremely small scale to produce nanophase particles. If magnetic, these particles are valuable for magnetic recording media, manufacture of permanent magnets, and other uses. The nanophase particles agglomerate, however, which limits their utility for these magnetic applications. To keep the particles isolated, we extract the particles from the n-alkane reaction solvent in a polar solvent and cast the extracted particles with a polymer, such as polyvinylpyrrolidone.

Abstract: A process for producing finely divided 20 to 500 angstrom metal particles, metals with oxide coatings or metal oxides using an alkalide or electride in a non-reactive solvent is described. The process produces various forms of the metal depending upon the oxidizability of the metal initially produced by the process. The process is useful for producing catalysts, alloys, colloidal solutions, semi-conductors and the like.

Abstract: A process is described for the production of composite powders with ultrafine microstructures. The process involves three coordinated steps:1) preparation and mixing of an appropriate starting solution;2) spray drying to form a chemically homogeneous precursor powder; and3) fluid bed thermochemical conversion of the precursor into the desired nanophase composite powder.Both spray drying and fluid bed conversion are scaleable technologies, and together provide the means for producing bulk quantities of nanophase composite powders at low manufacturing cost. Processing parameters are controlled to ensure maintenance of chemical and microstructural uniformity at the nanoscale (less than 0.1 micron) level.Spray conversion processing is a versatile technology, which can be applied to a variety of metal--metal (e.g. W--Cu), ceramic-metal (e.g. WC--Co), and ceramic--ceramic (e.g. Al.sub.2 O.sub.3 --SiO.sub.2) nanophase composite powders ceramic-metal (e.g. WC--Co), and ceramic--ceramic (e.g. Al.sub.2 O.sub.3 --SiO.

Abstract: The invention relates to nano-composite powders of alumina and metal constituted of grains of micronic size. Each grain comprises a compact matrix of alumina of a specific surface area less than 5 m.sup.2 /g, in which are dispersed crystallites of transition metals of alloys of these metals, of sizes less than 50 nm. The powder according to the invention may be produced starting with a precursor comprised of a mixed carboxylic salt of aluminum and one or more transition metals. The powders according to the invention permit producing by sintering cermets of alumina/metal benefitting from greatly improved mechanical and thermo-mechanical properties.

Abstract: A for preparing uniform, agglomerate free, submicron/nanosize ceramic powders from a polymeric foam comprising metal cations homogeneously incorporated within a foam cell structure of the polymeric foam. The polymeric foam is heated to remove any solvent, and calcined at a temperature of about 400.degree. C. to about 1400.degree. C. for about 1 minute to about 96 hours to produce the desired ceramic or metal powder.

Abstract: A process for the production of a fine powder suitable for use in the fields of electronic materials, catalysts, powder metallurgy, pigments and adsorbens. The powder has a primary particle diameter of not more than 0.5 .mu.m, an average secondary aggregate particle diameter of not more than 10 .mu.m and a secondary aggregate particle specific surface area of 2 to 250 m.sup.2 /g, and is produced by a process comprising heating an organic acid metal salt in the presence of palladium, which lowers the thermal decomposition temperature of the salt, at a temperature elevation rate of 0.5.degree. to 20.degree.C./minute and thermally decomposing the organic acid metal salt in the presence of the palladium in the temperature range of not higher than 400.degree.C.

Abstract: A process for preparing uniform, agglomerate free, submicron/nanosize ceramic powders from a polymeric foam comprising metal cations homogeneously incorporated within a foam cell structure of the polymeric foam. The polymeric foam is heated to remove any solvent, and calcined at a temperature of about 400.degree. C. to about 1200.degree. C. for about 1/2 to about 8 hours to produce the desired ceramic or metal powder.

Abstract: A process is provided for preparing carbon-containing substantially oxide-free iron powders or iron-based powders or both wherein oxygen impurities from an iron powder are removed without substantial decarburization, by heating the iron powder or iron-based powders or both under a substantially pure hydrogen atmosphere from ambient temperatures to a first intermediate temperature in an enclosure, then replacing the substantially pure hydrogen atmosphere by a substantially pure nitrogen atmosphere in the enclosure and then heating the powder to a second temperature which is higher that the first intermediate temperature, then cooling down the powder under an inert atmosphere to at least a temperature where substantially no more oxidation of the powder occurs, then removing the powder from the enclosure, the first and second temperatures being sufficient to reduce substantially all oxide impurities in the powder without substantial decarburization.

Abstract: Iron whiskers are produced by thermal decomposition of iron pentacarbonyl vapor in an indirectly heated empty-space decomposer in which the cross-sectional area for entry of the iron pentacarbonyl into the empty-space decomposer is from 10 to 40% of the cross-sectional area of the empty-space decomposer, the mass flow density of the iron pentacarbonyl vapor, based on the cross-sectional area of the decomposer, is from 0.01 to 0.07 kg per square meter per second, and the temperature in the empty-space decomposer should at no point be below 360.degree. C.

Abstract: The present invention provides a process for producing ultrafine metal particles by gas-phase pyrolysis of 0.1 to 30% by volume transition metal carbonyl compound diluted with a diluent gas to form a mixed gas, which comprises supplying 1 to 30% by volume of the mixed gas of up to 200.degree. C. and 99 to 70 % by volume of a second diluent gas. The second gas heated to at least 400.degree. C., serves as a heat feed source for gas-phase pyrolysis to a reaction zone. The gases are mixed together there to carry out gas-phase pyrolysis in the presence of a magnetic field of at least 100 gauss.

Abstract: A method for forming a single-phase, homogeneous and high surface area metal alloy by reducing a heteropolymetallic complex in the presence of H.sub.2 at a low temperature. Also disclosed is a method for forming a single-phase, homogeneous and high surface area metal alloy by thermolysis of a heteropolymetallic complex in an inert atmosphere at a low temperature.

Abstract: There is provided a process for producing graphite whiskers by supplying a carbon source compound with a carrier gas into a heating zone in a reactor and decomposing the carbon source compound in a gas phase in the presence of a catalyst, characterized in that the catalyst comprises ultrafine particles of a transition metal which have been obtained by the gas-phase thermal decomposition of a carbonyl compound of a transition metal in the presence of at least one organic compound containing oxygen and/or sulfur.

Abstract: A magnetic metal powder comprising fine particles of a transition metal which contain 0.2 to 2.5% by weight of carbon substantially in the form of metal carbide and which are of such a geometry as a minor axis length of 100 to 300 .ANG. and a (major to minor) axial ratio of 1 to 50.

Abstract: A method for forming a single-phase, homogeneous and high surface area metal alloy by reducing a polyheterometallic complex at a low temperature in hydrogen-containing gas.

Abstract: A method of generating iron/cobalt alloy filaments which includes atomizing and spraying a solution of dicobalt octacarbonyl in iron pentacarbonyl through an atomizing hole (12) into a reaction chamber (14) surrounded by a solenoidal field (19), while simultaneously decomposing the solution to produce iron/cobalt filaments.