ARL 24-15
Updated
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ARL 24-15P
TITLE OF INVENTION: Flux Growth and Nucleation Casting Technique
EXECUTIVE SUMMARY OVERVIEW:
(The purpose of this overview is to provide a brief summarized overview of the invention as described in this invention disclosure document and a direct explanation on what is new about the invention and information about potential military and commercial uses)
1. What is this Invention?
This invention, Flux Growth Nucleation Casting, is a novel casting technique designed to enhance the mechanical properties of metal alloys through the controlled nucleation and growth of high-temperature secondary phases that form as the first to solidify out of the melt, e.g. primaries. This method significantly influences and imparts control on the volume fraction and morphology of these strengthening phases to target improvements in alloy strength, wear resistance, elastic modulus, and potentially other physical properties.
2. What is the basic premise of the design?
The Flux Growth and Nucleation Casting technique operates by holding the prior fully molten alloy isothermally at a temperature below that required for the formation of high melting point secondary phases, e.g. primaries followed by returning the melt to a higher temperature to facilitate suitable fluidity and good castability. This technique can be applied to alloys systems with two characteristics, 1) a system with secondary phase with a melt temperature 110-310% of the matrix melt temperature, or 2) a system with a secondary phase that has a very high enthalpy of formation when compared to the matrix phase. The initial melt temperature, the temperature of the isothermal hold, and the duration of the isothermal hold can all be varied to achieve the desired final microstructure.
3. What is new about this Invention?
The Flux Growth and Nucleation Casting technique is new in that it relies only on the temperature profile and history of the molten alloy in the casting process to generate and control the volume fraction and morphology of primaries in the alloy, unlike traditional casting or rheocasting which requires both the cooling of the alloy to a temperature where liquid and solid phases are stable and mechanical stirring to impart control on the volume fraction and morphology of the strengthening phases.
4. Has this Invention been verified?
The Flux Growth and Nucleation Casting technique has been verified in multiple physical castings, casting forms, isothermal holds, and alloy compositions.
5. Identify Potential Military Uses of the Invention:
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