Method for forming high fraction solid metal compositions and composition therefor

Claim 1

The method for forming a metal composition having solid discrete degenerate dendrites homogeneously dispersed within a liquid phase of said metal composition which comprises: a. heating a first metal composition to form a liquid-solid mixture of said first metal composition wherein greater than about 65 weight percent up to a weight percent of primary solids where there is sufficient fusion of the primary solids to each other which prevents the primary solids from sliding along their boundaries when the mixture is subjected to shear forces, and b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites derived from said first metal composition, said degenerate dendrites comprising greater than about 65 weight percent of the heated metal composition and wherein the remainder of the heated metal composition is liquid wherein the surface in said agitation zone contacting said liquid-solid mixture is stable against degradation by said liquid-solid mixture and is not wet by said liquid-solid mixture, and c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture to maintain the primary solids content of said mixture above about 65 weight percent.

Claim 2

The method for forming a metal composition having solid discrete degenerate dendrites homogeneously dispersed within a liquid phase of said metal composition which comprises: a. heating a first metal composition to form a liquid-solid mixture of said first metal composition wherein greater than about 65 weight percent up to a weight percent of primary solids where there is sufficient fusion of the primary solids to each other which prevents the primary solids from sliding along their boundaries when the mixture is subjected to shear forces, and b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites derived from said first metal composition, said degenerate dendrites comprising greater than about 65 weight percent of the heated metal composition and wherein the remainder of the heated metal composition is liquid wherein the surface in said agitation zone contacting said liquid-solid mixture is stable against degradation by said liquid-solid mixture and is not wet by said liquid-solid mixture, and c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture to maintain the primary solids content of said mixture above about 65 weight percent.

Claim 3

The method for forming a solid metal composition containing discrete degenerate dendrites homogeneously dispersed within a secondary phase of said solid metal composition which comprises: a. heating a first metal composition to form a liquid-solid mixture of said first metal composition wherein greater than about 65 weight percent up to a weight percent of primary solids where there is sufficient fusion of the primary solids to each other which prevents the primary solids from sliding along their boundaries when the mixture is subjected to shear forces, and b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites derived from said first metal composition, said degenerate dendrites comprising greater than about 65 weight percent of the heated metal composition wherein the surface in said agitation zone contacting said liquid-solid mixture is stable against degradation by said liquid-solid mixture and is not wet by said liquid-solid mixture, and c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture to maintain the primary solids content of said mixture above about 65 weight percent, and d. cooling said heated composition to solidify the liquid remaining after the degenerate dendrites are formed thereby forming a solid secondary phase of said metal composition.

Claim 4

The method for forming a solid metal composition containing discrete degenerate dendrites homogeneously dispersed within a secondary phase of said solid metal composition which comprises: a. heating a first metal composition to form a liquid-solid mixture of said first metal composition wherein greater than about 65 weight percent up to a weight percent of primary solids where there is sufficient fusion of the primary solids to each other which prevents the primary solids from sliding along their boundaries when the mixture is subjected to shear forces, and b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites derived from said first metal composition, said degenerate dendrites comprising greater than about 65 weight percent of the heated metal composition wherein the surface in said agitation zone contacting said liquid-solid mixture is stable against degradation by said liquid-solid mixture and is not wet by said liquid-solid mixture, and c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture to maintain the primary solids content of said mixture above about 65 weight percent, and d. cooling said heated composition to solidify the liquid remaining after the degenerate dendrites are formed thereby forming a solid secondary phase of said metal composition.

Claim 5

The method for shaping a metal composition which comprises: a. forming a metal composition having solid discrete degenerate dendrites homogeneously dispersed within a liquid phase of said metal composition by: i. heating a first metal composition to form a liquid-solid mixture of said first metal composition wherein more than about 65 weight percent primary solids up to a weight percent of primary solids where there is sufficient fusion of the primary solids to each other which prevents the primary solids from sliding along their boundaries when the mixture is subjected to shear forces, and ii. vigorously agitating said mixture in an agitation zone to convert the liquid-solid mixture therein to discrete degenerate dendrites derived from said metal composition, said degenerate dendrites comprising greater than about 65 weight percent of the heated metal composition and wherein the remainder of the heated metal composition is liquid, wherein the surface in said agitation zone contacting said liquid-solid mixture is stable against degradation by said liquid-solid mixture and is not wet by said liquid-solid mixture, b. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture to maintain the primary solids content of said mixture above about 65 weight percent, and c. shaping the heated metal composition comprising degenerated dendrites and liquid metal.

Claim 6

The method for shaping a metal composition which comprises: a. forming a metal composition having solid discrete degenerate dendrites homogeneously dispersed within a liquid phase of said metal composition by: i. heating a first metal composition to form a liquid-solid mixture of said first metal composition wherein more than about 65 weight percent primary solids up to a weight percent of primary solids where there is sufficient fusion of the primary solids to each other which prevents the primary solids from sliding along their boundaries when the mixture is subjected to shear forces, and ii. vigorously agitating said mixture in an agitation zone to convert the liquid-solid mixture therein to discrete degenerate dendrites derived from said metal composition, said degenerate dendrites comprising greater than about 65 weight percent of the heated metal composition and wherein the remainder of the heated metal composition is liquid, wherein the surface in said agitation zone contacting said liquid-solid mixture is stable against degradation by said liquid-solid mixture and is not wet by said liquid-solid mixture, b. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture to maintain the primary solids content of said mixture above about 65 weight percent, and c. shaping the heated metal composition comprising degenerated dendrites and liquid metal.

Claim 7

The method for forming a metal composition comprising a metal alloy matrix and third phase solid particles homogeneously suspended in said matrix, said metal alloy having solid descrete degenerate dendrites homogeneously dispersed within a secondary phase of said metal alloy which comprises: a. heating a first metal alloy to form an initial liquid-solid mixture of said first metal alloy wherein more than about 65 weight percent is primary solid up to a weight percent of primary solids where there is sufficient fusion of the primary solids from sliding along their boundaries when the mixture is subjected to shear forces, and b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites comprising more than about 65 weight percent of said heated alloy and wherein the remainder of said heated metal alloy is a liquid secondary phase wherein the surface in said agitation zone contacting said liquid-solid mixture is stable against degradation by said liquid-solid mixture and is not wet by said liquid-solid mixture, and c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture to maintain the primary solids content of said mixture above about 65 weight percent, and d. adding solid third phase particles to said alloy comprising degenerate dendrites and liquid secondary phase, and e. dispersing said third phase particles and said degenerate dendrites homogeneously in said secondary phase, said third phase particles comprising up to about 30 weight percent of the weight of the metal alloy and third phase particles.

Claim 8

The method for forming a metal composition comprising a metal alloy matrix and third phase solid particles homogeneously suspended in said matrix, said metal alloy having solid descrete degenerate dendrites homogeneously dispersed within a secondary phase of said metal alloy which comprises: a. heating a first metal alloy to form an initial liquid-solid mixture of said first metal alloy wherein more than about 65 weight percent is primary solid up to a weight percent of primary solids where there is sufficient fusion of the primary solids from sliding along their boundaries when the mixture is subjected to shear forces, and b. vigorously agitating said liquid-solid mixture in an agitation zone to convert the solid therein to discrete degenerate dendrites comprising more than about 65 weight percent of said heated alloy and wherein the remainder of said heated metal alloy is a liquid secondary phase wherein the surface in said agitation zone contacting said liquid-solid mixture is stable against degradation by said liquid-solid mixture and is not wet by said liquid-solid mixture, and c. continuously monitoring the apparent viscosity or an analog of the apparent viscosity of the liquid-solid mixture thereby to control the heat extracted from said mixture to maintain the primary solids content of said mixture above about 65 weight percent, and d. adding solid third phase particles to said alloy comprising degenerate dendrites and liquid secondary phase, and e. dispersing said third phase particles and said degenerate dendrites homogeneously in said secondary phase, said third phase particles comprising up to about 30 weight percent of the weight of the metal alloy and third phase particles.