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The invention is a process for manufacturing a nano aluminum/alumina metal matrix composite and composition produced therefrom. The process is characterized by providing an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and

The invention is a process for manufacturing a nano aluminum/alumina metal matrix composite and composition produced therefrom. The process is characterized by providing an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5 m2/g, hot working the aluminum powder, and forming a superfine grained matrix aluminum alloy. Simultaneously there is formed in situ a substantially uniform distribution of nano particles of alumina. The alloy has a substantially linear property/temperature profile, such that physical properties such as strength are substantially maintained even at temperatures of 250° C. and above.

대표청구항 ▼

1. A process for manufacturing a nano aluminum composite, comprising the steps of: a) providing, an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5.0 m2/g;b) hot worki

1. A process for manufacturing a nano aluminum composite, comprising the steps of: a) providing, an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5.0 m2/g;b) hot working the aluminum powder at a temperature below the recrystallization temperature of the powder, and forming thereby a superfine grained matrix aluminum alloy; andc) simultaneously with the hot working of step b), redistributing the aluminum powder into uniformly dispersed nano particles of alumina throughout said alloy;wherein said alloy has a substantially linear ultimate tensile strength vs temperature. 2. The process as claimed in claim 1, wherein said aluminum powder has an average particle size of less than about 30 μm. 3. The process as claimed in claim 1, wherein said superfine grained matrix aluminum alloy has an average particle size of about 200 nm. 4. The process as claimed in claim 1, wherein the step of hot working is carried out at a temperature less than the melting point of said alloy. 5. The process as claimed in claim 1, wherein the aluminum powder is formed by a powder atomization manufacturing process and has a particle size of less than about 30nm in diameter and the natural layer of aluminum oxide has a thickness of between 3-7nm regardless of the type of atomization gas and alloy type used during the powder atomization manufacturing process. 6. The process as claimed in claim 1, wherein the aluminum powder comprises a particle size distribution (PSD) such that 100% of the aluminum powder is less than about 30 μm and the aluminum powder comprises a d50 between about 1 and about 20 μm regardless of an atomization gas or alloy composition used in forming said powder. 7. The process as claimed in claim 1, wherein said process is free of mechanical alloying. 8. A nano aluminum powder, comprising an aluminum matrix; and from about 0.1 to about 4.5 wt. % aluminum oxide having a particle size of less than 30 microns and a surface area of from about 0.3 to about 5.0 m2/g, wherein the aluminum oxide particles are uniformly distributed in the aluminum matrix. 9. The nano aluminum powder as claimed in claim 8 further comprising from about 5 to about 40 wt. % of ceramic particulates selected from the group consisting of silica, silicon carbide, boron carbide; boron nitride, titanium oxide, titanium diboride, and mixtures thereof, wherein the aluminum oxide particles have an oxide skin of 3-7 nm and a grain size of about 200 nm and are present in the amount of up to about 4 wt. %. 10. The nano aluminum powder as claimed in claim 9, comprising from about 5 to about 40 wt. boron carbide particles having a particle size distribution of 100% less than about 250 μm, and wherein the boron carbide panicles are nuclear grade. 11. The nano aluminum powder as claimed in claim 10, wherein the boron carbide particles are uniformly dispersed throughout the aluminum matrix. 12. A nano aluminum composite consisting essentially of a pure aluminum powder comprising, an aluminum matrix and from about 0.1 and about 4.5 wt. % aluminum oxide particles having a surface area of from about 0.3 and about 5.0 m2/g.