Sodium/molybdenum composite metal articles and methods for producing metal articles
A method for producing a metal article may include: Producing a supply of a composite metal powder by: providing a supply of molybdenum metal powder; providing a supply of a sodium compound; combining the molybdenum metal powder and the sodium compound with a liquid to form a slurry; feeding the slurry into a stream of hot gas; and recovering the composite metal powder; and consolidating the composite metal powder to form the metal article, the metal article comprising a sodium/molybdenum metal matrix. Also disclosed is a metal article produced accordance with this method.
1. A method of producing a metal article, comprising:
producing a supply of a composite metal powder by:
providing a supply of molybdenum metal powder;
providing a supply of sodium molybdate;
combining said molybdenum metal powder and said sodium molybdate with a liquid to form a slurry, said sodium molybdate being added to said molybdenum metal powder in an amount comprising from about 3% by weight to about 15% by weight sodium molybdate before being combined with said liquid;
feeding said slurry into a stream of hot gas to produce the composite metal powder; and
recovering the composite metal powder, said composite metal powder comprising from about 0.2% by weight to about 3.5% by weight retained sodium; and
consolidating said composite metal powder to form the metal article, said metal article comprising a sodium/molybdenum metal matrix.
2. The method of claim 1 , wherein said consolidating said composite metal powder comprises cold isostatic pressing.
3. The method of claim 1 , wherein consolidating comprises pressing said composite metal powder into a shape and sintering the shape.
4. The method of claim 3 , wherein said sintering is conducted in a hydrogen atmosphere.
5. The method of claim 4 , wherein said sintering is conducted at a temperature of less than about 825° C.
6. The method of claim 1 , wherein consolidating comprises hot isostatic pressing.
7. The method of claim 6 , wherein said hot isostatic pressing is conducted at a temperature of at least about 900° C.
8. The method of claim 7 , further comprising sintering the metal article after said consolidating.
9. The method of claim 8 , wherein said sintering is conducted at a temperature of less than about 825° C.
10. A method of producing a metal article, comprising:
providing a supply of a sodium/molybdenum composite metal powder comprising a substantially homogeneous dispersion of sodium and molybdenum sub-particles that are fused together to form individual particles of said composite metal powder, said sodium/molybdenum composite metal powder comprising from about 0.2% by weight to about 3.5% by weight retained sodium; and
consolidating said sodium/molybdenum composite metal powder to form said metal article, said metal article comprising a sodium/molybdenum metal matrix.
11. The method of claim 10 , wherein said consolidating said sodium/molybdenum composite metal powder comprises one or more selected from the group consisting of cold isostatic pressing and hot isostatic pressing.
12. The method of claim 10 , wherein said consolidating said sodium/molybdenum composite metal powder comprises pressing said composite metal powder into a shape and sintering the shape.
13. The method of claim 12 , wherein said sintering is conducted in a hydrogen atmosphere.
14. The method of claim 13 , wherein said sintering is conducted at a temperature of less than about 825° C.
15. The method of claim 10 , wherein the oxygen content of said metal article is less than or equal to about 6% by weight.
16. The method of claim 10 , wherein said metal article comprises a sputter target.