Methods for producing molybdenum/molybdenum disulfide metal articles

1. A method for producing a metal article, comprising:

providing a composite metal powder comprising a substantially homogeneous dispersion of molybdenum and molybdenum disulfide sub-particles that are fused together to form individual particles of said composite metal powder; and

compressing said molybdenum/molybdenum disulfide composite metal powder to form said metal article.

2. The method of claim 1 , wherein said compressing comprises axial pressing.

3. The method of claim 2 , wherein said axial pressing comprises applying a pressure of about 240 MPa.

4. The method of claim 1 , wherein said compressing comprises hot isostatic pressing.

5. The method of claim 1 , wherein said compressing comprises cold isostatic pressing.

6. The method of claim 1 , wherein said compressing comprises warm isostatic pressing.

7. The method of claim 1 , wherein said compressing imparts to said metal article a green density in a range of about 6.0 g/cc to about 7.0 g/cc.

8. The method of claim 1 , wherein said compressing imparts to said metal article a green density of about 6.4 g/cc.

9. The method of claim 1 , wherein providing a supply of composite metal powder comprises:

providing a supply of molybdenum metal powder;

providing a supply of molybdenum disulfide powder;

combining said molybdenum metal powder and said molybdenum disulfide powder with a liquid to form a slurry;

feeding said slurry into a stream of hot gas; and

recovering the composite metal powder.

10. The method of claim 9 , wherein feeding said slurry into a stream of hot gas comprises atomizing said slurry and contacting said atomized slurry with the stream of hot gas.

11. The method of claim 9 , wherein combining said molybdenum metal powder and said molybdenum disulfide powder with a liquid comprises combining said molybdenum metal powder and said molybdenum disulfide powder with water to form a slurry.

12. The method of claim 9 , wherein said slurry comprises between about 15 percent by weight to about 50 percent by weight liquid.

13. The method of claim 9 , further comprising:

providing a supply of a binder material; and

combining said binder material with said molybdenum metal powder, said molybdenum disulfide powder, and said water to form a slurry.

14. The method of claim 13 , wherein said binder comprises polyvinyl alcohol.

15. The method of claim 13 , wherein said supply of molybdenum disulfide powder is added to said supply of molybdenum metal powder in amounts ranging from about 1% by weight to about 50% by weight before combining said supply of molybdenum metal powder and said supply of molybdenum disulfide with said liquid to form said slurry.

16. The method of claim 13 , further comprising heating the recovered composite metal powder at a temperature sufficient to drive-off substantially all of said binder.

17. The method of claim 16 , wherein said heating further comprises heating in a hydrogen atmosphere.

18. The method of claim 17 , wherein said heating in a hydrogen atmosphere is conducted at a temperature in a range of about 500° C. to about 825° C.

19. The method of claim 1 , further comprising sintering after said compressing.

20. A method for producing a composite metal powder, comprising:

providing a supply of molybdenum metal powder;

providing a supply of molybdenum disulfide powder;

combining said molybdenum metal powder and said molybdenum disulfide powder with a liquid to form a slurry;

feeding said slurry into a stream of hot gas; and

recovering the composite metal powder, said composite metal powder comprising a substantially homogeneous dispersion of molybdenum and molybdenum disulfide sub-particles that are fused together to form individual particles of said composite metal powder.