Macro-chip reinforced alloy
Described herein are methods of forming a neutron shielding material. Such material may comprise a powder blend comprising a first component comprising a blend of a first metal particle and a first ceramic particle; and a second component comprising a reinforcing chip, the reinforcing chip comprising a second ceramic particle dispersed within a chip metal matrix.
1. A method of forming a neutron shielding material comprising:
a) mixing together a first metal particle having a first grain growth temperature; a first ceramic particle; and a reinforcing chip to form a powder blend; and
b) sintering the powder blend into a billet and extruding the billet at a hot-work temperature;
wherein the reinforcing chip comprises a second ceramic particle homogeneously dispersed within a chip metal matrix having a second grain growth temperature;
wherein the first metal particle is virgin aluminum powder; and
wherein the hot-work temperature is lower than both of the first and second grain growth temperatures.
2. The method according to claim 1 , wherein the hot-work temperature is less than about 1100° F.
3. The method according to claim 1 , wherein the reinforcing chip is present in a non-zero amount ranging up to about 35 wt. % based on the total weight of the powder blend.
4. The method according to claim 1 , wherein the billet is extruded into a sheet material.
5. The method according to claim 1 , wherein the first metal particle has D100 that is less than about 30 μm.
6. The method according to claim 5 , wherein the first metal particle has D50 between about 1 μm and about 20 μm.
7. The method according to claim 1 , wherein the first ceramic particle comprises boron carbide.
8. The method according to claim 7 , wherein the boron carbide is boron carbide powder.
9. The method according to claim 8 , wherein the boron carbide powder has a particle size distribution of 100% less than about 250 μm.
10. The method according to claim 1 , wherein the second ceramic particle comprises boron carbide.
11. The method according to claim 10 , wherein the boron carbide is boron carbide powder.
12. The method according to claim 11 , wherein the boron carbide powder has a particle size distribution of 100% less than about 250 μm.
13. The method according to claim 1 , wherein the chip metal matrix comprises aluminum powder.
14. The method according to claim 13 , wherein the aluminum powder has D100 that is less than about 30 μm.
15. The method according to claim 14 , wherein the aluminum powder has D50 between about 1 μm and about 20 μm.
16. A method of forming a neutron shielding material comprising:
a) mixing together a first metal particle having a first grain growth temperature; a first ceramic particle; and a reinforcing chip to form a powder blend; and
b) sintering the powder blend into a billet and extruding the billet at a hot-work temperature;
wherein the reinforcing chip comprises a second ceramic particle dispersed within a chip metal matrix having a second grain growth temperature;
wherein the hot-work temperature is lower than both of the first and second grain growth temperatures; and
wherein the reinforcing chip is formed prior to step a) by the steps comprising:
i) mixing the second ceramic particle and a metal;
ii) forming a billet from the mixture;
iii) extruding the billet into a shaped form; and
iv) machining the shaped form into the reinforcing chip mold.
17. The method according to claim 16 , wherein the extrusion is performed at a temperature lower than the grain growth temperature of the metal.
18. The method according to claim 17 , wherein the metal is aluminum powder and the second ceramic particle is boron carbide powder.
19. A method of forming a neutron shielding material comprising:
a) mixing together a first metal particle having a first grain growth temperature; a first ceramic particle comprising boron carbide; and a reinforcing chip to form a powder blend; and
b) sintering the powder blend into a billet and extruding the billet at a hot-work temperature;
wherein the reinforcing chip comprises a second ceramic particle dispersed within a chip metal matrix having a second grain growth temperature; and
wherein the hot-work temperature is lower than both of the first and second grain growth temperatures.
20. The method according to claim 19 , wherein
wherein the reinforcing chip is formed prior to step a) by the steps comprising:
i) mixing the second ceramic particle and a metal;
ii) forming a billet from the mixture;
iii) extruding the billet into a shaped form; and
iv) machining the shaped form into the reinforcing chip.