US3197847A - Clad materials and process of fabricating the same - Google Patents

Clad materials and process of fabricating the same Download PDF

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Publication number
US3197847A
US3197847A US105892A US10589261A US3197847A US 3197847 A US3197847 A US 3197847A US 105892 A US105892 A US 105892A US 10589261 A US10589261 A US 10589261A US 3197847 A US3197847 A US 3197847A
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United States
Prior art keywords
metal
particles
binder
base
film
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Expired - Lifetime
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US105892A
Inventor
Donald R Kerstetter
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GTE Sylvania Inc
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Sylvania Electric Products Inc
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/02—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers
    • B22F7/04—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite layers with one or more layers not made from powder, e.g. made from solid metal
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063—Nonparticulate metal component
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12014—All metal or with adjacent metals having metal particles
    • Y10T428/12028—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, etc.]
    • Y10T428/12063—Nonparticulate metal component
    • Y10T428/12104—Particles discontinuous
    • Y10T428/12111—Separated by nonmetal matrix or binder [e.g., welding electrode, etc.]
    • Y10T428/12118—Nonparticulate component has Ni-, Cu-, or Zn-base

Definitions

  • This invention relates to the process of making a metal laminate and the product resulting from the mode of .ianufacture.
  • Another object of the invention is to clad a metal base with an improved thin substantially impenetrable layer, particularly where the layer is of refractory metal.
  • Yet another object of the invention is to produce an improved clad metallic structure or fabric.
  • a curved or flat strip of metal or wire is coated with a film of metal dispersed in a combustible binder and the metal of the film is sintered onto the strip or Wire. Since the process is the same for whatever form the metal base may partake, subsequent description, for simplification, will refer to the metal coated as a strip although it is obvious the strip may find its equivalent in wires, tubes or the like.
  • the film is of the type disclosed in the application of Donald R. Kerstetter and Samuel .T. Montgomery for Towdered Metal Films, Serial No. 105,891 filed of even date herewith, to which reference may be had for further disclosure, and it may be applied to a metal base by the method disclosed in Patent No. 2,986,671, Kerstetter and Wennin, for Application of Strip Coating to Cathodes (on an application, S.N. 453,235, filed August 31, 1954).
  • the film comprises an organic binder with about 75 to 97%, by weight of the film, of metal powder of 7 .L9p. particle size distributed homogeneously throughout the film with the particles in contact with one another.
  • the whole is sintered at a temperature amen-able to the metal base resulting in a sintered mass, the sintered particles of which are uniformly distributed over the base metal. If desired, the sintered mass can then be rolled to secure compacting of the sintered particles, to secure penetration of the metal particles in the film into the metal base, and to secure the desired overall thickness of the laminate.
  • the above method of producing clad metals or laminates is particularly useful where refractory metals such as tungsten or molybdenum are employed in the film.
  • the film itself as explained in detail in the above Kerstetter application, is formed from a viscous mass or slurry of metal powder in an organic binder.
  • the organic binder is dissolved in an organic solvent mixture, and the mass is cast on a moving surface and partially dried thereon. Subsequently, the film so formed or cast is stripped therefrom, after which the solvent is wholly evaporated.
  • Sufficient plasticizer is embodied within the slurry to maintain the resulting film pliable for subsequent handling.
  • a ductile nickel strip may be coated by the process set forth in the above refer-red to disclosures with a film approximately .002" thick containing about tungsten powder, by weight of the film.
  • the tungsten particles of the powder may be of the order of 3 1. to 9 in size, the smallest size being preferred.
  • This film when sintered on o the nickel base, yields a tungsten film of about 35% density and a thickness of about .0015".
  • the tungsten laminae Upon rolling this laminated fabric to .002", the tungsten laminae has a thickness of about .0005 or less and the density is compacted to between and close to Obviously, under the condition outlined, there is a considerable amount of diffusion of the metals into each other which results in conversion, at least in part, of the ductile cathode base nickel into a tungsten nickel alloy. Thus, where a cathode sleeve is to be fabricated, it can be very easily formed from the sintered nickel tungsten laminated sheet into an oval or cylindrical or rectangular sleeve.
  • This cathode sleeve may then be heated and annealed to form a hard rigid sleeve which, when coated with emissive material, is suitable for use in electron tubes.
  • the tungsten film may be applied to the nickel on one or both sides thereof.
  • the process disclosed above may be used to produce many types of laminated structures in strip or wire form which are made from various metals and have various densities and various alloy characteristics. For instance, it has been found that laminates having carefully controlled predictable characteristics can be made from combinations of certain ones of such metals as aluminum, iron, steel, copper, molybdenum, etc. as well as the nickel and tungsten laminate described above as one specific example of the invention.
  • a laminated structure comprised of a base metal and an overlying pliable cast film strip comprising a binder and a metal powder with contiguous particles, the particles being homogeneously distributed in the binder.
  • the process of forming a laminated metal fabric comprising the step of applying a self-supporting pliable film strip embodying metal powder in a combustible binder to a metal base, the metal powder film strip having particles in contiguous relationship in the binder and homogeneously distributed throughout the binder, and the step of sintering the powder particles to each other and to the metal base.
  • the process of forming a laminated metal fabric comprising the step of applying a self-supporting pliable film strip embodying metal powder in a combustible binder to a metal base, the metal powder film strip having particles in contiguous relationship in the binder and homogeneously distributed throughout the binder, the step of sintering the particles to each other and to the base metal, and the step of rolling the thus formed laminate to produce a laminate of high surface density and required thickness.

Description

United States Patent 3,197,847 CLAD' MATERHALS AND ERQCEfifi OF FARRICATTNG THE SAME it. Kerstetter, Emporium, Pa., assignor to Sylvania Electric Products The, a corporation of Delaware No Drawing, Filed Apr. 27, 1961, Ser. No. 105,892 Claims. (Cl. 29182.3)
This invention relates to the process of making a metal laminate and the product resulting from the mode of .ianufacture.
it has been the practice to produce laminated metal structures by many techniques including drag coating the base metal through a liquid containing a binder and particles of the metal to be deposited thereon. The base, which is covered with the binder and deposited metal particles, is subsequently heated to drive off the binder and sinter the particles together. It has been found that such a process does not produce a coating or laminae which is uniform in thickness or density, nor can the metal particles be homogeneously and contiguously deposited relative to one another. In addition there is little if any diffusion of the metal particles into the base metal. This latter feature is important where some controlled alloy characteristics such as strength are desired in the end product.
Accordingly, it is an object of the invention to reduce the aforementioned disadvantages by improving the application of metal particles to a base metal.
Another object of the invention is to clad a metal base with an improved thin substantially impenetrable layer, particularly where the layer is of refractory metal.
Yet another object of the invention is to produce an improved clad metallic structure or fabric.
Other objects will become apparent after consideration of the following specification and claims.
In carrying out the method of this invention, a curved or flat strip of metal or wire is coated with a film of metal dispersed in a combustible binder and the metal of the film is sintered onto the strip or Wire. Since the process is the same for whatever form the metal base may partake, subsequent description, for simplification, will refer to the metal coated as a strip although it is obvious the strip may find its equivalent in wires, tubes or the like.
The film is of the type disclosed in the application of Donald R. Kerstetter and Samuel .T. Montgomery for Towdered Metal Films, Serial No. 105,891 filed of even date herewith, to which reference may be had for further disclosure, and it may be applied to a metal base by the method disclosed in Patent No. 2,986,671, Kerstetter and Wennin, for Application of Strip Coating to Cathodes (on an application, S.N. 453,235, filed August 31, 1954). in general, the film comprises an organic binder with about 75 to 97%, by weight of the film, of metal powder of 7 .L9p. particle size distributed homogeneously throughout the film with the particles in contact with one another. After the film has been applied to the metal base, the whole is sintered at a temperature amen-able to the metal base resulting in a sintered mass, the sintered particles of which are uniformly distributed over the base metal. If desired, the sintered mass can then be rolled to secure compacting of the sintered particles, to secure penetration of the metal particles in the film into the metal base, and to secure the desired overall thickness of the laminate.
The above method of producing clad metals or laminates is particularly useful where refractory metals such as tungsten or molybdenum are employed in the film. The film itself, as explained in detail in the above Kerstetter application, is formed from a viscous mass or slurry of metal powder in an organic binder. The organic binder is dissolved in an organic solvent mixture, and the mass is cast on a moving surface and partially dried thereon. Subsequently, the film so formed or cast is stripped therefrom, after which the solvent is wholly evaporated. Sufficient plasticizer is embodied within the slurry to maintain the resulting film pliable for subsequent handling.
Where thin cladding of a metal base is desired, as a covering of tungsten on a ductile nickel base which is adaptable for use as a cathode sleeve or as a directly heated cathode filament in an electron tube, a ductile nickel strip, .005" thick, may be coated by the process set forth in the above refer-red to disclosures with a film approximately .002" thick containing about tungsten powder, by weight of the film. The tungsten particles of the powder may be of the order of 3 1. to 9 in size, the smallest size being preferred. This film, when sintered on o the nickel base, yields a tungsten film of about 35% density and a thickness of about .0015". Upon rolling this laminated fabric to .002", the tungsten laminae has a thickness of about .0005 or less and the density is compacted to between and close to Obviously, under the condition outlined, there is a considerable amount of diffusion of the metals into each other which results in conversion, at least in part, of the ductile cathode base nickel into a tungsten nickel alloy. Thus, where a cathode sleeve is to be fabricated, it can be very easily formed from the sintered nickel tungsten laminated sheet into an oval or cylindrical or rectangular sleeve. This cathode sleeve may then be heated and annealed to form a hard rigid sleeve which, when coated with emissive material, is suitable for use in electron tubes. If desired, the tungsten film may be applied to the nickel on one or both sides thereof.
The process disclosed above may be used to produce many types of laminated structures in strip or wire form which are made from various metals and have various densities and various alloy characteristics. For instance, it has been found that laminates having carefully controlled predictable characteristics can be made from combinations of certain ones of such metals as aluminum, iron, steel, copper, molybdenum, etc. as well as the nickel and tungsten laminate described above as one specific example of the invention.
Although several embodiments of the invention have been described, it will be apparent to those skilled in the art that various changes and modifications may be made therein without departing from the scope of the invention as defined by the appended claims.
What is claimed is:
1. A laminated structure comprised of a base metal and an overlying pliable cast film strip comprising a binder and a metal powder with contiguous particles, the particles being homogeneously distributed in the binder.
2;. The process of forming a laminated metal fabric comprising the step of applying a self-supporting pliable film strip embodying metal powder in a combustible binder to a metal base, the metal powder film strip having particles in contiguous relationship in the binder and homogeneously distributed throughout the binder, and the step of sintering the powder particles to each other and to the metal base.
*3. The process of forming a laminated metal fabric comprising the step of applying a self-supporting pliable film strip embodying metal powder in a combustible binder to a metal base, the metal powder film strip having particles in contiguous relationship in the binder and homogeneously distributed throughout the binder, the step of sintering the particles to each other and to the base metal, and the step of rolling the thus formed laminate to produce a laminate of high surface density and required thickness.
4. The process of forming a laminated metal fabric comprising applying to a nickel base a self-supporting pliable film strip containing an organic binder and tungsten powder particles with the film strip particles of powder approximately in the range of 75 to 97% of the weight of the film and sintering the particles to each other and to the nickel base.
5. The process of forming a laminated metal fabric comprising applying to a nickel base a self-supporting pliable film strip containing an organic binder and tungsten powder particles with the film strip particles of powder approximately in the range of 75 to 97% of the weight of the film, sintering the particles to each other and to the nickel base, and rolling the laminate thus tungsten.
References Qited by the Examiner UNITED STATES PATENTS CARL D. QUARFORTH, Primary Examiner. formed to a desired thickness and density of the sintered 15 OSCAR R. VERTIZ, Examin r.

Claims (2)

1. A LAMINATED STRUCTURE COMPRISED OF A BASE METAL AND AN OVERLYING PLIABLE CAST FILM STRIP COMPRISING A BINDER AND A METAL POWDER WITH CONTIGUOUS PARTICLES, THE PARTICLES BEING HOMOGENEOUSLY DISTRIBUTED IN THE BINDER.
2. THE PROCESS OF FORMING A LAMINATED METAL FABRIC COMPRISING THE STEP OF APPLYING A SELF-SUPPORTING PLIABLE FILM STRIP EMBODYING METAL POWDER IN A COMBUSTIBLE BINDER TO A METAL BASE, THE METAL POWDER FILM STRIP HAVING PARTICLES IN CONTIGUOUS RELATIONSHIP IN THE BINDER AND HOMOGENEOUSLY DISTRIBUTED THROUGHOUT THE BINDER, AND THE STEP OF SINTERING THE POWDER PARTICLES TO EACH OTHER AND TO THE METAL BASE.
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Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3310870A (en) * 1967-03-28 Process for producing nickel-coated steel
US3323915A (en) * 1964-12-04 1967-06-06 Sylvania Electric Prod Double cast porous electrode
US3327158A (en) * 1963-06-26 1967-06-20 Sylvania Electric Prod Semi-dispenser cathode with overlying emissive coating
US3330654A (en) * 1964-04-28 1967-07-11 Kennecott Copper Corp Continuous process for producing sheet metal and clad metal
US3351486A (en) * 1966-11-23 1967-11-07 Sylvania Electric Prod Cathodes
US3362838A (en) * 1964-04-30 1968-01-09 Int Nickel Co Process for producing nickel-coated steel
US3403999A (en) * 1965-10-13 1968-10-01 Texas Instruments Inc Manufacture of braze shim stock
US3433632A (en) * 1967-06-30 1969-03-18 Union Carbide Corp Process for producing porous metal bodies
US3441409A (en) * 1967-01-26 1969-04-29 Chase Brass & Copper Co Method of producing a corrosion resistant alloy of cu-ni by liquid phase sintering
US3453105A (en) * 1966-11-24 1969-07-01 Lignes Telegraph Telephon Process for manufacturing high porosity sintered parts
US3489555A (en) * 1967-05-18 1970-01-13 Clevite Corp Method of slip casting titanium structures
US3879830A (en) * 1971-06-30 1975-04-29 Gte Sylvania Inc Cathode for electron discharge device having highly adherent emissive coating of nickel and nickel coated carbonates
WO2011144309A1 (en) * 2010-05-15 2011-11-24 Friedrich-Alexander-Universität Erlangen-Nürnberg Method for producing a multiple-layer metallic composite plate using a particle suspension; corresponding composite plate
DE102016216456A1 (en) 2016-08-31 2018-03-01 Siemens Aktiengesellschaft Method for connecting sheets of a sheet stack by means of nanoscale metal oxide powder

Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2172207A (en) * 1936-09-19 1939-09-05 Siemens Ag Glow cathode
US2198254A (en) * 1936-08-07 1940-04-23 Gen Motors Corp Method of making composite metal structures
US2251410A (en) * 1939-04-27 1941-08-05 Gen Motors Corp Composite metal structure and method of making same
US2289658A (en) * 1939-05-01 1942-07-14 Gen Motors Corp Method of making composite metal elements
US2337588A (en) * 1939-11-10 1943-12-28 Chrysler Corp Composite porous metal article
US2350179A (en) * 1941-01-16 1944-05-30 Gen Motors Corp Method and apparatus for making composite metal parts
US2391456A (en) * 1944-01-29 1945-12-25 Mallory & Co Inc P R Spark plug electrode
US2488731A (en) * 1942-03-21 1949-11-22 Gen Electric Electron-emitting electrode for electric discharge tubes
US2775531A (en) * 1949-05-10 1956-12-25 Univ Ohio State Res Found Method of coating a metal surface

Patent Citations (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2198254A (en) * 1936-08-07 1940-04-23 Gen Motors Corp Method of making composite metal structures
US2172207A (en) * 1936-09-19 1939-09-05 Siemens Ag Glow cathode
US2251410A (en) * 1939-04-27 1941-08-05 Gen Motors Corp Composite metal structure and method of making same
US2289658A (en) * 1939-05-01 1942-07-14 Gen Motors Corp Method of making composite metal elements
US2337588A (en) * 1939-11-10 1943-12-28 Chrysler Corp Composite porous metal article
US2350179A (en) * 1941-01-16 1944-05-30 Gen Motors Corp Method and apparatus for making composite metal parts
US2488731A (en) * 1942-03-21 1949-11-22 Gen Electric Electron-emitting electrode for electric discharge tubes
US2391456A (en) * 1944-01-29 1945-12-25 Mallory & Co Inc P R Spark plug electrode
US2775531A (en) * 1949-05-10 1956-12-25 Univ Ohio State Res Found Method of coating a metal surface

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3310870A (en) * 1967-03-28 Process for producing nickel-coated steel
US3327158A (en) * 1963-06-26 1967-06-20 Sylvania Electric Prod Semi-dispenser cathode with overlying emissive coating
US3330654A (en) * 1964-04-28 1967-07-11 Kennecott Copper Corp Continuous process for producing sheet metal and clad metal
US3362838A (en) * 1964-04-30 1968-01-09 Int Nickel Co Process for producing nickel-coated steel
US3323915A (en) * 1964-12-04 1967-06-06 Sylvania Electric Prod Double cast porous electrode
US3403999A (en) * 1965-10-13 1968-10-01 Texas Instruments Inc Manufacture of braze shim stock
US3351486A (en) * 1966-11-23 1967-11-07 Sylvania Electric Prod Cathodes
US3453105A (en) * 1966-11-24 1969-07-01 Lignes Telegraph Telephon Process for manufacturing high porosity sintered parts
US3441409A (en) * 1967-01-26 1969-04-29 Chase Brass & Copper Co Method of producing a corrosion resistant alloy of cu-ni by liquid phase sintering
US3489555A (en) * 1967-05-18 1970-01-13 Clevite Corp Method of slip casting titanium structures
US3433632A (en) * 1967-06-30 1969-03-18 Union Carbide Corp Process for producing porous metal bodies
US3879830A (en) * 1971-06-30 1975-04-29 Gte Sylvania Inc Cathode for electron discharge device having highly adherent emissive coating of nickel and nickel coated carbonates
WO2011144309A1 (en) * 2010-05-15 2011-11-24 Friedrich-Alexander-Universität Erlangen-Nürnberg Method for producing a multiple-layer metallic composite plate using a particle suspension; corresponding composite plate
DE102016216456A1 (en) 2016-08-31 2018-03-01 Siemens Aktiengesellschaft Method for connecting sheets of a sheet stack by means of nanoscale metal oxide powder

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