U.S. patent application number 15/127447 was filed with the patent office on 2017-06-22 for synthesis of alloy and diffusion material nanoparticles.
The applicant listed for this patent is United Technologies Corporation. Invention is credited to James T. Beals, Michael J. Birnkrant, Lei Chen, Weina Li, Georgios S. Zafiris.
Application Number | 20170175282 15/127447 |
Document ID | / |
Family ID | 54834525 |
Filed Date | 2017-06-22 |
United States Patent
Application |
20170175282 |
Kind Code |
A1 |
Li; Weina ; et al. |
June 22, 2017 |
SYNTHESIS OF ALLOY AND DIFFUSION MATERIAL NANOPARTICLES
Abstract
A method for preparing an alloy nanocellular foam includes at
least partially coating a nanocellular precursor into a multiple
composition nanoparticle precursor and converting the multiple
composition nanoparticle precursor into an alloy via a diffusion
process.
Inventors: |
Li; Weina; (South
Glastonbury, CT) ; Chen; Lei; (South Windsor, CT)
; Zafiris; Georgios S.; (Glastonbury, CT) ; Beals;
James T.; (West Hartford, CT) ; Birnkrant; Michael
J.; (Wethersfield, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
United Technologies Corporation |
Farmington |
CT |
US |
|
|
Family ID: |
54834525 |
Appl. No.: |
15/127447 |
Filed: |
March 11, 2015 |
PCT Filed: |
March 11, 2015 |
PCT NO: |
PCT/US2015/019839 |
371 Date: |
September 20, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61969307 |
Mar 24, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B22F 1/025 20130101;
C25D 17/12 20130101; C22C 1/08 20130101; C25D 7/006 20130101; C25D
17/16 20130101 |
International
Class: |
C25D 7/00 20060101
C25D007/00; C25D 17/12 20060101 C25D017/12; C25D 17/16 20060101
C25D017/16 |
Claims
1. A method for preparing an alloy nanocellular foam comprising:
disposing a nanoparticle precursor in an electrochemical deposition
apparatus; operating said electrochemical deposition apparatus,
thereby at least partially coating said nanoparticle precursor into
a multiple composition nanoparticle precursor, wherein the coated
nanoparticle precursor forms an alloy nanoparticle via a diffusion
process conducted subsequent to the coating process; removing said
converted nanoparticle precursor from said electrochemical
deposition apparatus; and constructing a nanocellular foam from
said converted alloy nanoparticle precursor.
2. The method of claim 1, wherein said converted nanoparticle
precursor is an alloy of nickel and the metals deposited on the
precursor is at least one of aluminum (Al), cobalt (Co), chromium
(Cr), tungsten (W), rhenium (Re), tantalum (Ta), hafnium (Hf),
yttrium (Y), carbon (C), boron (B), zirconium (Zr).
3. The method of claim 2, wherein said alloy is an alloy of nickel
and aluminum.
4. The method of claim 1, wherein disposing a nanoparticle
precursor in an electrochemical deposition apparatus comprises:
disposing said nanoparticle precursor in a cathode pouch made from
mesh materials of said electrochemical deposition apparatus;
disposing said cathode pouch in an electrolyte solution; and
disposing an anode of the electrochemical deposition apparatus in
the electrolyte solution.
5. The method of claim 1, wherein disposing a nanoparticle
precursor in an electrochemical deposition apparatus comprises:
disposing said pure material nanoparticle precursor in a powder bed
hosted in a tubular housing element of said electrochemical
deposition apparatus; disposing an electrolyte solution in said
tubular housing element, such that said pure material nanoparticle
precursor is covered by said electrolyte solution; inserting a
cathode of said electrochemical deposition apparatus into said
tubular housing that contains the said pure material nanoparticle
precursor dispersed in the electrolyte; and disposing an anode of
said electrochemical deposition apparatus at least partially in
said electrolyte solution.
6. The method of claim 1, wherein the step of disposing a pure
material nanoparticle precursor in an electrochemical deposition
apparatus is performed during the step of operating said
electrochemical deposition apparatus, thereby at least partially
converting said pure material nanoparticle precursor into a
converted nanoparticle precursor, and comprises: passing said pure
material nanoparticle precursor through a powder feed of said
electrochemical deposition apparatus into a tank at least partially
filled with an electrolyte solution; allowing said pure material
nanoparticle precursor to pass between a cathode of said
electrochemical deposition apparatus and at least one anode of said
electrochemical deposition apparatus, wherein the cathode and the
at least one anode are at least partially submerged in said
electrolyte solution; allowing a particulate of at least pure
material nanoparticle precursor and connected nanoparticle
precursor to exit the tank; filtering the particulate, thereby
isolating the pure material nanoparticle precursor and the
converted nanoparticle precursor; and returning the pure material
nanoparticle precursor to the powder feed.
7. The method of claim 1, wherein the step of disposing a pure
material nanoparticle precursor in an electrochemical deposition
apparatus comprises: disposing the pure material nanoparticle
precursor in a powder bed of a cathode tube in a tank of said
electrochemical deposition apparatus; at least partially submerging
said cathode tube in an electrolyte solution disposed in said tank
such that the electrolyte solution intermixes with the pure
material nanoparticle precursor in the powder bed; and disposing an
anode of the electrochemical deposition apparatus at least
partially in the electrolyte solution.
8. The method of claim 1, wherein the step of operating said
electrochemical deposition apparatus comprises: providing a
positive charge to an anode of the electrochemical deposition
apparatus, providing a negative charge to a cathode of the
electrochemical deposition apparatus; allowing an electrolyte
solution to intermix with said pure material nanoparticle
precursor; and causing ions from the anode to be conducted through
the electrolyte solution and coat the pure material nanoparticle
precursor.
9. The method of claim 8, wherein causing ions from the anode to be
conducted through the electrolyte solution and coat the pure
material nanoparticle precursor causes the pure material
nanoparticle precursor to be converted into at least one of an
alloy nanoparticle precursor and a diffusion material nanoparticle
precursor.
10. The method of claim 9, wherein the allowing an electrolyte
solution to intermix with said pure material nanoparticle precursor
comprises at least one of allowing the electrolyte solution to flow
through a mesh structure of said cathode, allowing the electrolyte
solution to flow around a solid rotating cathode, and allowing the
electrolyte solution to flow through a tube cathode.
11. The method of claim 1, wherein said electrochemical deposition
apparatus utilizes at least one of an inorganic, organic,
metalorganic, and ionic liquid electrolyte containing ions of at
least one of aluminum (Al), cobalt (Co), chromium (Cr), tungsten
(W), rhenium (Re), tantalum (Ta), hafnium (Hf), yttrium (Y), carbon
(C), boron (B), zirconium (Zr).
12. The method of claim 11, wherein the liquid electrolyte is a
blend of at least two of an inorganic, organic, metalorganic, and
ionic liquid electrolyte.
13. An electrochemical deposition apparatus for converting a pure
material nanoparticle precursor into a converted nanoparticle
precursor comprising: a power source having a positive terminal
connected to an anode and a negative terminal connected to a
cathode; a storage component at least partially filled with an
electrolyte solution; a powder bed for retaining a nanoparticle
precursor, wherein the powder bed is disposed within said storage
component such that said electrolyte solution intermixes with a
nanoparticle precursor contained within said powder bed; and
wherein said anode is at least partially disposed in said
electrolyte solution, and wherein said cathode contacts at least a
portion of said nanoparticle precursor.
14. The electrochemical deposition apparatus of claim 13, wherein
said storage component is a tube, said powder bed is disposed in a
bend of said tube, and said cathode is inserted at least partially
into a nanoparticle particulate disposed in said powder bed.
15. The electrochemical deposition apparatus of claim 13, wherein
said storage component is a tank, and wherein said anode is at
least partially submerged in said electrolyte solution.
16. The electrochemical deposition apparatus of claim 15, wherein
said cathode comprises an electrically conductive mesh container,
and wherein said powder bed is disposed inside said electrically
conductive mesh container.
17. The electrochemical deposition apparatus of claim 15, wherein
said cathode comprises a rotatable cylinder having an internal
cavity, and wherein the powder bed is disposed in said internal
cavity.
18. The electrochemical deposition apparatus of claim 13, further
comprising a second anode connected to said power source, and
wherein said cathode is a rotatable cylinder disposed between said
anodes.
19. The electrochemical apparatus of claim 18, wherein said powder
bed is disposed beneath said cathode, and wherein said
electrochemical deposition apparatus further comprises a powder
feed disposed above said cathode, wherein said powder feed is
operable to feed a stream pure material nanoparticle precursor
between said cathode and at least one of said anodes.
20. A method for synthesizing a nanocellular foam comprising:
converting a base material nanoparticle precursor into a converted
nanoparticle precursor; constructing said nanocellular foam from
said converted nanoparticle precursor; and wherein converting a
base material nanoparticle precursor into a converted nanoparticle
precursor comprises converting the base material nanoparticle
precursor into an alloy material nanoparticle precursor and a
diffusion material nanoparticle precursor.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to U.S. Provisional
Application No. 61/969307 filed on Mar. 24, 2014.
TECHNICAL FIELD
[0002] The present disclosure relates generally to the preparation
of nanoparticles for nanocellular foams, and more specifically to
the preparation of alloy and diffusion material nanoparticles for
the synthesis of nanocellular foams via a sequential
electrochemical deposition and heat-treatment method.
BACKGROUND
[0003] Lightweight materials capable of handling high temperatures
with minimal adverse effects are desirable for both military and
commercial aircraft applications. One type of material that can be
utilized in such applications is a nanocellular foam.
[0004] In some examples, a nanocellular foam can be synthesized
from nanomaterials such as pure material nanoparticles. Pure
material based nanocellular foams necessarily include some
properties that are less than ideal. With previous materials, the
less than ideal properties were adjusted or compensated for via the
utilization of an alloy or a diffusion material instead of a pure
material. However, the traditional methods to prepare alloys from
pure materials may not be suitable for the synthesis of
nanocellular foams.
SUMMARY OF THE INVENTION
[0005] A method for preparing an alloy nanocellular foam according
to an exemplary embodiment of this disclosure, among other possible
things includes disposing a nanoparticle precursor in an
electrochemical deposition apparatus, operating the electrochemical
deposition apparatus, thereby at least partially coating the
nanoparticle precursor into a multiple composition nanoparticle
precursor, the coated nanoparticle precursor forms of an alloy
nanoparticle via a diffusion process conducted subsequent to the
coating process, removing the converted nanoparticle precursor from
the electrochemical deposition apparatus, and constructing a
nanocellular foam from said converted alloy nanoparticle
precursor.
[0006] In a further embodiment of the foregoing method, the
converted nanoparticle precursor is an alloy of nickel and the
metals deposited on the precursor is at least one of aluminum (Al),
cobalt (Co), chromium (Cr), tungsten (W), rhenium (Re), tantalum
(Ta), hafnium (Hf), yttrium (Y), carbon (C), boron (B), zirconium
(Zr).
[0007] In a further embodiment of the foregoing method, the alloy
is an alloy of nickel and aluminum.
[0008] A further embodiment of the foregoing method includes
disposing a nanoparticle precursor in an electrochemical deposition
apparatus includes, disposing the nanoparticle precursor in a
cathode pouch made from mesh materials of the electrochemical
deposition apparatus, disposing the cathode pouch in an electrolyte
solution, and disposing an anode of the electrochemical deposition
apparatus in the electrolyte solution.
[0009] A further embodiment of the foregoing method includes
disposing a nanoparticle precursor in an electrochemical deposition
apparatus includes, disposing the pure material nanoparticle
precursor in a powder bed hosted in a tubular housing element of
the electrochemical deposition apparatus, disposing an electrolyte
solution in the tubular housing element, such that the pure
material nanoparticle precursor is covered by the electrolyte
solution, inserting a cathode of the electrochemical deposition
apparatus into the tubular housing that contains the pure material
nanoparticle precursor dispersed in the electrolyte, and disposing
an anode of the electrochemical deposition apparatus at least
partially in the electrolyte solution.
[0010] In a further embodiment of the foregoing method, the step of
disposing a pure material nanoparticle precursor in an
electrochemical deposition apparatus is performed during the step
of operating the electrochemical deposition apparatus, thereby at
least partially converting the pure material nanoparticle precursor
into a converted nanoparticle precursor, and includes, passing the
pure material nanoparticle precursor through a powder feed of the
electrochemical deposition apparatus into a tank at least partially
filled with an electrolyte solution, allowing the pure material
nanoparticle precursor to pass between a cathode of the
electrochemical deposition apparatus and at least one anode of the
electrochemical deposition apparatus, the cathode and the at least
one anode are at least partially submerged in the electrolyte
solution, allowing a particulate of at least pure material
nanoparticle precursor and connected nanoparticle precursor to exit
the tank, filtering the particulate, thereby isolating the pure
material nanoparticle precursor and the converted nanoparticle
precursor, and returning the pure material nanoparticle precursor
to the powder feed.
[0011] In a further embodiment of the foregoing method, the step of
disposing a pure material nanoparticle precursor in an
electrochemical deposition apparatus includes, disposing the pure
material nanoparticle precursor in a powder bed of a cathode tube
in a tank of the electrochemical deposition apparatus, at least
partially submerging the cathode tube in an electrolyte solution
disposed in the tank such that the electrolyte solution intermixes
with the pure material nanoparticle precursor in the powder bed,
and disposing an anode of the electrochemical deposition apparatus
at least partially in the electrolyte solution.
[0012] In a further embodiment of the foregoing method, the step of
operating the electrochemical deposition apparatus includes
providing a positive charge to an anode of the electrochemical
deposition apparatus, providing a negative charge to a cathode of
the electrochemical deposition apparatus, allowing an electrolyte
solution to intermix with the pure material nanoparticle precursor,
and causing ions from the anode to be conducted through the
electrolyte solution and coat the pure material nanoparticle
precursor.
[0013] A further embodiment of the foregoing method includes
causing ions from the anode to be conducted through the electrolyte
solution and coat the pure material nanoparticle precursor causes
the pure material nanoparticle precursor to be converted into at
least one of an alloy nanoparticle precursor and a diffusion
material nanoparticle precursor.
[0014] A further embodiment of the foregoing method includes the
allowing an electrolyte solution to intermix with said pure
material nanoparticle precursor includes at least one of allowing
the electrolyte solution to flow through a mesh structure of the
cathode, allowing the electrolyte solution to flow around a solid
rotating cathode, and allowing the electrolyte solution to flow
through a tube cathode.
[0015] In a further embodiment of the foregoing method, the
electrochemical deposition apparatus utilizes at least one of an
inorganic, organic, metalorganic, and ionic liquid electrolyte
containing ions of at least one of aluminum (Al), cobalt (Co),
chromium (Cr), tungsten (W), rhenium (Re), tantalum (Ta), hafnium
(Hf), yttrium (Y), carbon (C), boron (B), zirconium (Zr).
[0016] In a further embodiment of the foregoing method, the liquid
electrolyte is a blend of at least two of an inorganic, organic,
metalorganic, and ionic liquid electrolyte.
[0017] An Electrochemical deposition apparatus for converting a
pure material nanoparticle precursor into a converted nanoparticle
precursor according to an exemplary embodiment of this disclosure,
among other possible things includes a power source having a
positive terminal connected to an anode and a negative terminal
connected to a cathode, a storage component at least partially
filled with an electrolyte solution, a powder bed for retaining a
nanoparticle precursor, the powder bed is disposed within the
storage component such that the electrolyte solution intermixes
with a nanoparticle precursor contained within the powder bed, and
the anode is at least partially disposed in the electrolyte
solution, and the cathode contacts at least a portion of the
nanoparticle precursor.
[0018] In a further embodiment of the foregoing electrochemical
deposition apparatus, the storage component is a tube, the powder
bed is disposed in a bend of the tube, and the cathode is inserted
at least partially into a nanoparticle particulate disposed in the
powder bed.
[0019] In a further embodiment of the foregoing electrochemical
deposition apparatus, the storage component is a tank, and the
anode is at least partially submerged in the electrolyte
solution.
[0020] In a further embodiment of the foregoing electrochemical
deposition apparatus, the cathode includes an electrically
conductive mesh container, and the powder bed is disposed inside
the electrically conductive mesh container.
[0021] In a further embodiment of the foregoing electrochemical
deposition apparatus, the cathode includes a rotatable cylinder
having an internal cavity, and the powder bed is disposed in the
internal cavity.
[0022] A further embodiment of the foregoing electrochemical
deposition apparatus, includes a second anode connected to the
power source, and the cathode is a rotatable cylinder disposed
between the anodes.
[0023] In a further embodiment of the foregoing electrochemical
deposition apparatus, the powder bed is disposed beneath the
cathode, and the electrochemical deposition apparatus includes a
powder feed disposed above the cathode, the powder feed is operable
to feed a stream pure material nanoparticle precursor between the
cathode and at least one of the anodes.
[0024] A method for synthesizing a nanocellular foam according to
an exemplary embodiment of this disclosure, among other possible
things includes converting a base material nanoparticle precursor
into a converted nanoparticle precursor, constructing the
nanocellular foam from the converted nanoparticle precursor, and
converting a base material nanoparticle precursor into a converted
nanoparticle precursor includes converting the base material
nanoparticle precursor into an alloy material nanoparticle
precursor and a diffusion material nanoparticle precursor.
[0025] The foregoing features and elements may be combined in any
combination without exclusivity, unless expressly indicated
otherwise.
[0026] These and other features of the present invention can be
best understood from the following specification and drawings, the
following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0027] FIG. 1 schematically illustrates a gas turbine engine.
[0028] FIG. 2A schematically illustrates a known electrochemical
deposition apparatus.
[0029] FIG. 2B schematically illustrates a portion of a cathode of
FIG. 2A after operation of the electrochemical deposition
apparatus.
[0030] FIG. 3 illustrates an example electrochemical deposition
apparatus.
[0031] FIG. 4 illustrates a second example electrochemical
deposition apparatus.
[0032] FIG. 5 illustrates a third example electrochemical
deposition apparatus.
[0033] FIG. 6 illustrates a fourth example electrochemical
deposition apparatus.
[0034] FIG. 7 illustrates a fifth example electrochemical
deposition apparatus.
DETAILED DESCRIPTION OF AN EMBODIMENT
[0035] FIG. 1 schematically illustrates an example machine, which
in this example is a gas turbine engine 20. It is to be understood
that the examples herein are not limited to gas turbine engines and
that other types of engines and machines may benefit from the
disclosed nanocelluar foam synthesis.
[0036] The gas turbine engine 20 is disclosed herein as a two-spool
turbofan that generally incorporates a fan section 22, a compressor
section 24, a combustor section 26 and a turbine section 28.
Alternative engines might include an augmentor section (not shown)
among other systems or features. The fan section 22 drives air
along a bypass flow path B in a bypass duct defined within a
nacelle 15, while the compressor section 24 drives air along a core
flow path C for compression and communication into the combustor
section 26 then expansion through the turbine section 28. Although
depicted as a two-spool turbofan gas turbine engine in the
disclosed non-limiting embodiment, it should be understood that the
concepts described herein are not limited to use with two-spool
turbofans as the teachings may be applied to other types of turbine
engines including three-spool architectures.
[0037] The exemplary engine 20 generally includes a low speed spool
30 and a high speed spool 32 mounted for rotation about an engine
central longitudinal axis A relative to an engine static structure
36 via several bearing systems 38. It should be understood that
various bearing systems 38 at various locations may alternatively
or additionally be provided, and the location of bearing systems 38
may be varied as appropriate to the application.
[0038] The low speed spool 30 generally includes an inner shaft 40
that interconnects a fan 42, a first (or low) pressure compressor
44 and a first (or low) pressure turbine 46. The inner shaft 40 is
connected to the fan 42 through a speed change mechanism, which in
exemplary gas turbine engine 20 is illustrated as a geared
architecture 48 to drive the fan 42 at a lower speed than the low
speed spool 30. The high speed spool 32 includes an outer shaft 50
that interconnects a second (or high) pressure compressor 52 and a
second (or high) pressure turbine 54. A combustor 56 is arranged in
exemplary gas turbine 20 between the high pressure compressor 52
and the high pressure turbine 54. A mid-turbine frame 57 of the
engine static structure 36 is arranged generally between the high
pressure turbine 54 and the low pressure turbine 46. The
mid-turbine frame 57 further supports bearing systems 38 in the
turbine section 28. The inner shaft 40 and the outer shaft 50 are
concentric and rotate via bearing systems 38 about the engine
central longitudinal axis A which is collinear with their
longitudinal axes.
[0039] The core airflow is compressed by the low pressure
compressor 44 then the high pressure compressor 52, mixed and
burned with fuel in the combustor 56, then expanded over the high
pressure turbine 54 and low pressure turbine 46. The mid-turbine
frame 57 includes airfoils 59 which are in the core airflow path C.
The turbines 46, 54 rotationally drive the respective low speed
spool 30 and high speed spool 32 in response to the expansion. It
will be appreciated that each of the positions of the fan section
22, compressor section 24, combustor section 26, turbine section
28, and fan drive gear system 48 may be varied. For example, gear
system 48 may be located aft of combustor section 26 or even aft of
turbine section 28, and fan section 22 may be positioned forward or
aft of the location of gear system 48.
[0040] The engine 20 in one example is a high-bypass geared
aircraft engine. In a further example, the engine 20 bypass ratio
is greater than about six (6), with an example embodiment being
greater than about ten (10), the geared architecture 48 is an
epicyclic gear train, such as a planetary gear system or other gear
system, with a gear reduction ratio of greater than about 2.3 and
the low pressure turbine 46 has a pressure ratio that is greater
than about five. In one disclosed embodiment, the engine 20 bypass
ratio is greater than about ten (10:1), the fan diameter is
significantly larger than that of the low pressure compressor 44,
and the low pressure turbine 46 has a pressure ratio that is
greater than about five (5:1). Low pressure turbine 46 pressure
ratio is pressure measured prior to inlet of low pressure turbine
46 as related to the pressure at the outlet of the low pressure
turbine 46 prior to an exhaust nozzle. The geared architecture 48
may be an epicycle gear train, such as a planetary gear system or
other gear system, with a gear reduction ratio of greater than
about 2.3:1. It should be understood, however, that the above
parameters are only exemplary of one embodiment of a geared
architecture engine and that the present invention is applicable to
other gas turbine engines including direct drive turbofans.
[0041] A significant amount of thrust is provided by the bypass
flow B due to the high bypass ratio. The fan section 22 of the
engine 20 is designed for a particular flight condition--typically
cruise at about 0.8 Mach and about 35,000 feet. The flight
condition of 0.8 Mach and 35,000 ft, with the engine at its best
fuel consumption--also known as "bucket cruise Thrust Specific Fuel
Consumption (`TSFC`)"--is the industry standard parameter of lbm of
fuel being burned divided by lbf of thrust the engine produces at
that minimum point. "Low fan pressure ratio" is the pressure ratio
across the fan blade alone, without a Fan Exit Guide Vane ("FEGV")
system. The low fan pressure ratio as disclosed herein according to
one non-limiting embodiment is less than about 1.45. "Low corrected
fan tip speed" is the actual fan tip speed in ft/sec divided by an
industry standard temperature correction of [(Tram .degree.
R)/(518.7.degree. R)]0.5. The "Low corrected fan tip speed" as
disclosed herein according to one non-limiting embodiment is less
than about 1200 ft/second.
[0042] It has previously been proposed to utilize nanoparticles to
construct components for the above described engine 20 from a
nanocellular foam. Existing synthesis techniques generate
nanocellular foams from a pure material, such as Nickel. While
operable, pure material nanocellular foams can have insufficient
performance, such as reduced strength and oxidation resistance,
reduced microstructural control, reduced oxidation and corrosion
resistance, reduced creep strength, reduced oxidation resistance,
and reduced grain boundary ductility. Traditionally, pure materials
have been combined with additional materials to form alloys, with
the alloys improving one or more of the poorly optimized aspects of
the pure material.
[0043] A method by which alloys or diffusion materials have been
formed is illustrated in FIG. 2A. FIG. 2A illustrates an
electrochemical process and apparatus 100 for the deposition of a
material layer onto a dissimilar material substrate. Subsequent
high-temperature treatment allows for the formation of an alloy or
diffusion material layer, the thickness of which depends on the
amount of the deposited material and post-deposition
high-temperature treatment conditions and duration. An exemplary
case includes the formation of a nickel-aluminum (Ni--Al) alloy.
Alternative alloys and diffusion materials can be generated
utilizing the same principle and apparatus. The illustrated
electrochemical deposition apparatus includes an anode 120
constructed of Aluminum, and a cathode 110 constructed of Nickel,
both submerged in an electrolyte 150 that is contained in a tank
140. The electrolyte 150 comprises a non-aqueous inorganic,
organic, metalorganic or ionic liquids and blends thereof
containing Aluminum and Aluminum complex ions. The anode 120 is
connected to a positive terminal of a direct current (DC) power
source 130. Similarly, the cathode 110 is connected to a negative
terminal of the power source 130. When power is supplied from the
power source 130 to the anode 120 and the cathode 110, the aluminum
ions are conducted through the electrolyte 150 to the cathode 110
and deposited on the surface of the cathode 110 via a reduction
reaction to form a coating 122. High temperature diffusion is
subsequently conducted to form an alloy composition.
[0044] In alternative systems, the aluminum is diffused into the
Nickel to create a Nickel-Aluminum diffusion material
(Nickel-Aluminide). One skilled in the art will recognize that
diffusion materials and alloys have different properties and are
suitable for different purposes, with the appropriate material for
any given application being determinable by one of skill in the
art, especially active metals hard to be prepared by other methods,
including but not limited to Al, Mg, and Cr, etc.
[0045] FIG. 2B schematically illustrates a portion of the cathode
110 with an Aluminum coating 122. In the portion of the cathode
immediately interior to the Aluminum coating 122, the Nickel of the
cathode 124 has bonded with the Aluminum. In this way, the
electroplating process forms a Nickel Aluminum alloy.
Alternatively, other alloys using other metals can be created
according to similar processes.
[0046] Nanoparticle precursors used for the synthesis of a
nanocellular foam are in the form of a powder. Since the above
described electrochemical deposition apparatus and process requires
use of a bulk solid cathode component, it cannot be employed on
nanoparticle precursor powders to form alloy or diffusion material
nanoparticles.
[0047] FIG. 3 illustrates a first example electrochemical
deposition apparatus 200 for creating nanoparticle alloys and
nanoparticle diffusion materials from a nanoparticle precursor. As
with the electrochemical deposition apparatus 100 of FIG. 2, the
electrochemical deposition apparatus of FIG. 3 utilizes a tank 240,
with an electrolyte solution 250 at least partially filling the
tank 240. An anode 220 constructed of the coating material is
disposed partially in the electrolyte solution 250. In alternative
examples, the anode 220 can be fully submerged in the electrolyte
solution 250.
[0048] A cathode 210 constructed of an electrically conductive
porous material is also disposed partially in the electrolyte
solution 250. The porous material forms a pouch to house
nanoparticle precursors. Contained within the mesh or porous
cathode 210 is nanoparticles 260. The nanoparticles 260 are fully
submerged in the electrolyte solution 250, and the electrolyte
solution is allowed to intermix throughout the powder 260.
[0049] A power source 230 is connected to each of the anode 220 and
the cathode 210, with the positive terminal of the power source 230
being connected to the anode 220 and the negative terminal of the
power source being connected to the cathode 210.
[0050] FIG. 4 illustrates an alternative electrochemical
disposition apparatus 300 for creating nanoparticle alloys and
nanoparticle diffusion materials. The apparatus of FIG. 4 utilizes
a tube 340 including a bend region 342. Nanoparticles powder 360 is
disposed in the bend portion 342. The tube 340 is then partially
filled with an electrolyte solution 350, with the electrolyte
solution 350 at least covering and intermixing with the pure
material nanoparticles 360.
[0051] A cathode 310 is inserted into the tube and at least
partially inserted into the bend portion 342 such that the cathode
310 is disposed partially in the powder 360. An anode 320 is
inserted into the tube 340 and at least partially disposed in the
electrolyte solution 350, with the anode 320 being entirely outside
of the pure material nanoparticles 360. Each of the cathode 310 and
the anode 320 are connected to a power source 330 as in the example
of FIG. 3.
[0052] During operation, power is provided from the power source
330 to the anode 320 and the cathode 310. The anode material (for
example Aluminum) oxidizes to form cations in the electrolyte 350.
The cations are then directed towards the cathode 310. Because the
pure material nanoparticles 360 are intermixed with the electrolyte
350, the cations are carried into contact with the pure material
nanoparticles 360 as they are being drawn towards the cathode 310.
The cations are then reduced onto the nanoparticles to form a
material layer deposit. Multiplicity of material layers can be
electrodeposited onto the pure material nanoparticles by
sequentially employing the above described method. Subsequent
high-temperature treatment of the coated nanoparticles produces the
desired binary or multi-component alloy or diffusion material
nanoparticles, which can be used to synthesize a nanocellular
foam.
[0053] FIG. 5 illustrates a third alternative electrochemical
deposition apparatus 400. As with the example of FIG. 3, the
electrochemical deposition apparatus 400 includes a tank 440 with
an electrolyte fluid 450 at least partially filling the tank.
Disposed within the tank 440, and partially submerged by the
electrolyte fluid is a cathode 410 and two anodes 420. The cathode
410 is an electrically conductive cylinder that is capable of
rotating within the tank 440. Adjacent and partially surrounding
the cathode 410 are two conforming anodes 420. The anodes 420
remain stationary during operation of the electrochemical
deposition device.
[0054] Disposed generally above the cathode 410 is a powder feed
470 that feeds a pure material nanoparticle 460 powder into the
tank 440. The powder falls between the cathode 410 and the anodes
420. As the nanoparticle powder 460 falls onto the cathode 410 the
powder 460 makes electrical contact with the cathode 410 allowing
for electrodeposition of the desired material onto the pure
material nanoparticles or nanoparticle precursors 460. As with the
previous examples, when electrical power is supplied with positive
potential to the anodes 420 and negative potential to the cathode
410, metals are deposited onto the nanoparticle material 460.
[0055] The particulate from the powder feed passes down to a
particulate exit 472. Electrolyte solution 450 is drawn through the
particulate exit 472 via a pump 474. The electrolyte solution 450
including the particulate is passed to a filter 476. The filter 476
is used to collect the coated powder when sufficient amount of
metals are deposited. If insufficient material is deposited, the
plating process can be repeated on the powder by recirculating the
powder back to 470. The electrolyte solution is recirculated back
into the tank 440 via a recirculation line 478
[0056] If the powder feed 470 is provided with a constant source of
pure material nanoparticles precursors the apparatus 400 can
continuously operate and produce electroplated or coated
nanoparticles more efficiently than the examples of FIGS. 3 and
4.
[0057] FIG. 6 illustrates a fourth example electrochemical
deposition apparatus 500. In the example of Figure, an anode 520 is
inserted at least partially into an electrolyte solution disposed
in a tank 540. A powder bed is disposed in the electrolyte 550, and
contained within a mesh 562. The mesh 562 is partially submerged
into the electrolyte 550. A cathode tube 510 is located above the
powder bed, and is at least partially submerged in the electrolyte
solution. The cathode tube 510 rotates in a rotation direction 580
about an axis defined by the cathode tube 510. As the cathode 510
is rotated, the nanoparticles 560 are disturbed, and the
electrolyte solution 550 is caused to intermix with the
nanoparticles 560.
[0058] FIG. 7 illustrates a fifth example electrochemical
deposition apparatus 600. As with the apparatus 500 of FIG. 6, an
anode 620 is inserted at least partially into an electrolyte
solution disposed in a tank 640. A powder bed is disposed in the
electrolyte solution and contained within a mesh 662. A cathode
tube 610 is positioned above the powder bed and is at least
partially submerged in the electrolyte solution. The cathode tube
610 rotates in a rotation direction 680 about an axis defined by
the cathode tube 610. As the cathode tube 610 is rotated, the
nanoparticles 660 are disturbed and the electrolyte solution 650 is
caused to intermix with the nanoparticles 660.
[0059] With reference to the examples of FIGS. 6 and 7, when a
positive potential is applied to the anode 520 and 620, and a
negative potential is applied to the cathode 510, 610, ions of the
anode material are caused to conduct through the electrolyte
solution 550, 650 toward the cathode 510, 610. As a result of the
conduction, and the electrolyte solution 550, 650 intermixing with
the nanoparticles 560, 660, the nanoparticles 560 and 660 are
converted into the coated powder.
[0060] Once the pure material nanoparticles have been plated and
subsequently heat-treated and converted into an alloy or diffusion
material according to any of the above described processes, the
converted nanoparticles can be utilized to synthesize a
nanocellular foam according to any known process. Furthermore, the
above described apparatuses and processes may be utilized as a
partial step in the preparation of nanoparticle precursors for the
synthesis of nanocellular foam
[0061] While the above discussed apparatus and method is described
generally with regards to a Nickel Aluminum alloy, one of skill in
the art will understand that the disclosed principles can also be
applied to alternative Nickel based allows including alloys that
are a combination of Nickel and at least one of Aluminum (Al),
Cobalt (Co), Chromium (Cr), Tungsten (W), Rhenium (Re), Tantalum
(Ta), Hafnium (Hf), Yttrium (Y), Carbon (C), Boron (B), Zirconium
(Zr). In alternative examples any other suitable material can be
alloyed with a base nanomaterial according to the above
description. Furthermore, the above description describes the
utilization of a pure material nanoparticle. One skilled in the
necessary art will understand that "pure material nanoparticle"
refers to the original base material, and is not limited to only
base materials of a single element.
[0062] It is further understood that any of the above described
concepts can be used alone or in combination with any or all of the
other above described concepts. Although an embodiment of this
invention has been disclosed, a worker of ordinary skill in this
art would recognize that certain modifications would come within
the scope of this invention. For that reason, the following claims
should be studied to determine the true scope and content of this
invention.
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