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Abstract

A method for preparing cast composite materials of nonmetallic carbide particles in a metallic matrix, wherein the particles are roasted and then mixed into a molten metallic alloy to wet the molten metal to the particles, and the particles and metal are sheared past each other to promote wetting of the particles by the metal. The particles are roasted in air or other source of oxygen to remove the carbon from the near-surface region of the particles and to produce an oxide surface diffusion barrier, resulting in a reduction of carbide formation in the molten matrix. The mixing occurs while minimizing the introduction of gas into the mixture, and while minimizing the retention of gas at the particle-liquid interface. Mixing is done at a maximum temperature whereat the particles do not substantially chemically degrade in the molten metal during the time required for processing, and casting is done at a temperature sufficiently high that there is no solid metal present in the melt.

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First Claim