Tony Stark was nearly replaced as Iron Man by his own sentient armor, as Ultron once unleashed a powerful virus that gave one of the hero's suits its own consciousness as it nearly killed its maker. In Iron Man (1998) from Marvel Comics, the Ultron Imperative was accidentally uploaded into one of Tony Stark's armors, leading it to become sentient and rise up against its creator. The suit nearly ended Tony Stark's life, as Ultron's virus created a powerful new villain for Iron Man to deal with.
Iron Man has let his own tech be used against more times than he'd like to admit, as the hero's inventions have consistently fallen into the wrong hands. Whether it's Zeke Stane repurposing his armor to get revenge for his father, Stark's designs leading to multiple villains suiting up in advanced armor during the Armor Wars arc, or carelessly giving HYDRA agent Veronica Eden access to S.H.I.E.L.D., Iron Man has inadvertently created and helped arm several villains. However, one of the strangest villains he ever faced off against was a Sentient suit of armor that had been infected by a virus from Ultron that nearly replaced him.
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In Iron Man #26-31 by Joe Quesada, Sean Chen, Alitha Martinez, Steve Oliff, Frank Tieri, Rob Hunter, and Comicraft's Troy Peteri and Richard Starkings, one of Tony Stark's suits of armor had gained its own A.I. after Jacosta, Iron Man's android assistant (originally built by Ultron) was temporarily uploaded into it after her usual body was destroyed. However, it was secretly infected with the Ultron Imperative virus, leading it to become sentient. After briefly serving as a sidekick to Iron Man, the sentient suit of armor tries to kill
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