Abstract:
The present invention relates to a novel process for removal of at least a portion of at least one metallic component of a metallic constituent from a multi-phase composite body. Particularly, by providing at least one of an infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere to be in communication with a permeable mass, which contacts at least a portion of a composite body, said metallic component of the composite body, when made molten, is caused to spontaneously infiltrate the permeable mass. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum. The metallic constituent is essentially leached or removed from the multi-phase body by spontaneous infiltration.
Abstract:
A method of making a composite material consists of entraining finely divided solid additive particles in a stream of ionized inert gas and ionizing the inert gas and utilizing heat generated by the ionized gas to heat the solid particles to a high temperature which is less than the temperature in at which the solid particles become non-solid due to melting sublimination or dissociation. Then, injecting the stream of gas and entrained heated solid particles into a molten metal mass to provide a mixture of finely divided solid particles and molten metal and thereafter causing physical agitation of the mixture of molten metal and solid particles to establish a substantially uniform distribution of solid particles in the molten metal. Such physical agitation of molten metal is continued until the mixture of finely divided particles and metals is completely solidified.
Abstract:
The present invention relates to novel ceramic-filled metal matrix composites and methods for making the same. Particularly, a permeable mass of filler material is spontaneously infiltrated by, for example, an aluminum alloy, in the presence of nitrogen-containing atmosphere. A reservoir feeding technique for forming metal matrix composite bodies is also disclosed. The reservoir feeding technique can also be used to form complex (e.g., a metal bonded to a metal matrix composite) metal matrix composite bodies.
Abstract:
A silver-metal oxide composite material comprising a silver matrix, (a) from 1 to 20% by weight, in terms of elemental metal, of an oxide of at least one element selected from the group consisting of Sn, Cd, Zn and In and, optionally, (b) an oxide of Mg, Zr, etc. and/or (c) an oxide of Cd, Sb, etc.; the oxides being dispersed in the form of fine particles with a particle size of not more than about 0.1 .mu.m uniformly and being bound to the silver matrix with no space left, and a process for producing the same. The composite material is excellent in physical and chemical strengths at high temperatures. The process can produce the composite product even with thick walls, within a markedly short time in high productivity. The composite material is useful as electrical contact materials and electrode materials for electric welding.
Abstract:
A net shaped ceramic-reinforced aluminum matrix composite is formed by forming a permeable mass of ceramic material with a defined surface boundary having a barrier, and contacting a molten aluminum-magnesium alloy with the permeable mass of ceramic material in the presence of a gas comprising from about 10 to 100% nitrogen, by volume, balance nonoxidizing gas, e.g. hydrogen or argon. Under these conditions, the molten alloy spontaneously infiltrates the ceramic mass under normal atmospheric pressures until it reaches the barrier. A solid body of the alloy can be placed adjacent to a permeable bedding of ceramic material having a barrier, and brought to the molten state, preferably to at least about 700.degree. C., in order to form the net shape aluminum matrix composite by infiltration. In addition to magnesium, auxiliary alloying elements may be employed with aluminum. The resulting composite products may contain a discontinuous aluminum nitride phase in the aluminum matrix.
Abstract:
Metal matrix composites are manufactured in a vacuum die casting machine. Solid aggregate material, at least 65 volume percent, is placed in a die, the die is evacuated and heated, and molten metal is driven by a piston to infiltrate the solid aggregate material where it subsequently solidifies to form a metal matrix composite.
Abstract:
A method for coating a ceramic with a strong, adherent, substantially defect-free, and thermomechanically shock resistant metallized layer for practical use at over 630.degree. C. comprising selecting a ceramic metallizing composition; preparing the composition by proportioning the differing sizes of the mixed ingredients to have gravitationally substantially nonsegregating qualities when applied onto said ceramic; coating the ceramic with the metallizing composition; heating the coated ceramic surface to achieve ceramic metallization; and keeping the composition molten sufficiently long time to form the required metallized layer.
Abstract:
A method for preparing a composite material comprises the steps of providing a first mixture of a molten aluminum-base matrix alloy having at least about 4 percent by weight magnesium, and a mass of discontinuous reinforcing particles that are not soluble in the molten matrix alloy, and mixing the first mixture to wet the matrix alloy to the particles and to distribute the particles throughout the volume of the molten matrix alloy. The first matrix alloy is diluted to reduce the magnesium content of the mixture to less than about 4 percent by weight magnesium, to produce a second mixture, and the second mixture is cast. The second mixture has at least about 5 volume percent particles, and preferably has about 5-25 volume percent particles.
Abstract:
A method for forming metallized coatings on ceramics for high-temperature uses above about 630.degree. C. comprising the steps of: preparing a metallizing composition of mixed ingredients of differing sizes, proportioning the differing sizes to have nonsegregating qualities when applied onto the ceramics, coating the metallizing composition on the ceramics and heating to form the desired metallized layers.
Abstract:
The present invention relates to a novel method for forming metal matrix composite bodies and the novel products produced therefrom. A negative shape or cavity, which is complementary to the desired metal matrix composite body to be produced, is first formed. The formed cavity is thereafter filled with a permeable mass of filler material. Molten matrix metal is then induced to spontaneously infiltrate the filled cavity. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the filler material, at least at some point during the process, which permits the matrix metal, when made molten, to spontaneously infiltrate the permeable mass of filler material, which at some point during the processing, may become self-supporting. In a preferred embodiment, cavities can be produced by a process which is similar to the so-called lost-wax process.