Abstract:
The present invention relates to a novel process for forming net or near net-shape metal matrix composite bodies. Particularly, a molten matrix metal is in contact with a filler material or a preform in the presence of a reactive atmosphere, at least at some point during the process, which permits molten matrix metal to react, at least partially or substantially completely, with the reactive atmosphere, thereby causing molten matrix metal to infiltrate the filler material or preform due to the creation of a self-generated vacuum. Forming a glassy seal on the reaction system, the self-generated vacuum infiltration occurs without the application of any external pressure or vacuum. The molten matrix metal infiltrates the filler material up to at least a portion of a provided barrier means.
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 contracting 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:
A process for producing high-strength, substantially nonporous alloys by means of a three-component mixture, including admixing a first component of one or more low-melting temperature metals or alloys thereof, a second component of one or more high-melting temperature metals or alloys thereof, and a substantially inert third component of one or more refractory compounds, subjecting the mixture to changes in temperature so as to form a mixture capable of being shaped at a temperature well below the melting or decomposition temperature of the highest melting metal and the inert refractory compound.
Abstract:
The present invention relates to the formation of a metal matrix composite body by the spontaneous infiltration of a molten matrix metal into a three-dimensionally interconnected material. Moreover, the three-dimensionally interconnected material may contain filler material within at least a portion of its porosity. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material and/or a three-dimensionally interconnected material and/or a matrix metal at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the three-dimensionally interconnected material and any filler material contained within at least a portion of the porosity of the three-dimensionally interconnected material.
Abstract:
This invention relates generally to materials and processes for making materials and, more particularly, to high performance boride dispersion strengthened materials, including alloy-modified, boride dispersion strengthened materials and techniques for making such materials.
Abstract:
A method is taught for the introduction of in-situ precipitated second phase materials, such as ceramic or intermetallic particles in a metal matrix, to a host metal. When an initial solvent-assisted reaction is utilized, metal-second phase composites having highly superior properties may be obtained. The invention may utilize the reaction of the second phase-forming constituents in a solvent metal medium to provide an intermediate material of finely-dispersed second phase particles in an intermediate metal matrix, in the form of a porous mass or sponge. Any desired loading of second phase in the final composite may be achieved by the admixture of this preformed intermediate material having a relatively high content of particulate material, with a molten host metal. Exemplary materials include titanium diboride in an aluminum matrix and titanium carbide in an aluminum matrix.
Abstract:
This invention relates to a composite material comprising an in-situ precipitated second phase in an intermetallic matrix, and to the process for making such a composite.
Abstract:
A method for improving the reliability of a ceramic-metal joint by reducing the dynamic mismatch stresses and strains on the ceramic due to the mismatch in thermal expansions of the two materials. This is done by bonding with a metal layer the ceramic to metal to form a bonding interfacial region between the ceramic and metal; and radially grading the interface region the thermal conductivity, thermal expansion coefficient, or tensile strength of the metal layer. An article in the form of a laterally graded, metallic bonding disc for overcoming problems of dynamic mismatch stresses and strains is also disclosed and claimed.
Abstract:
An aluminum metal matrix composite comprises an aluminum metal matrix embedding a second filter, such as a ceramic second filler, and is formed by contacting, for example, a molten aluminum metal with a permeable mass of second filler within a ceramic impervious mold formed by growing a polycrystalline oxidation reaction product into a first filler. By hermetically sealing the second filler within the mold with a body of molten aluminum metal, the latter spontaneously infiltrates the mass of second filler at moderate temperatures, e.g. about 900.degree. C., without need of any other infiltration expedients. The molten mass containing the infiltrated ceramic filler is solidified to provide the metal matrix composite which may be recovered from the mold. Optionally, the solidification is carried out under bonding conditions including maintaining the solidifying material in direct contact with the ceramic mold, to provide the metal matrix composite joined to the mold, or a part thereof, as a structural component.
Abstract:
A process is described for making a composite article without shrinkage, particularly of ceramic and metal wherein the article includes complex internal surfaces or cavities. The process requires forming an insert body that includes an external surface that corresponds to an internal cavity of the article. The insert body consists of a material having a melting temperature less than that of the article. The process further requires forming a porous compact about the insert body wherein the compact is formed into the substantially the net shape of the article. The compact is made of a material that is wetted by liquid insert material and has a sintering temperature greater than the wetting temperature of the insert material. The process further requires heating the article to a temperature such that the inserts substantially melts and infiltrates the porous compact forming the finished composite article. The process produces products including complex internal surfaces without the necessity of costly and sometimes technically difficult internal machining operations.