Abstract: The invention relates to a method that involves (a) removing graphite from at least one surface of a metal graphite composite material; (b) chemically cleaning or plasma etching the surface of the metal graphite composite material; (c) applying a metal-containing material to the surface of the chemically cleaned or plasma etched metal graphite composite material, and thereby forming an intermediate layer; (d) applying a metal coating on the intermediate layer, and thereby forming a composite material. The invention also relates to a composite material comprising (a) a metal graphite composite substrate having at least one surface that is substantially free of graphite; (b) a metal-containing intermediate layer located on a surface of the substrate; and (c) a metal coating on the intermediate layer.

Abstract: The invention relates to a method that involves (a) removing graphite from at least one surface of a metal graphite composite material; (b) chemically cleaning or plasma etching the surface of the metal graphite composite material; (c) applying a metal-containing material to the surface of the chemically cleaned or plasma etched metal graphite composite material, and thereby forming an intermediate layer; (d) applying a metal coating on the intermediate layer, and thereby forming a composite material. The invention also relates to a composite material comprising (a) a metal graphite composite substrate having at least one surface that is substantially free of graphite; (b) a metal-containing intermediate layer located on a surface of the substrate; and (c) a metal coating on the intermediate layer.

Abstract: The invention relates to a method that involves (a) removing graphite from at least one surface of a metal graphite composite material; (b) chemically cleaning or plasma etching the surface of the metal graphite composite material; (c) applying a metal-containing material to the surface of the chemically cleaned or plasma etched metal graphite composite material, and thereby forming an intermediate layer; (d) applying a metal coating on the intermediate layer, and thereby forming a composite material. The invention also relates to a composite material comprising (a) a metal graphite composite substrate having at least one surface that is substantially free of graphite; (b) a metal-containing intermediate layer located on a surface of the substrate; and (c) a metal coating on the intermediate layer.

Abstract: A process for manufacturing a soluble casting core for use in casting complex shaped metal matrix composite components. The soluble casting core is generated by a sequence of steps which provide a molten slurry mixture composed of an alkali metal salt such as sodium carbonate and a plurality of ceramic particulates such as magnesium oxide dispersed therein. After heating and mixing the slurry mixture is solidified in a mold pattern to form a casting core configured to generate a complex shaped component during a casting process. The soluble casting core is used for casting molten metal alloys therein, without failure of the casting surfaces and forming of a complex shaped metal matrix composite component. The soluble casting core is readily dissolved and separated from the soluble casting core by immersing the core mold in heated water and/or exposing to steam, without damage to the metal matrix composite component.

Abstract: A process for manufacturing a soluble casting core for use in casting complex shaped metal matrix composite components. The soluble casting core is generated by a sequence of steps which provide a molten slurry mixture composed of an alkali metal salt such as sodium carbonate and a plurality of ceramic particulates such as magnesium oxide dispersed therein. After heating and mixing the slurry mixture is solidified in a mold pattern to form a casting core configured to generate a complex shaped component during a casting process. The soluble casting core is used for casting molten metal alloys therein, without failure of the casting surfaces and forming of a complex shaped metal matrix composite component. The soluble casting core is readily dissolved and separated from the soluble casting core by immersing the core mold in heated water and/or exposing to steam, without damage to the metal matrix composite component.

Abstract: The invention relates to a method that involves (a) removing graphite from at least one surface of a metal graphite composite material; (b) chemically cleaning or plasma etching the surface of the metal graphite composite material; (c) applying a metal-containing material to the surface of the chemically cleaned or plasma etched metal graphite composite material, and thereby forming an intermediate layer; (d) applying a metal coating on the intermediate layer, and thereby forming a composite material. The invention also relates to a composite material comprising (a) a metal graphite composite substrate having at least one surface that is substantially free of graphite; (b) a metal-containing intermediate layer located on a surface of the substrate; and (c) a metal coating on the intermediate layer.

Abstract: A spray deposition apparatus comprises a source of aqueous fiber slurry that includes a mixture of milled graphite fibers in suspension. A slurry input of the spray deposition apparatus is coupled to the source of aqueous fiber slurry. The slurry input receives the mixture of aqueous fiber slurry. A gas pressure input receives pressurized gas. A nozzle aspirates the mixture of aqueous fiber slurry with the pressurized gas to produce a stream of fiber cluster droplets.