Abstract: Self-supporting bodies are produced by reactive infiltration of a parent metal into a boron donor material and a carbon donor material. The reactive infiltration typically results in a composite comprising a boron-containing compound, a carbon-containing compound and residual metal, if desired. The mass to be infiltrated may contain one or more inert fillers admixed with the boron donor material and carbon donor material. The relative amounts of reactants and process conditions may be altered or controlled to yield a body containing varying volume percents of ceramic, metal, ratios of one ceramic to another and porosity.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and novel metal matrix composite bodies produced thereby. Particularly, a polycrystalline oxidation reaction product of a parent metal and an oxidant is first formed. The polycrystalline oxidation reaction product is thereafter comminuted into an appropriately sized filler material which can be placed into a suitable container or formed into a preform. The filler material or preform of comminuted polycrystalline oxidation reaction product is thereafter placed into contact with a matrix metal alloy in the presence of an infiltration enhancer, and/or an infiltration enhancer precursor and/or an infiltrating atmosphere, at least at some point during the process, whereupon the matrix metal alloy spontaneously infiltrates the filler material or preform. As a result of utilizing comminuted or crushed polycrystalline oxidation reaction product, enhanced infiltration (e.g., enhanced rate or amount) is achieved.

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: The present invention relates to the use of a gating means in combination with a spontaneous infiltration process to produce a metal matrix composite body. Particularly, a permeable mass of filler material or a preform is spontaneously infiltrated by molten matrix metal to form a metal matrix composite body. A gating means is provided which controls or limits the areal contact between molten matrix metal and the filler material or preform. The use of a gating means provides for control of the amount of matrix metal which can contact the preform or filler material, which may result in less machining of a formed metal matrix composite body compared with a similar metal matrix composite body made without a gating means, moreover, the use of a gating means ameliorates the tendency of a formed metal matrix composite body to warp due to the contact between the formed composite body and matrix metal carcass.

Abstract: The present invention relates to a novel method for forming a metal matrix composite body, and products produced thereby. Particularly, a permeable mass of filler material is formed into a preform, the preform having at least a portion thereof which contains a cavity. An infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the preform when the preform is placed into molten matrix metal. An infiltrating atmosphere is provided in communication with the cavity in the preform for at least a portion of the process, and molten matrix metal is contacted with an exterior portion of the preform, such that molten matrix metal will spontaneously infiltrate the preform from an exterior surface thereof toward the cavity.

Abstract: The present invention relates to a novel method of manufacturing a composite body, such as a ZrB.sub.2 --ZrC--Z composite body, by utilizing a post-treatment technique. Moreover, the invention relates to novel products made according to the process. The novel process modifies at least a portion of a composite body by exposing said body to a source of second metal.

Abstract: The present invention relates to the formation of a metal matrix composite body by a spontaneous infiltration technique and thereafter thermo-forming the produced metal matrix composite body. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. After formation of the metal matrix composite body, the body is subjected to a thermo-forming technique such as rolling, extruding, die casting, pressing, etc.

Abstract: The present invention relates to forming a a metal matrix composite between at least two bodies having a similar or a different chemical composition, the metal matrix composite functioning as a bonding means which to bonds or fixes the bodies together. Particularly, a metal matrix composite is produced by a spontaneous infiltration technique by providing a filler material or preform with an infiltration enhancer and/or an infiltration enhancer precursor and/or and infiltrating atmosphere, which are in communication with the filler material or preform at least at some point during the process. Molten matrix metal then spontaneously infiltrates the filler material or preform, whereby the metal matrix composite serves to bond together two or more bodies.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies, and the metal matrix composite bodies produced according to the novel method. Particularly, a permeable mass of filler material is formed into a preform by first forming a negative cavity in a matrix metal and thereafter placing said permeable mass of filler material into said cavity. 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 along the process, which permit 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.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. The preform material can then be floated onto the surface of or into a matrix metal alloy, whereupon the matrix metal alloy spontaneously infiltrates the preform. After substantial complete infiltration of the preform, the preform begins to at least partially sink into the matrix metal alloy supply. The matrix metal which has infiltrated the preform is then allowed to cool, thus forming a metal matrix composite body.

Abstract: The present invention relates to modifying the properties of a metal matrix composite body by a post formation process treatment and/or a substantially contiguous modification treatment. The post formation process treatment may be applicable to a variety of metal matrix composite bodies produced by various techniques, and is particularly applicable to modifying the properties of a metal matrix composite body produced by a spontaneous infiltration technique. The substantially contiguous modification process may also be used primarily in conjunction with metal matrix composite bodies produced according to a spontaneous infiltration technique. Particularly, at least a portion of the matrix metal of the metal matrix composite body and/or the filler material of the metal matrix composite body is modified or altered during and/or after the formation process.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. A permeable mass of filler material is spontaneously infiltrated by a molten matrix metal. Particularly, an infiltration enhancer and/or infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material. After infiltration has been completed to a desired extent, additional matrix metal is added to that matrix metal which has spontaneously infiltrated the filler material to result in a suspension of filler material and matrix metal, said suspension having a lower volume fraction of filler relative to matrix metal. The matrix metal then can be permitted to cool in situ or the mixture of matrix metal and filler material can be poured into a second container as a casting process to form a desired shape which corresponds to the second container.

Abstract: The present invention relates to the formaton of metal matrix composite bodies by a spontaneous infiltration technique, and novel metal matrix composite bodies produced according to the method. An ingot of matrix metal is surrounded by a permeable mass of filler matrial. 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 permit the shaped ingot of matrix metal, when made molten, to spontaneously infiltrate the surrounding permeable mass of filler material. After the spontaneous infiltration, a metal matrix composite body is produced having therein a cavity which substantially corresponds in shape to the original ingot of matrix metal.

Abstract: A method of producing shaped, self-supporting ceramic bodies includes preparing a mold by applying a permeable, conformable material to a shape-defining surface of an expendable pattern. The permeable, conformable material, when set or stable, provides a mold with a shaped surface which is defined by, and is therefore substantially congruent to, the shape-defining surface. Upon heating, the material of the expendable pattern combusts or volatilizes and thus establishes the shaped cavity mold. A molten parent metal is then vaporized with a vapor-phase oxidant in such a manner as to form a ceramic body which grows into the mold cavity, and is shaped by it. The ceramic body is recovered from the mold having a shaped surface replicating the shape-defining surface of the expendable pattern.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. An infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the preform when the preform is placed into the molten matrix metal. A means for maintaining the preform at least partially below the surface of the molten matrix metal can also be utilized.

Abstract: There is disclosed a method of producing a self-supporting ceramic composite body having therein at least one cavity which inversely replicates the geometry of an expendable pattern. The method includes the steps of surrounding the expendable pattern with a filler material to thereby form a filled cavity within the filler material. The expendable pattern is chemically or physically removed from the filler material and a quantity of a parent metal is put into the cavity. The parent metal is heated to a temperature above its melting point and an oxidation reaction process begins whereby the oxidation reaction product infiltrates and embeds the surrounding filler material. Excess filler material and/or excess parent metal are removed, thus resulting in a self-supporting ceramic composite body having a cavity in the shape of the expendable pattern.

Abstract: An aluminum metal matrix composite comprises an aluminum metal matrix embedding a second filler, 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.

Abstract: A method for producing a self-supporting ceramic composite structure which includes a ceramic matrix embedding a filler, includes oxidizing a parent metal to form a polycrystalline material comprising the oxidation reaction product of the parent metal with an oxidant and, optionally, one or more metallic constituents, and the filler embedded by the matrix. The method includes heating a first source of molten parent metal and a source of molten parent metal and contacting the first source of molten parent metal with a permeable bedding of filler. The first source of molten parent metal is reacted with the oxidant to form the oxidation reaction product and is replenished from the reservoir as the reacting continues for a time sufficient to grow the oxidation reaction product to a desired extent and thereby embed at least a portion of the bedding of filler within the oxidation reaction product to form the ceramic composite structure.

Abstract: A method of producing shaped, self-supporting ceramic bodies includes preparing a mold by applying a gas-permeable, conformable material to a shape-defining surface of a shaped parent metal. The gas-permeable material, when set or stable, provides a mold with a shaped surface which is defined by, and is therefore substantially congruent to, the shape-defining surface. Upon heating, the parent metal melts and flows from the mold into a receptacle without disturbing the mold. Oxidation reaction product is then grown by oxidation of the molten parent metal with a vapor-phase oxidant to form an oxidation reaction product which grows into the mold cavity and is shaped by it. A ceramic body is recovered from the mold and has substantially the same shape as the pattern section of the original shaped parent metal.

Abstract: The invention relates to ceramic composite articles formed by infiltration of a particulate, permeable bed or permeable preform with a polycrystalline matrix a metal-oxidant reaction product. The bed or preform includes a dross material.