Abstract: A metal matrix composite (MMC), such as a brake drum, includes a preform having ceramic particles and ceramic fibers and defining a plurality of voids. The metal matrix composite also includes a support element, such as a metal, disposed within the voids of the preform. The MMC has a wear surface defined by both the preform and the support element.

Abstract: A method of forming a metal matrix composite (MMC),such as a brake drum, by impregnating a preform, which is formed of ceramic particles and ceramic fibers, with a support element, such as a metal. The MMC has a wear surface defined by both the preform and the support element.

Abstract: A ceramic article comprises ceramic fibers having an aspect ratio of greater than or equal to 10:1, ceramic particles, and an inorganic binder comprising silica. Greater than 90 out of 100 ceramic fibers are randomly oriented in three dimensions in the ceramic article, and greater than 85 out of 100 ceramic fibers are spaced at least one ceramic fiber diameter away from an adjacent ceramic fiber. The ceramic article has a consistent density of from 0.9 to 1.1 g/cm3 in x-, y-, and z-dimensions and has a uniform strength in three dimensions as measured in accordance with ASTM C1424.

Abstract: A brake rotor assembly, and method for forming a brake rotor assembly, that includes an integrally formed first disc member coupled to an integrally formed second disc member, wherein a first portion of the outer surface of the first disc member and the second disc member is formed from a metal matrix composite and the remainder of the first disc member and second disc member is formed from the support element used in the first portion.

Abstract: A ceramic article comprises ceramic fibers having an aspect ratio of greater than 3:1 and ceramic particles. The ceramic fibers are substantially randomly oriented in three dimensions in the ceramic article. A method of forming the ceramic article includes the step of providing a composition including ceramic fibers having an aspect ratio of greater than 3:1 and ceramic particles. The composition is extruded through a multi-screw extruder having at least three intermeshing screws to form an extrudate. The extrudate is heated to form the ceramic article.

Abstract: A metal matrix composite (MMC) includes a preform comprising ceramic particles and ceramic fibers and defines a plurality of voids. The MMC also includes a support element comprising a metal, which is disposed within the voids of the preform. The MMC has a wear surface defined by both the preform and the support element.

Abstract: The present invention relates to a metal matrix composite (MMC) and the method of manufacturing the MMC. The MMC includes a preform formed from a composition having ceramic particles and ceramic fibers. The metal matrix composite also includes a support element formed from a metal where the metal impregnates through the preform. The method of forming the MMC includes the step of extruding the composition through a multi-screw extruder to form an extrudate. The method also includes the step of heating the preform and positioning the preform within a mold. The method further includes the step of heating the metal for forming a molten metal and injecting the molten metal into a cavity of the mold under pressure for infiltrating the preform with the molten metal. The method also includes cooling the molten metal to solidify the molten metal and form the metal matrix composite and removing the metal matrix composite from the mold.

Abstract: The present invention relates to a metal matrix composite (MMC) and the method of manufacturing the MMC. The MMC includes a preform formed from a composition having ceramic particles and ceramic fibers. The metal matrix composite also includes a support element formed from a metal where the metal impregnates through the preform. The method of forming the MMC includes the step of extruding the composition through a multi-screw extruder to form an extrudate. The method also includes the step of heating the preform and positioning the preform within a mold. The method further includes the step of heating the metal for forming a molten metal and injecting the molten metal into a cavity of the mold under pressure for infiltrating the preform with the molten metal. The method also includes cooling the molten metal to solidify the molten metal and form the metal matrix composite and removing the metal matrix composite from the mold.

Abstract: A method of controlling evaporation of a fluid, such as water, in an article includes the step of encapsulating the article with a film such that the fluid is prevented from evaporating from the article. The method further includes the step of heating the article encapsulated with the film to a first desired temperature for a first period of time while preventing the fluid from evaporating from the article. The method also includes the step of removing the film from the article after heating the article to the first desired temperature for the first period of time and, after the step of removing the film the article, the method includes the step of further heating the article to a second desired temperature for a second period of time while the fluid freely evaporates from the article.

Abstract: The present invention relates to a method of forming a preform from a material having a first edge and a second edge utilizing a mandrel. The method comprises the step of extruding the material through an extruder to form an extrudate. The first edge of the extrudate has a configuration complementary to a configuration of the second edge of the extrudate. The method also includes wrapping the material around the mandrel by abutting the first edge and the second edge to form a spiral joint. The invention uses a manufacturing apparatus comprising a multi-screw extruder having at least three intermeshing screws for forming the extrudate. The mandrel receives the extrudate and a pressure-applying device adjacent to the mandrel engages the extrudate and applies pressure to the spiral joint to create a smooth exterior surface of the extrudate and to define the preform.

Abstract: The present invention relates to a metal matrix composite (MMC) and the method of manufacturing the MMC. The MMC includes a preform formed from a composition having ceramic particles and ceramic fibers. The metal matrix composite also includes a support element formed from a metal where the metal impregnates through the preform. The method of forming the MMC includes the step of extruding the composition through a multi-screw extruder to form an extrudate. The method also includes the step of heating the preform and positioning the preform within a mold. The method further includes the step of heating the metal for forming a molten metal and injecting the molten metal into a cavity of the mold under pressure for infiltrating the preform with the molten metal. The method also includes cooling the molten metal to solidify the molten metal and form the metal matrix composite and removing the metal matrix composite from the mold.

Abstract: A ceramic article comprises ceramic fibers having an aspect ratio of greater than 3:1 and ceramic particles. The ceramic fibers are substantially randomly oriented in three dimensions in the ceramic article. A method of forming the ceramic article includes the step of providing a composition including ceramic fibers having an aspect ratio of greater than 3:1 and ceramic particles. The composition is extruded through a multi-screw extruder having at least three intermeshing screws to form an extrudate. The extrudate is heated to form the ceramic article.

Abstract: The subject invention discloses a sweep unit assembly having a series of stations defining a path for an elongated article. A cradle is coupled to each of the stations. The stations are movable to introduce a first curve into the path and the article and each of the cradles are independently movable for introducing a second curve into the path and the article. A mount is included that supports at least one of the stations. The mount engages a base such that each of the stations are movably secured to the base and remain easily accessible for adjusting the stations and the cradles to impart various degrees of curvature into the path and the article. The sweep unit assembly is capable of imparting a curve into an elongated article formed of a metal and having a tensile strength greater than 80 KSI and a yield strength of 6 to 9 percent. The subject invention also discloses a method of adjusting the sweep unit assembly and a method of introducing a curve into the elongated article.