Abstract: Disclosed are reinforced metal matrix composites and methods of shaping powder materials to form such composites. Articles of manufacture are formed in layers by a laser fabrication process. In the process, powder is melted and cooled to form successive layers of a discontinuously reinforced metal matrix. The matrix exhibits fine grain structure with enhanced properties over the unreinforced metal, including higher tensile modulus, higher strength, and greater hardness. In some preferred embodiments, an in-situ alloy powder, a powder metallurgy blend, or independently provided powders are reinforced with boron and/or carbon to form the composite.

Abstract: The present invention provides new polymer induction bonding technology. Induction heating technologies are utilized to weld, forge, bond or set polymer materials. The invention provides controlled-temperature induction heating of polymeric materials by mixing ferromagnetic particles in the polymer to be heated. Temperature control is obtained by selecting ferromagnetic particles with a specific Curie temperature. The ferromagnetic particles will heat up in an induction field, through hysteresis losses, until they reach their Curie temperature. At that point, heat generation through hysteresis loss ceases. This invention is applicable to bonding thermoplastic materials, wherein only the area to be bonded has ferromagnetic particles in it; bonding of thermoset composites, which have been processed with a layer of thermoplastic material on one side; curing of thermoset adhesives or composite resins; or consolidating thermoplastic composites.

Abstract: The invention provides new high-use temperature, lightweight polymer/inorganic nanocomposite materials with enhanced thermal stability and performance characteristics. The invention provides two techniques that enhance the thermal stability of the nanocomposite systems from their current limits of 100-150.degree. C. to over 250.degree. C. The two unique approaches are based on innovative chemical design of the organic-inorganic interface using (i) more thermally stable surfactants/compatibility agents, and (ii) more thermally stable synthetic organically-modified layered-silicate reinforcements to create unique nanocomposites. These approaches offer processibility through both solution techniques, as well as solvent-free direct melt intercalation technique. The use of synthetic organically-modified layered silicates (having built-in surfactants) eliminates the poisonous alkyl ammonium surfactants that limit the applications of nanocomposites as food packaging materials.