Abstract: A thermal management device suitable for use as an electronic chassis includes a monolithic, monocoque body having integrally formed channels for carrying thermal energy away from a heat source, such as electronic components. The device may be fabricated using additive/subtractive manufacturing processes such as ultrasonic consolidation.

Abstract: A thermal management device suitable for use as an electronic chassis includes a monolithic, monocoque body having integrally formed channels for carrying thermal energy away from a heat source, such as electronic components. The device may be fabricated using additive/subtractive manufacturing processes such as ultrasonic consolidation.

Abstract: A method for producing aluminum matrix composites containing refractory aluminide whiskers or particulates which are formed in-situ is disclosed. Aluminum and refractory metal materials are blended in powder form and then heated to a temperature above the melting point of aluminum. A solid/liquid reaction between the molten aluminum and solid refractory metal provides a desired volume fraction of refractory aluminide reinforcement phase (in situ whiskers or particulates). Upon cooling the molten, unreacted portion of aluminum solidifies around the in situ reinforcements to create the improved composite material.

Abstract: A method for producing aluminum matrix composites containing refractory aluminide whiskers or particulates which are formed in-situ is disclosed. Aluminum and refractory metal materials are blended in powder form and then heated to a temperature above the melting point of aluminum. A solid/liquid reaction between the molten aluminum and solid refractory metal provides a desired volume fraction of refractory aluminide reinforcement phase (in situ whiskers or particulates). Upon cooling the molten, unreacted portion of aluminum solidifies around the in situ reinforcements to create the improved composite material.

Abstract: Microcracks in fiber-reinforced/titanium aluminide matrix composite materials are inhibited by employing a matrix comprising a titanium aluminide alloy having (1) from ten to twelve atomic percent niobium and (2) a critical admixture of from two to six atomic percent of a member selected from a group consisting of molybdenum, tungsten and vanadium. The tendency of the fiber/matrix interfacial reaction to increase the stability of the Alpha 2 phase in the matrix adjacent to the interface and the tendency to form a "beta phase depletion zone" are unexpectedly negated. Suppression of the beta depletion zone formation inhibits the formation and growth of interfacial microcracks, and allows the fabrication of crack-free titanium matrix composite materials. The need for an extraneous beta phase stabilization treatment at the fiber/matrix interface is eliminated.

Abstract: Light weight refractory aluminides, such as Al.sub.3 Nb and related aluminides may be produced from metallic powders by a high temperature exothermic reaction of refractory metals with molten aluminum. Mixtures of refractory metals and aluminum may be prepared and densified by powder metalurgy techniques. Applicant's process permits near net formations of stock shapes and parts by conducting the reaction in situ in a die.