Abstract: A method for fabricating an infiltrated metal-matrix composite (MMC) tool includes positioning at least one boundary form within an infiltration chamber of a mold assembly and thereby segregating the infiltration chamber into at least a first zone and a second zone. Reinforcement materials are deposited into the infiltration chamber and include a first composition loaded into the first zone and a second composition loaded into the second zone. The first and second compositions are then infiltrated with at least one binder material to provide the infiltrated MMC tool with differing mechanical, chemical, physical, thermal, atomic, magnetic, or electrical properties between the first and second zones.

Abstract: An infiltrated metal-matrix composite drill bit includes a bit body comprising a reinforced composite material including reinforcing particles infiltrated with a binder material. A plurality of cutting elements is coupled to an exterior of the bit body. A mandrel is positioned within the bit body and made of an M-based alloy selected from the group consisting of a titanium-based alloy, a nickel-based alloy, a copper-based alloy, a cobalt-based alloy, and a refractory metal-based alloy, wherein the element designated by “M” is the most prevalent element in the alloy composition. A shank is coupled to the mandrel.

Abstract: A metal matrix composite (MMC) tool includes a mesoscale-reinforced hard composite portion that comprises reinforcing particles and mesoscale reinforcing structures dispersed in a binder material. The mesoscale reinforcing structures are printed using at least one additive manufacturing technique and are larger than an average powder-size distribution of the reinforcing particles.

Abstract: A mold assembly system includes a mold assembly that defines an infiltration chamber used for forming an infiltrated metal-matrix composite (MMC) tool. Reinforcement materials are deposited within the infiltration chamber, and a binder material is used to infiltrate the reinforcement materials. At least one preformed mesh is positioned within the infiltration chamber and embedded within the reinforcement materials. The at least one preformed mesh includes a porous body and provides skeletal reinforcement to the infiltrated MMC tool following infiltration.

Abstract: A fixed-cutter drill bit is provided that includes a metal-matrix composite body having at least one metal-matrix composite blade. Cutters are disposed on the blades. A ductile insert is partially disposed within the body and has an exposed surface. The ductile insert has a greater ductility than the metal-matrix composite thereby alleviating stresses imposed on the metal-matrix composite during manufacture of the bit or drilling.

Abstract: A mold assembly system includes a mold assembly that defines an infiltration chamber used for forming an infiltrated metal-matrix composite (MMC) tool, and at least one boundary form positioned within the infiltration chamber and segregating the infiltration chamber into at least a first zone and a second zone. Reinforcement materials are deposited within the infiltration chamber and include a first composition loaded into the first zone and a second composition loaded into the second zone. At least one binder material infiltrates the first and second compositions, wherein infiltration of the first and second compositions results in differing mechanical, chemical, physical, thermal, atomic, magnetic, or electrical properties between the first and second zones in the infiltrated MMC tool.

Abstract: A method for joining engine components includes positioning a first plurality of thermal protection structures across a thermal protection space between a first thermal protection surface and a second thermal protection surface. The first and second engine components are locally joined by forming a first plurality of transient liquid phase (TLP) or partial transient liquid phase (PTLP) bonds along corresponding ones of the first plurality of thermal protection structures between the first thermal protection surface and the second thermal protection surface. The second thermal protection surface is formed from a second surface material different from a first surface material of the first thermal protection surface.

Abstract: A part includes a three-dimensional porous metallic workpiece printed via an additive manufacturing process and subsequently subjected to a diffusion-based process to convert at least a portion of the porous metallic workpiece to a ceramic workpiece or an intermetallic workpiece.

Abstract: A metal matrix composite tool that includes a hard composite portion comprising a reinforcement material infiltrated with a binder material, wherein the reinforcement material comprises a refractory metal component dispersed with reinforcing particles, wherein a surface roughness of the reinforcing particles is at least two times greater than the refractory metal component, wherein the refractory metal component has a failure strain of at least 0.05 and a shear modulus of 200 GPa or less, and wherein the reinforcing particles have a failure strain of 0.01 or less but at least five times less than the failure strain of the refractory metal component, and the reinforcing particles have a shear modulus of greater than 200 GPa and at least two times greater than the shear modulus of the refractory metal component. The reinforcing particles may comprise an intermetallic, a boride, a carbide, a nitride, an oxide, a ceramic, and/or a diamond.

Abstract: A means for attaching a metallic component to a non-metallic component using a compliant material having thermal properties intermediate those of the metallic component to a non-metallic component is provided. The method can accommodate CTE mismatches and wear-type problems common to many assemblies of dissimilar materials. In particular, the method provides a sufficient wear surface to accommodate relative motion and provide a durable wear surface that does not excessively wear/gall/mico-weld itself together and provides the necessary damping and motion for proper operation in aeronautical applications.

Abstract: An industrial product comprising a polymer substrate formed in a shape of the industrial product, and a metallic plating layer plated on at least one surface of the industrial product is described. The industrial product may be nuclear waste equipment, industrial equipment exposed to saline, a satellite or satellite component, or heating, ventilation, air-conditioning and refrigeration (HVACR) equipment.

Abstract: A method of fabricating a metal matrix composite (MMC) tool includes coating at least a portion of an interior of a mold assembly with one or more layers of a material coating, where the mold assembly defines at least a portion of an infiltration chamber. Reinforcing materials are deposited into the infiltration chamber, and infiltrated with a binder material. One or more layers of the material coating may then be reacted with the binder material to form an outer shell on selected outer surfaces of the MMC tool.

Abstract: A composite component and a plated polymer component are disclosed. The composite component may comprise a body portion formed from an organic matrix composite, a first metal coating applied to a surface of the body portion, and an outer metal layer on the first metal coating that is erosion-resistant. The plated polymer component may comprise a polymer substrate, a metal plating layer applied to a surface of the polymer substrate, and at least one selectively thickened region in the metal plating layer. The at least one selectively thickened region may assist in protecting the plated polymer component against wear and/or erosion.

Abstract: A method for fabricating a metal-matrix composite tool includes positioning an inner mold within an outer mold and thereby defining a gap between the inner and outer molds. A first reinforcement material is then loaded into the gap, and the first reinforcement material is infiltrated at a first temperature with a first binder material and thereby forming an outer shell. The inner mold is then removed and a second reinforcement material is loaded at least partially into the outer shell and infiltrated at a second temperature with a second binder material and thereby forming a reinforced composite material. The second temperature is lower than the first temperature and the second binder material is different than the first binder material. The outer shell is attached to exterior portions of the reinforced composite material.

Abstract: A composite component is disclosed. The composite component may comprise a metal plating deposited on a surface of the composite component, and a metallic feature adhesively bonded to the metal plating. The composite component may further comprise an adhesive layer between the metal plating and the metallic feature. The metal plating may provide a metal-to-metal interface between the surface of the composite component and the metallic feature.

Abstract: An example mold assembly system includes a mold assembly including a mold forming a bottom of the mold assembly, a funnel operatively coupled to the mold, and an infiltration chamber defined at least partially by the mold and the funnel, the infiltration chamber being used for forming an infiltrated downhole tool. A mold assembly cap is positionable on the mold assembly and including a sidewall extendable about an outer periphery of the mold assembly at least partially along a height of the mold assembly. The sidewall exhibits a horizontal cross-sectional shape that accommodates a shape of the mold assembly and the sidewall is made of a thermal material that promotes directional solidification of the infiltrated downhole tool during fabrication.

Abstract: An example thermal sink system includes a quench plate having an upper surface for receiving a mold assembly to be cooled. A thermal fluid is in thermal communication with the mold assembly via conduction through the quench plate. The quench plate prevents the thermal fluid from contacting the mold assembly.

Abstract: A mold transfer assembly includes a transfer housing providing an interior defined by one or more sidewalls and a top. The transfer housing is sized to receive and encapsulate a mold as the mold is moved between a furnace and a thermal heat sink. An arm is coupled to the transfer housing to move the transfer housing and the mold encapsulated within the transfer housing between the furnace and a thermal heat sink. The transfer housing exhibits one or more thermal properties to control a thermal profile of the mold.

Abstract: An example system for fabricating an infiltrated downhole tool includes a mold assembly having one or more component parts and defining an infiltration chamber to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated downhole tool. One or more thermal conduits are positioned within the one or more component parts for circulating a thermal fluid through at least one of the one or more component parts and thereby placing the thermal fluid in thermal communication with the infiltration chamber.

Abstract: An example mold assembly for fabricating an infiltrated downhole tool includes a mold defining a bottom of the mold assembly and a funnel operatively coupled to the mold. An infiltration chamber is defined at least partially by the mold and the funnel to receive and contain matrix reinforcement materials and a binder material used to form the infiltrated downhole tool. A thermal mass is positioned within the infiltration chamber above the infiltrated downhole tool for imparting heat to the infiltrated downhole tool following an infiltration process.