Abstract: A part is manufactured from a composite material containing an aluminum alloy as a metal matrix. Blanks are prepared from a billet of the composite material, and worked on in a press, while they are held at a temperature ranging from the solidus temperature, Ta, of the aluminum alloy minus 50 (Ta−50) deg. C. to Ta deg. C. At a temperature below (Ta−50), the blanks have too high a resistance to plastic deformation to be easily worked on. At a temperature over Ta, a liquid phase is produced and makes the blanks likely to crack easily during plastic deformation.

Abstract: For forming a preform of composite material, such as aluminum-based composite material (MMC) by using friction during the forming thereof, ceramic reinforcement, such as Al2O3 and binder are prepared, and the prepared reinforcement and the silanor group binder are put into a die for press forming. During the forming, polycondensation occurs due to frictional heat generated between the fibrous or grain-like particles of the reinforcement and the silanor group binder to harden it, thereby obtaining a preform in which the particles of the reinforcement are fixedly connected to one another.

Abstract: A molded brake disc having a central hub portion and an annular disc portion extending from the hub portion in a radial outward direction for frictional engagement with brake pads, wherein the disc portion is formed of metal matrix composite having a reinforcing material added to a metal matrix, and the hub portion is formed of metal which is inexpensive as compared to the metal matrix composition. Due to a limited use of the expensive metal matrix composite, the molded brake disc as a whole is inexpensive as compared to a conventional molded brake disc entirely formed of metal matrix composite.

Abstract: A method for injection molding a metallic material is disclosed in which an injecting material comprised of a half-solidified metallic material and a molten metallic material is injected into a cavity of a die from an injection cylinder through a gate thereof. A non-product portion remaining at the gate of the die is separated from a product portion while it is still hot. The separated high-temperature non-product portion is press-formed into a billet in the injection cylinder. Utilization of heat from the injecting material in melting the high-temperature billet enables reuse of the non-product portion remained at the gate and reduction of heat energy required in melting the billet.

Abstract: A method for injection molding a metallic material is disclosed in which an injecting material comprised of a half-solidified metallic material and a molten metallic material is injected into a cavity of a die from an injection cylinder through a gate thereof. A non-product portion remaining at the gate of the die is separated from a product portion while it is still hot. The separated high-temperature non-product portion is press-formed into a billet in the injection cylinder. Utilization of heat from the injecting material in melting the high-temperature billet enables reuse of the non-product portion remained at the gate and reduction of heat energy required in melting the billet.

Abstract: A method for injection molding a metallic material is disclosed in which an injecting material comprised of a half-solidified metallic material and a molten metallic material is injected into a cavity of a die from an injection cylinder through a gate thereof. A non-product portion remaining at the gate of the die is separated from a product portion while it is still hot. The separated high-temperature non-product portion is press-formed into a billet in the injection cylinder. Utilization of heat from the injecting material in melting the high-temperature billet enables reuse of the non-product portion remained at the gate and reduction of heat energy required in melting the billet.

Abstract: A part is manufactured from a composite material containing an aluminum alloy as a metal matrix. Blanks are prepared from a billet of the composite material, and worked on in a press, while they are held at a temperature ranging from the solidus temperature, Ta, of the aluminum alloy minus 50 (Ta−50) deg. C to Ta deg. C. At a temperature below (Ta−50), the blanks have too high a resistance to plastic deformation to be easily worked on. At a temperature over Ta, a liquid phase is produced and makes the blanks likely to crack easily during plastic deformation.

Abstract: A method for manufacturing an aluminum-based composite plate is disclosed. The method comprises the step of producing an aluminum-based composite billet. The billet production step includes reducing, by magnesium nitride, an oxide-based ceramic as a porous molded body. The reduced oxide-based ceramic has improved wettability. An aluminum alloy is then caused to infiltrate into porous sections of the reduced oxide-based ceramic to thereby provide the aluminum-based composite billet. The billet is extrusion molded into a flat plate form by using an extrusion press. Plates of desired shapes are punched from the molded flat plate by using a press.

Abstract: For forming a preform of composite material, such as aluminum-based composite material (MMC) by using friction during the forming thereof, ceramic reinforcement, such as Al2O3 and binder are prepared, and the prepared reinforcement and the silanor group binder are put into a die for press forming. During the forming, polycondensation occurs due to frictional heat generated between the fibrous or grain-like particles of the reinforcement and the silanor group binder to harden it, thereby obtaining a preform in which the particles of the reinforcement are fixedly connected to one another.

Abstract: For forming a preform of composite material, such as aluminum-based composite material (MMC) by using friction during the forming thereof, ceramic reinforcement, such as Al2O3 and binder are prepared, and the prepared reinforcement and the silanor group binder are put into a die for press forming. During the forming, polycondensation occurs due to frictional heat generated between the fibrous or grain-like particles of the reinforcement and the silanor group binder to harden it, thereby obtaining a preform in which the particles of the reinforcement are fixedly connected to one another.

Abstract: A formed porous body of oxide ceramic and an aluminum alloy block are placed in a crucible in an atmospheric furnace, and a magnesium source is placed in another crucible in the atmospheric furnace. An argon gas is then introduced into the atmospheric furnace, which is then heated to produce a magnesium vapor from the magnesium source and melt the aluminum alloy block. Then, the argon gas is replaced with a nitrogen gas to generate magnesium nitride. The magnesium nitride reduces an oxide on surfaces of the formed porous body, exposing metal atoms on the surfaces of the formed porous body. The molten aluminum alloy permeates the formed porous body under a pressure lower or higher than the atmospheric pressure or alternate pressures lower and higher than the atmospheric pressure.

Abstract: Disclosed is a method for producing metal-ceramic composite materials, comprising setting a porous shaped material of an oxide-type ceramic and magnesium in a furnace; establishing a rare gas atmosphere, subliming the magnesium under heat, and dispersing the resulting magnesium vapor into the porous shaped material all within the furnace; introducing nitrogen gas into the furnace, causing the gas to react with the sublimed magnesium to form magnesium nitride (Mg.sub.3 N.sub.2), bringing the magnesium nitride into contact with the oxide in the surface of the porous shaped material thereby reducing the oxide and exposing metal atoms at the material surface, and thereafter infiltrating a molten metal into the porous shaped material.

Abstract: A method for producing an aluminum alloy composite material comprises disposing in a mold, in sequence from bottom to top, an infiltration enhancer containing Mg, a preform and an aluminum matrix alloy ingot, and then inserting the mold into an atmospheric furnace. The interior of the atmospheric furnace is then turned into an argon atmosphere. Thereafter, the internal temperature of the furnace is raised to a first predetermined temperature which is maintained for a given period of time so that the infiltration enhancer sublimates to permit the Mg component thereof to infiltrate into the preform. The atmosphere inside the furnace is then turned from the argon atmosphere into a nitrogen atmosphere.

Abstract: A process is disclosed for producing an aluminum or an aluminum alloy sintering, comprising successive steps of maintaining a rare gas atmosphere inside a sintering furnace while heating a compact of aluminum particles or aluminum alloy particles, together with a magnesium source; reducing the pressure inside the sintering furnace while heating further for thereby sublimating magnesium nitrogen to generate Mg.sub.3 N.sub.2 and bringing the generated Mg.sub.3 N.sub.2 into contact with Al.sub.2 O.sub.3 in the surface of the compact for the reduction of Al.sub.2 O.sub.3, thereby effecting heating and sintering at a temperature lower than the melting point of aluminum. The process increases the bonding strength of the aluminum alloy particles while fully taking the advantage of a sintering process. Thus, it enables aluminum sinterings or aluminum-alloy sinterings improved in yield point, strength, and elongation.