Abstract: A manufacturing method for producing metal matrix composite (MMC) sheets without intermediate process losses associated with extrusion and rolling edge cracks. The method results in theoretical sheet yield rates from the initial MMC billet of up to 100%, compared to 30 to 60% yield rates for prior-art manufacturing processes. The methods in this invention comprise the following processes: (a) preparing a MMC powder mixture; (b) preparing a frame and a billet consolidation tool; (c) loading and compacting the MMC mixture to form a framed MMC compact; (d) consolidation of the framed MMC compact to form a framed MMC billet; (e) preparing the framed billet to be a framed roll-preform; and (e) rolling the framed roll-preform to MMC sheet.

Abstract: A method for manufacturing and producing metal alloy billet products from particulate starting materials, particularly adapted for use with aluminum and aluminum alloy wrought products and their manufacture involving the use of powdered starting materials. The method includes the basic steps of preparing elemental, master alloy or prealloyed metal powders with or without a foreign reinforcement phase, compacting the prepared powder into pellets, introducing and compacting the pellets into a die, consolidating the compacted powder into a billet.

Abstract: A three-phase nanocomposite that comprises about 0.5 to 10 vol % nano-scale aluminum oxide particles and about 1 to 45% high modulus ceramic particles and an aluminum alloy matrix. The nano phase is to enhance nanocomposite strength and the modulus phase is to enhance the specific modulus of the resulting nanocomposite.