Abstract: Additive manufacturing processes, systems and three-dimensional articles include the formation of voxels and/or portions of three-dimensional articles with different properties relative to other voxels and/or portions. The processes generally include changing one or more laser beam parameters including power level, exposure time, hatch spacing, point distance, velocity, and energy density during the formation of selected voxels and/or portions of the three-dimensional articles. Also disclosed are processes that include an additive manufacturing process that provides localized secondary heat treatment of certain voxels and/or regions at a temperature below the melting point of the three-dimensional article but high enough to effect a localized property change.

Abstract: The present disclosure relates to a method of manufacturing composite airfoils bonded to a metallic root. A composite body may be formed with a metallic co-molded member. The co-molded member may be transient liquid phase (TLP) bonded to a metallic root. The metallic root may allow the composite body to be attached to a rotor. The airfoil may also have a metallic edge which is TLP bonded to the composite body via a co-molded edge.

Abstract: An electronic component includes a wire winding wound around a central axis. The wire winding having first and second ends, and first and second terminals are connected to or formed by the first and second ends. The terminals provide electrical contacts for connecting the component into a circuit. The component has a wet press molded body made of a mixture of magnetic and non-magnetic material that is heated and pressed about the wire winding. The wet press molded body leaves at least a portion of the terminals exposed for mounting the component to the circuit.

Abstract: A carbon fiber composite including: carbon fiber; and silicon carbide coated on the surface of the carbon fiber, and a production method of the same are provided. The carbon fiber composite may reduce weight, implement an outstanding heat-dissipating efficiency by using high thermal conductivity, and be used in various ways in electronic products and the like where heat-dissipating characteristics are required.

Abstract: Methods of forming bi-metallic castings are provided. In one method, a metal preform of a desired base shape is provided defining a substrate surface. A natural oxide layer is removed from the substrate surface, yielding a cleaned metal preform. The method includes forming a thin metallic film on at least a portion of the substrate surface of the cleaned metal preform, and metallurgically bonding the portion of the metal preform having the metallic film with an overcast metal to form a bi-metallic casting. The metallic film promotes a metallurgical bond between the metal preform and the overcast metal. In one aspect, the metal preform may include aluminum (Al) and the metallic film may include zinc (Zn).

Abstract: A method including positioning an insert in a vertical mold including a first mold portion and a second mold portion; and casting a material including a metal around at least a portion of the insert.

Abstract: A method of manufacturing metallic components consisting of at least two different materials, one of them being an iron-based alloy and the other an aluminum-based alloy, and involving the steps of: depositing a metallic layer onto the body made from the iron-based alloy, said layer being an aluminum-based alloy, preferably based on Al—Si or Fe, placing the coated body in a casting mold and casting an aluminum-based alloy about the coated body. Prior to placing the body in the casting mold, the metallic layer of the body is sprayed and/or blasted with silicon powder and/or Borax (Na2B4O7—10H2O, hydrated sodium borate).

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite, forming a porous perform structure, reacting the aluminum or first aluminum base alloy with nitrogen to form a rigid and continuous skeleton and infiltrating the porous structure with molten aluminum or second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example, selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite, forming a porous preform structure, reacting the aluminum or first aluminum base alloy with nitrogen to form a rigid skeleton and infiltrating the porous structure with molten aluminum or second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: A process of fabricating a light alloy casting, such as an aluminum alloy casting, including at least one metal insert includes applying a coating of lampblack to a face of the insert intended to be in contact with the alloy of the component and casting the component with the molten alloy in a mold cavity in which the insert is positioned. Applications include fabricating engine blocks with integrally cast liners made of cast iron.

Abstract: A method for the manufacture of a three-dimensional object includes the steps of forming a mixture that contains a binder and a least one of aluminum or a first aluminum-base alloy into a green composite, removing the binder from said green composite forming a porous preform structure and infiltrating the porous structure with a molten second aluminum base alloy to form the three-dimensional object with near theoretical density. The green composite may be formed by an additive process such as computer aided rapid prototyping, for example selective laser sintering. The method facilitates the rapid manufacture of aluminum components by an inexpensive technique that provides high dimensional stability and high density.

Abstract: Disclosed are an insert of pour-around die casting, which is incorporated by an aluminum alloy die casting and has an organic film formed on the surface of the insert, wherein the organic film contains a higher fatty acid ester, a petroleum sulfonate and a mineral oil and has a thickness of from 0.5 to 2 &mgr;m, a rust preventive oil used therefor, and a method for incorporating the insert with an aluminum alloy die casting.

Abstract: A method and apparatus for manufacturing composite materials are provided. In a first embodiment, a binding material is placed on a heat-resistant filter that is placed on hollow particles in a pressurizable container. Under pressure and heat, the binding material flows through the filter and infiltrates the spaces between the hollow particles. In a further embodiment, composite material wire is produced by coating the surfaces of inorganic fiber bundles with a metal oxide by dipping in a solution of a hydrolyzable organic metal compound and hydrolyzing and heat-treating prior to continuous infiltration under pressure. In a further embodiment, the apparatus includes orifices with enlarged diameter sections. In a still further embodiment, an apparatus is provided with ultrasonic vibration.

Abstract: Often, metal matrix composites (MMC's) lack adequate machinability and possess excessive abrasiveness because hard ceramic materials, such as silicon carbide, are used as the reinforcement phase. To make a metal matrix composite body having a more machinable and less abrasive surface, an MMC comprising an aluminum nitride reinforcement is formed on the surface of the body. In one embodiment, a layer is provided to a permeable mass or preform at the surface at issue, the layer featuring at least a reduced loading of ceramic filler material, and sometimes no ceramic material at all. The reduced loading is achieved by incorporating a fugitive material into the coating layer. Molten matrix metal is caused to infiltrate the permeable mass or preform and the coating layer to produce a macrocomposite body comprising a metal matrix composite coating and substrate.

Abstract: The present invention relates to a liquid-solid rolling bonding method for heterogeneous metals and an apparatus therefor. The method comprises: pouring a liquid metal onto the surface of a heterogeneous solid base metal coated with a soldering flux; rolling the liquid metal and the solid metal under pressure; solidifying the liquid metal and making it bond to the surface of the solid base metal under rapid cooling to realize metallurgical bonding of the two or more metals. The apparatus comprises an unrolling machine, a soldering flux tank, a drying-heating apparatus, a pouring nozzle, an interior water-cooling rollers and a roll-collecting machine arranged in order, a pouring basket is disposed above the pouring nozzle and a base frame is disposed below the pouring nozzle. The present invention has the advantages of high bonding strength, lower production cost, high production efficiency, good product quality, fewer investment for the apparatus and lower consumption of energy.

Abstract: The aim is to improve the strength of an intermetallic bond between engine component made from an aluminium alloy and a reinforcing element made from austenitic cast iron. For that purpose, the reinforcing element is annealed in a decarbonising atmosphere before the known prior art alfin process is carried out, in order to obtain an alfin layer largely free of graphite scales.

Abstract: An aluminum-based composite member having an increased strength of bond between an aluminum-based body and a cast iron material portion which is incorporated into the aluminum-based body by casting is provided by an improved process. The following steps are employed in the process: a step of removing an oxide film on the surface of the cast iron material portion and activating such surface; a step of forming a protecting plated-layer having a thickness a in a range of 0.8 .mu.m.ltoreq.a.ltoreq.5 .mu.

Abstract: The present invention is directed to a process for fabricating ceramic-metal composites having continuous ceramic and metal phases. The process includes the steps of contacting a porous ceramic matrix material with a molten metal whereby capillary action pulls the metal into the ceramic matrix to substantially fill the void space. The present invention also provides a ceramic-metal composite having continuous metal and ceramic phases.

Abstract: A new class of binders for binding finely divided inert inorganic molding particles when shaped into objects by known mechanical shaping techniques such as injection molding. The novel binders are solid polymer solutions containing a major fraction of a low molecular weight solid relatively non-volatile chemical as solvent in which is substantially dissolved a minor fraction of at least one high molecular weight solid polymer. The solid polymer solution binders when molten are homogeneous solutions and can be readily uniformly mixed with the usual inorganic molding particles into a readily flowable mixture which can be shaped and solidified. When solidified, the polymer and solid chemical remain a substantially homogeneous solution without appreciable phase separation.

Abstract: A method for the mass production of squirrel-cage rotors for electric motors includes the step of die casting-in-place rotor bars within the slots formed by stacked steel laminations. The molten metal alloy utilized in the method is high conductivity aluminum. Before introduction of the molten aluminum, the steel laminations are treated in a solution of sodium nitrite, sodium tetraborate decahydrate, and a wetting agent to prevent soldering of the aluminum to the steel.

Abstract: A cast composite material is made from particles and a matrix alloy of preselected composition that is difficult to wet to the particles. A wetting alloy having a composition that readily wets the particles is first mixed with the particles under conditions that wet the wetting alloy to the particles. The wetting alloy is selected so that it has no alloying elements in excess of that in the preselected matrix alloy, and preferably with wettability inhibiting elements reduced. After wetting and mixing have been achieved, the remaining alloying ingredients are added to the melt to adjust the matrix to the desired composition. The approach is applicable to cast composite materials containing both reactive and nonreactive particles.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. An infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere are also in communication with the preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the preform when the preform is placed into the molten matrix metal. A means for maintaining the preform at least partially below the surface of the molten matrix metal can also be utilized. In a preferred embodiment a reservoir may be employed to supply a second metal which has a different composition from the first source of matrix metal.

Abstract: Sintered ceramic preforms for metal matrix composites fabricated by a method comprising: (a) preparing a homogeneous mixture containing appropriate amounts of silicon-containing fibers/particulates, such as silicon carbide, at least one solvent, at least one polymer, and an oxide-containing material, such as boric acid or phosphoric acid, capable of forming a low melting silicate with a silicon oxide, such as a borosilicate; (b) shaping a green ceramic preform from the mixture, such as by injection molding; (c) removing the solvent(s) and the polymer(s); (d) oxidizing the surfaces of the silicon-containing fibers to form a layer of the silicon oxide thereon; (e) heating the preform to a temperature sufficient to react the oxide-containing material with the silicon oxide to form the low melting silicate material; (f) liquid phase sintering the fibers in the presence of liquid silicate material to strengthen the preform; and (g) cooling the sintered preform to ambient.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies by using a reactive barrier material. Particularly, an infiltration enhancer or an infiltration enhancer precursor or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform up to the reactive barrier material. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum. Accordingly, shaped metal matrix composite bodies can be produced having superior surface finish.

Abstract: The present invention relates to the formation of a metal matrix composite body by a spontaneous infiltration technique. Particularly, an infiltration enhancer or infiltration enhancer precursor can be positioned at least partially between or at an interface between a matrix metal and a filler material (or preform) which is to be infiltrated by molten matrix metal. Moreover, at least at some point during the process, an infiltrating atmosphere may be in communication with the filler material or preform or matrix metal.

Abstract: A metal matrix composite is formed by contacting a molten matrix metal with a permeable mass of filler material or preform in the presence of an infiltrating atmosphere. Under these conditions, the molten matrix metal will spontaneously infiltrate the permeable mass of filler material or preform under normal atmospheric pressures. Once a desired amount of spontaneous infiltration has been achieved, or during the spontaneous infiltration step, the matrix metal which has infiltrated the permeable mass of filler material or preform is directionally solidified. The directionally solidified metal matrix composite may be heated to a temperature in excess of the liquidus temperature of the matrix metal and quenched. This technique allows the production of spontaneously infiltrated metal matrix composites having improved microstructures and properties.

Abstract: The present invention relates to modifying the properties of a metal matrix composite body by a post formation process modification treatment. The post formation process treatment may be applicable to a variety of metal matrix composite bodies produced by various techniques, and is particularly applicable to modifying the properties of a metal matrix composite body produced by a spontaneous infiltration technique. Particularly, at least a portion of the matrix metal of the metal matrix composite body and/or the filler material of the metal matrix composite body is modified or altered after the formation process. Preferably, the preform contains a second non-metal material, an infiltration enhancer of infiltration enhancer precursor, and an infiltration atmosphere.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and novel products produced by the method. Particularly, a permeable mass of filler material or a preform is provided which has included therein at least two different matrix metal powders. Moreover, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material or preform, at least at some point during the process, which permits molten matrix metal, upon contact with the filler material or preform, to spontaneously infiltrate the filler material or preform. The presence of powdered matrix metal in the preform or filler material reduces the relative volume fraction of filler material to matrix metal.

Abstract: The present invention relates to a novel process for forming metal matrix composite bodies. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Such spontaneous infiltration occurs without the requirement for the application of any pressure or vacuum.

Abstract: A process for producing composite materials with a metal matrix and with a content of powder reinforcer agent lower than is minimum theoretical compaction value, with said process being based on an infiltration technique, is disclosed, which essentially consists in charging the reinforcer material to a casting mould, and then infiltrating into the same mould the metal matrix in the molten state, with said metal matrix being let cool until it solidifies, and characterized in that the reinforcer agent, consisting of non-metal powders, is blended, before being charged to said casting mould, with a diluting agent having a different compaction degree, constituted by metal fibres and/or ceramic fibres and/or ceramic whiskers and/or metal powders of the same composition as of the matrix.

Abstract: A sintered ceramic article which is to be joined to metal or form a composite member with metal comprises a metal compound or a metal separated and diffused in surface layers of particles of the sintered ceramic article. The sintered ceramic article is manufactured, for example, by forming a shaped article of ceramic powder, provisionally firing the shaped article, thereafter impregnating the provisionally fired article with a metal salt and/or a metal complex; and fully firing the provisionally fired article to produce a sintered ceramic article.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. A permeable mass of filler material is spontaneously infiltrated by a molten matrix metal. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltration atmosphere are in communication with the filler material, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material. After infiltration has been completed to a desired extent, additional matrix metal is added to that matrix metal which has spontaneously infiltrated the filler material to result in a suspension of filler material and matrix metal, said suspension having a lower volume fraction of filler relative to matrix metal. The matrix metal then can be permitted to cool in situ or the mixture of matrix metal and filler material can be poured into a second container as a casting process to form a desired shape which corresponds to the second container.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and the novel products produced therefrom. A negative shape or cavity, which is complementary to the desired metal matrix composite body to be produced, is first formed. The formed cavity is thereafter filled with a permeable mass of filler material. Molten matrix metal is then induced to spontaneously infiltrate the filled cavity. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the filler material, at least at some point during the process, which permits the matrix metal, when made molten, to spontaneously infiltrate the permeable mass of filler material, which at some point during the processing, may become self-supporting. In a preferred embodiment, cavities can be produced by a process which is similar to the so-called lost-wax process.

Abstract: The present invention relates to the formation of a metal matrix composite body by a spontaneous infiltration technique. Particularly, an infiltration enhancer and/or infiltration enhancer precursor can be positioned at least partially between or at an interface between a matrix metal and a filler material (or preform) which is to be infiltrated by molten matrix metal. Moreover, at least at some point during the process, an infiltrating atmosphere may be in communication with the filler material or preform and/or matrix metal.

Abstract: A metal matrix composite is formed by contacting a molten matrix alloy with a permeable mass of filler material or preform in the presence of an infiltrating atmosphere. Under these conditions, the molten matrix alloy will spontaneously infiltrate the permeable mass of filler material or preform under normal atmospheric pressures. Once a desired amount of spontaneous infiltration has been achieved, or during the spontaneous infiltration step, the matrix metal which has infiltrated the permeable mass of filler material or preform is directionally solidified. The directionally solidified metal matrix composite may be heated to a temperature in excess of the liquidus temperature of the matrix metal and quenched. This technique allows the production of spontaneously infiltrated metal matrix composites having improved microstructures and properties.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. An infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the preform when the preform is placed into the molten matrix metal. A means for maintaining the preform at least partially below the surface of the molten matrix metal can also be utilized.

Abstract: A cast composite material is made from particles and a matrix alloy of preselected composition that is difficult to wet to the particles. A wetting alloy having a composition that readily wets the particles is first mixed with the particles under conditions that wet the wetting alloy to the particles. The wetting alloy is selected so that is has no alloying elements in excess of that in the preselected matrix alloy, and preferably with wettability inhibiting elements reduced. After wetting and mixing have been achieved, the remaining alloying ingredients are added to the melt to adjust the matrix to the desired composition. The approach is applicable to cast composite materials containing both reactive and nonreactive particles. (aluminum matrix with silicon additions).

Abstract: The present invention relates to the formation of a macrocomposite body by spontaneously infiltrating a permeable mass of filler material or a preform with molten matrix metal and bonding the spontaneously infiltrated material to at least one second material such as a ceramic or ceramic containing body and/or a metal or metal containing body. Particularly, an infiltration enhancer and/or infiltration enhancer precursor and/or infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Moreover, prior to infiltration, the filler material or preform is placed into contact with at least a portion of a second material such that after infiltration of the filler material or preform, the infiltrated material is bonded to the second material, thereby forming a macrocomposite body.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and novel products produced by the method. Particularly, a permeable mass of filler material or a preform has included therein at least some matrix metal powder. Moreover, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. The presence of powdered matrix metal in the preform or filler material reduces the relative volume fraction of filler material to matrix metal.

Abstract: The present invention relates to the formation of a metal matrix composite body by a spontaneous infiltration technique. Particularly, an infiltration enhancer and/or infiltration enhancer precursor can be positioned at least partially between or at an interface between a matrix metal and a filler material (or preform) which is to be infiltrated by molten matrix metal. Moreover, at least at some point during the process, an infiltrating atmosphere may be in communication with the filler material or preform and/or matrix metal.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and the novel products produced therefrom. A negative shape or cavity, which is complementary to the desired metal matrix composite body to be produced, is first formed. The formed cavity is thereafter filled with a permeable mass of filler material. Molten matrix metal is then induced to spontaneously infiltrate the filled cavity. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the filler material, at least at some point during the process, which permits the matrix metal, when made molten, to spontaneously infiltrate the permeable mass of filler material, which at some point during the processing, may become self-supporting. In a preferred embodiment, cavities can be produced by a process which is similar to the so-called lost-wax process.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies and novel metal matrix composite bodies produced thereby. Particularly, a polycrystalline oxidation reaction product of a parent metal and an oxidant is first formed. The polycrystalline oxidation reaction product is thereafter comminuted into an appropriately sized filler material which can be placed into a suitable container or formed into a preform. The filler material or preform of comminuted polycrystalline oxidation reaction product is thereafter placed into contact with a matrix metal alloy in the presence of an infiltration enhancer, and/or an infiltration enhancer precursor and/or an infiltrating atmosphere, at least at some point during the process, whereupon the matrix metal alloy spontaneously infiltrates the filler material or preform. As a result of utilizing comminuted or crushed polycrystalline oxidation reaction product, enhanced infiltration (e.g., enhanced rate or amount) is achieved.

Abstract: The present invention relates to the formation of a metal matrix composite body by a spontaneous infiltration technique and thereafter thermo-forming the produced metal matrix composite body. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. After formation of the metal matrix composite body, the body is subjected to a thermo-forming technique such as rolling, extruding, die casting, pressing, etc.

Abstract: The present invention relates to the formaton of metal matrix composite bodies by a spontaneous infiltration technique, and novel metal matrix composite bodies produced according to the method. An ingot of matrix metal is surrounded by a permeable mass of filler matrial. An infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the filler material, at least at some point during the process, which permit the shaped ingot of matrix metal, when made molten, to spontaneously infiltrate the surrounding permeable mass of filler material. After the spontaneous infiltration, a metal matrix composite body is produced having therein a cavity which substantially corresponds in shape to the original ingot of matrix metal.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. The preform material can then be floated onto the surface of or into a matrix metal alloy, whereupon the matrix metal alloy spontaneously infiltrates the preform. After substantial complete infiltration of the preform, the preform begins to at least partially sink into the matrix metal alloy supply. The matrix metal which has infiltrated the preform is then allowed to cool, thus forming a metal matrix composite body.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. Particularly, a permeable mass of filler material is formed into a preform. An infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are also in communication with the preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the preform when the preform is placed into the molten matrix metal. A means for maintaining the preform at least partially below the surface of the molten matrix metal can also be utilized.

Abstract: The present invention relates to modifying the properties of a metal matrix composite body by a post formation process treatment and/or a substantially contiguous modification treatment. The post formation process treatment may be applicable to a variety of metal matrix composite bodies produced by various techniques, and is particularly applicable to modifying the properties of a metal matrix composite body produced by a spontaneous infiltration technique. The substantially contiguous modification process may also be used primarily in conjunction with metal matrix composite bodies produced according to a spontaneous infiltration technique. Particularly, at least a portion of the matrix metal of the metal matrix composite body and/or the filler material of the metal matrix composite body is modified or altered during and/or after the formation process.

Abstract: The present invention relates to a novel method for forming metal matrix composite bodies. A permeable mass of filler material is spontaneously infiltrated by a molten matrix metal. Particularly, an infiltration enhancer and/or infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material. After infiltration has been completed to a desired extent, additional matrix metal is added to that matrix metal which has spontaneously infiltrated the filler material to result in a suspension of filler material and matrix metal, said suspension having a lower volume fraction of filler relative to matrix metal. The matrix metal then can be permitted to cool in situ or the mixture of matrix metal and filler material can be poured into a second container as a casting process to form a desired shape which corresponds to the second container.

Abstract: A process for casting molten transition metal alloy comprising 15 to 35 at % of rare earth metal in which the molten alloy is contacted with a surface (26) of a backing member (25) and the alloy is caused to solidify while in contact with the surface (26) such that when the alloy has solidified there is produced a unitary structure (21) comprising a solid layer (27) of the alloy bonded to the backing member (25). The process minimizes the effects of cracking in the alloy and facilitates the use of the alloy as a sputter target.

Abstract: A method of preparing a composite aluminum material to be formed integrally by bonding aluminum or aluminum alloy to an aluminum or aluminum alloy member which is formed in advance in a specified shape by the method of internal chill, etc. The method comprises the steps of forming a chemical conversion coating of pentafluoroaluminate (K.sub.2 AlF.sub.5) by bringing a solution containing potassium ions and fluorine ions in contact with the surface of the aluminum member.