Abstract: A method of producing nanoporous material includes the steps of providing a liquid, providing nanoparticles, producing a slurry of the liquid and the nanoparticles, removing the liquid from the slurry, and producing monolith.

Abstract: A drill collar formed substantially entirely from a metal matrix material and one or more metal alloys, the drill collar being produced through a molding process. The metal matrix material of the drill collar minimizes lateral movement and vibration during drilling operations, while providing a weight greater than that of conventional drill collar materials, thereby enabling construction of drill collars and bottom hole assemblies having a reduced length.

Abstract: Some embodiments provide methods and systems for casting articles. One example of a method includes providing and positioning a thermal blanket within a mold cavity and then introducing a molten material into the mold cavity and into contact with the thermal blanket. The method allows the molten material to remain in a molten state during a dwell time that extends from the introduction of the molten material at least until the mold cavity is filled. In another example, a method of using a thermal blanket includes keeping a molten material in a molten state during a dwell time extending from first introduction of the molten material until pressurization. Systems including a variety of mold types, one or more thermal blankets, and in some cases preforms and/or inserts are also provided. Also described is a novel thermal blanket and method of manufacturing the same.

Abstract: A method of forming a metal matrix composite (MMC),such as a brake drum, by impregnating a preform, which is formed of ceramic particles and ceramic fibers, with a support element, such as a metal. The MMC has a wear surface defined by both the preform and the support element.

Abstract: A method for making a carbon nanotube metal composite includes the following steps. A number of carbon nanotubes is dispersed in a solvent to obtain a suspension. Metal powder is added into the suspension, and then the suspension agitated. The suspension containing the metal powder is allowed to stand for a while. The solvent is reduced to obtain a mixture of the number of carbon nanotubes and the metal powder.

Abstract: Methods of forming at least a portion of an earth-boring tool include providing particulate matter comprising a hard material in a mold cavity, melting a metal and the hard material to form a molten composition comprising a eutectic or near-eutectic composition of the metal and the hard material, casting the molten composition to form the at least a portion of an earth-boring tool within the mold cavity, and adjusting a stoichiometry of at least one hard material phase of the at least a portion of the earth-boring tool. Methods of forming a roller cone of an earth-boring rotary drill bit include forming a molten composition, casting the molten composition within a mold cavity, solidifying the molten composition to form the roller cone, and converting an eta-phase region within the roller cone to at least one of WC and W2C.

Abstract: A method of making a functionally graded metal matrix composite (MMC) sheet having a central layer of particulate matter, the particulate matter having a size of at least about 30 microns. The method includes providing a molten metal containing particulate matter to a pair of advancing casting surfaces. Solidifying the molten metal while advancing the molten metal between the advancing casting surfaces to form a first solid outer layer, a second solid outer layer, and a semi-solid central layer having a higher concentration of particulate matter than either of the outer layers. Solidifying the central layer to form a solid metal product including a central layer sandwiched between the outer layers and withdrawing the metal product from between the casting surfaces.

Abstract: A method of making an article adapted for use as a wear resistant working surface of a roll includes positioning hard elements in predetermined positions on a bottom surface of a mold. The hard elements comprise a first end and an opposed second end. The second end of each hard element rests on the bottom surface, partially filling a void space and defining an unoccupied volume in the mold. Inorganic particles are added to the mold to at least partially fill the unoccupied volume and provide a remainder space. The hard elements and the inorganic particles are heated to an infiltrating temperature and infiltrated with a matrix material. The matrix material is cooled and solidified and binds the hard elements and the inorganic particles in the article.

Abstract: A method for making a magnesium-based composite material includes mixing nanoscale reinforcements with a melted magnesium-based material to obtain a pre-mixture. The pre-mixture is agitated by an ultrasonic process to obtain a mixture. The mixture is sprayed to a substrate.

Abstract: A method of manufacturing a vehicle wheel is provided with the steps of forming a wheel rim preform by injection molding a material made of alloy wherein the wheel rim preform includes a holed center, a grooved rim, a plurality of spokes interconnecting the holed center and an inner surface of the grooved rim, and a plurality of openings each formed in the spoke; preparing an endless CFRP work piece; cutting the CFRP work piece into a plurality of CFRP members; placing the CFRP members in the openings of the spokes; and heating the wheel rim perform at a predetermined temperature for a predetermined period of time to melt the CFRP members, thereby forming a finished wheel.

Abstract: Nano-composite structures are formed by pre-loading carbon nanotubes (CNTs) into at least one of a plurality of channels running the length of a cartridge, placing the pre-loaded cartridge in a piston chamber of a die-casting machine, creating a vacuum therein, and filing the piston chamber with molten metal to soak the pre-loaded cartridge and fill empty cartridge channels. Pressure is applied via the piston to eject the carbon nanotubes and molten metal from the cartridge channels and inject the nano-composite mixture into a rod-shaped die cavity. The internal diameter of the cavity is equal to or less than the final diameter of the nozzle. The nano-composite mixture is cooled to form a solid nano-composite rod having the first predetermined diameter, wherein the carbon nanotubes are aligned in a non-random manner. Furthermore, drawing down the nano-composite rod to smaller diameter wire further disperses the nanotubes along the length of the wire.

Abstract: A Moineau style stator includes a helical reinforcement component that provides an internal helical cavity. A resilient liner is deployed on an inner surface of the helical reinforcement component. The helical reinforcement component includes a solder or braze material and is typically metallurgically bonded to an inner wall of a stator tube. In exemplary embodiments, the helical reinforcement component includes a composite mixture of solder and aggregate. Exemplary embodiments of this invention address the heat build up and subsequent elastomer breakdown in the lobes of prior arts stators by providing a helical reinforcement component. Solder reinforced stators tend to be less expensive to fabricate than reinforced stators of the prior art.

Abstract: A method of making a nanoparticle reinforced metal matrix component is provided. The method involves solid state processing nanoparticles into a metal matrix material at solid state processing conditions to form a master alloy. At least a portion of the master alloy is added to a mass of metal melt to produce the nanoparticle reinforced metal matrix component.

Abstract: A process for the production of an aluminum-diamond composite, characterized by comprising the step of preparing a diamond powder having a specific diameter, the step of adding a colloidal silica to the diamond powder to form a slurry, the step of subjecting the slurry to press forming or slip casting to produce a compact of the diamond particles, the step of firing the compact either in air or in a nitrogen atmosphere to form a porous diamond preform, the step of heating the porous diamond preform, the step of heating an aluminum alloy to a temperature equal to or above the melting point of the alloy and impregnating the molten alloy into the porous diamond preform to make a flat plate-like aluminum-diamond composite wherein both surfaces are covered with surface layers containing an aluminum-base metal, and the step of working the aluminum-diamond composite into an aluminum-diamond composite.

Abstract: Of the many embodiments provided, one embodiment is a drill bit mold assembly comprising: a mold having a bottom and at least one side; a core centrally disposed within the mold; and a filter disposed above the bottom of the mold and within a space formed between the at least one side of the mold and the core.

Abstract: A method of making a treating wash includes mixing brass granules with acetone, mixing carbon nanotube material, iron pyrite granules and copper granules in the acetone brass mixture, and straining the liquid from the remaining solid material. Methods of treating materials such as brass granules, iron pyrite granules, carbon nanotube material, and brass granules comprises washing the materials in the treating wash, followed by straining and drying the materials.

Abstract: A method of producing a composite material which includes a carbon-based material and a particulate or fibrous metal material Z. The method includes steps (a) to (c). In the step (a), at least a first carbon material and the metal material Z mixed into an elastomer, and dispersing the first carbon material and the metal material Z by applying a shear force to obtain a composite elastomer, the metal material Z having a melting point lower than a melting point of the first carbon material. In the step (b), the composite elastomer is heat-treated to vaporize the elastomer to obtain an intermediate composite material including a second carbon material and the metal material Z. In the step (c), the intermediate composite material is heat-treated together with a substance including an element Y having a melting point lower than the melting point of the metal material Z to vaporize the substance including the element Y.

Abstract: An apparatus and methods for controlling the location and distribution of loose ceramic particles in a ceramic metal composite component formed via casting. A retaining structure that may include loose ceramic particles is placed in a casting mold at a desired location for ceramic particles in the composite component prior to pouring molten metal into the casting mold. Alternatively, the loose ceramic particles may be introduced into the mold concurrently with the molten metal.

Abstract: Methods and processes are described that form ceramic wear surfaces on the outer surface of a cast part. A mold having a mold cavity is provided. The mold cavity may be washed using a refractory wash to provide for a smoother finish to the surface of the cast part and to maintain mold integrity. An adhesive is applied to predetermined locations in which increased wear during the use of the cast parts is anticipated to occur. Ceramic material may be applied to the predetermined locations by various means. A mask may be used to remove excess material from areas other than the predetermined locations. A molten metal is poured into the mold cavity and allowed to cool to form a cast part with a ceramic wear surface.

Abstract: A method for controlling a boride distribution in a metal matrix compost includes controlling a distribution of the boride particles are controlled during a solidification of a molten composite material. The controlling of the redistribution of the boride particles includes applying a heat to the composite material to form a molten composite material. The method includes, holding, by a mold (120, 715), the molten composite material. The method also includes focusing, by a reinforcement particle unit (100, 700), a location of the boride particles during a cooling of the molten composite material. The reinforcement particle unit could include a directed solidification unit (100). The reinforcement particle unit could also include centrifugal casting system (700). The arm includes a center mounting point (725).

Abstract: In various embodiments, composite materials containing a metal matrix having at least one metal and a carbon nanotube-infused fiber material are described herein. Illustrative metal matrices include, for example, aluminum, magnesium, copper, cobalt, nickel, zirconium, silver, gold, titanium and various mixtures thereof. The fiber materials can be continuous or chopped fibers and include, for example, glass fibers, carbon fibers, metal fibers, ceramic fibers, organic fibers, silicon carbide fibers, boron carbide fibers, silicon nitride fibers and aluminum oxide fibers. The composite materials can further include a passivation layer overcoating at least the carbon nanotube-infused fiber material and, optionally, the plurality of carbon nanotubes. The metal matrix can include at least one additive that increases compatibility of the metal matrix with the carbon nanotube-infused fiber material. The fiber material can be distributed uniformly, non-uniformly or in a gradient manner in the metal matrix.

Abstract: Methods, systems and compositions for manufacturing downhole tools and downhole tool parts for drilling subterranean material are disclosed. A model having an external peripheral shape of a downhole tool or tool part is fabricated. Mold material is applied to an external periphery of the model. The mold material is permitted to harden to form a mold about the model. The model is eliminated and a composite matrix material is cast within the mold to form a finished downhole tool or tool part.

Abstract: A method of producing a carbon-based material includes steps (a), (b) and (c). In the step (a), an elastomer and at least a first carbon material is mixed and the first carbon material is dispersed by applying a shear force to obtain a composite elastomer. In the step (b), the composite elastomer is heat-treated to vaporize the elastomer, and a second carbon material is obtained. In the step (c) the second carbon material is heat-treated together with a substance including an element Y to vaporize the substance including the element Y, a melting point of the element Y being low.

Abstract: A method for producing a carbon nanocomposite metal material with increased carbon nanomaterial dispersibility and increased binding between carbon nanomaterial and matrix metal stock is disclosed. A preform obtained by mixing a matrix metal stock and microparticulate-coated carbon nanomaterial without the need for a dispersant and then compacting the material is maintained for a set time period at a temperature that is at or above the melting point of the matrix metal stock. In this state, the heat-treated body is reduced to a temperature that allows hot working, and a compacting treatment is performed.

Abstract: A composite material comprising a plurality of hard particles surrounded by a matrix material comprising a plurality of nanoparticles. Earth boring tools including the composite material and methods of forming the composite material are also disclosed. A polycrystalline material having a catalyst material including nanoparticles in interstitial spaces between inter-bonded crystals of the polycrystalline material and methods of forming the polycrystalline material are also disclosed.

Abstract: A method has been found for centrifugal casting engine cylinders. A mold is charged with molten aluminum alloy and particulate silicon monoxide having an average size of 0.01 mm to 0.04 mm. The mold is rotated at a velocity and period of time to distribute the particulate silicon monoxide on an inner cylinder surface. The mold is allowed to cool until the aluminum alloy solidifies. A casting is demolded characterized in a uniform inner cylinder surface of the particulate silicon monoxide in an amount of 25 volume % and thickness 1 to 5 millimeters. The engine cylinders are distinguished in resistance to wear. Cylinder liners show no appreciable wear for over 100,000 miles of use.

Abstract: Earth-boring tools for drilling subterranean formations include a particle-matrix composite material comprising a plurality of silicon carbide particles dispersed throughout a matrix material, such as, for example, an aluminum or aluminum-based alloy. In some embodiments, the silicon carbide particles comprise an ABC-SiC material. Methods of manufacturing such tools include providing a plurality of silicon carbide particles within a matrix material. Optionally, the silicon carbide particles may comprise ABC-SiC material, and the ABC-SiC material may be toughened to increase a fracture toughness exhibited by the ABC-SiC material. In some methods, at least one of an infiltration process and a powder compaction and consolidation process may be employed.

Abstract: Methods of forming at least a portion of an earth-boring tool include providing particulate matter comprising a hard material in a mold cavity, melting a metal and the hard material to form a molten composition comprising a eutectic or near-eutectic composition of the metal and the hard material, casting the molten composition to form the at least a portion of an earth-boring tool within the mold cavity, and providing an inoculant within the mold cavity. Methods of forming a roller cone of an earth-boring rotary drill bit comprise forming a molten composition, casting the molten composition within a mold cavity, solidifying the molten composition to form the roller cone, and controlling grain growth using an inoculant as the molten composition solidifies. Articles comprising components of earth-boring tools are fabricated using such methods.

Abstract: Methods of forming at least a portion of an earth-boring tool include providing at least one insert in a mold cavity, providing particulate matter in the mold cavity, melting a metal and the hard material to form a molten composition, and casting the molten composition. Other methods include coating at least one surface of a mold cavity with a coating material having a composition differing from a composition of the mold, melting a metal and a hard material to form a molten composition, and casting the molten composition. Articles comprising at least a portion of an earth-boring tool include at least one insert and a solidified eutectic or near-eutectic composition including a metal phase and a hard material phase. Other articles include a solidified eutectic or near-eutectic composition including a metal phase and a hard material phase and a coating material in contact with the solidified eutectic or near-eutectic composition.

Abstract: A method of producing a carbon fiber composite material including: mixing an elastomer which includes an unsaturated bond or a group having affinity to carbon nanofibers with metal particles; and dispersing the carbon nanofibers into the elastomer including the metal particles by a shear force.

Abstract: A method of manufacturing a metal-carbon nanocomposite material in which aluminum is used as the matrix is disclosed. The manufacturing method comprises mixing a Si-coated carbon nanomaterial (30) and a powdered Mg material (33), heating the mixture to a melting point of the Mg material or higher, and thereafter cooling the mixture to obtain an Mg-carbon nanomaterial (34). A metal-carbon nanomaterial in which Al is used as the matrix is provided by cooling the Mg-carbon nanomaterial and molten Al (40) in a mixed state.

Abstract: Methods of fabricating earth-boring tools include forming an outer portion of an earth-boring tool from a powder mixture comprising hard particles and matrix particles comprising a metal matrix material, disposing a molten material at least partially within the outer portion of the earth-boring tool, and forming the molten material into another portion of the earth-boring tool. Methods of fabricating a bit body of an earth-boring rotary drill bit include forming an outer portion comprising a plurality of hard particles and a plurality of matrix particles comprising a metal matrix material and casting a molten material at least partially within the outer portion of the bit body to form another portion of the bit body. Earth-boring tools include a body for engaging a subterranean borehole having an outer portion and an inner portion comprising at least one material solidified within a cavity formed within the outer portion.

Abstract: An infiltration method of forming an article including providing a working mold including a solid binder member extending through an interior of the working mold, wherein the solid binder member is made of a binder material, and providing a layer of powder matrix material within a molding void of the working mold. The method further includes heating the working mold to form a molten binder pathway from the solid binder member to infiltrate the layer of powder matrix material.

Abstract: The present invention discloses a composite impactor for percussion crushers, said impactor comprising a ferrous alloy at least partially reinforced with titanium carbide according to a defined geometry, in which said reinforced portion comprises an alternating macro-microstructure of millimetric areas concentrated with micrometric globular particles of titanium carbide separated by millimetric areas essentially free of micrometric globular particles of titanium carbide, said areas concentrated with micrometric globular particles of titanium carbide forming a microstructure in which the micrometric interstices between said globular particles are also filled by said ferrous alloy.

Abstract: The present invention relates to a metal matrix composite (MMC) and the method of manufacturing the MMC. The MMC includes a preform formed from a composition having ceramic particles and ceramic fibers. The metal matrix composite also includes a support element formed from a metal where the metal impregnates through the preform. The method of forming the MMC includes the step of extruding the composition through a multi-screw extruder to form an extrudate. The method also includes the step of heating the preform and positioning the preform within a mold. The method further includes the step of heating the metal for forming a molten metal and injecting the molten metal into a cavity of the mold under pressure for infiltrating the preform with the molten metal. The method also includes cooling the molten metal to solidify the molten metal and form the metal matrix composite and removing the metal matrix composite from the mold.

Abstract: To provide a carbon fiber Ti—Al composite material having hardness, heat resistance and abrasion resistance, having reduced weight and improved strength and thermal conductivity and being excellent in uniformity of the quality. A carbon fiber Ti—Al composite material which is prepared by pressure impregnating a molded product containing fine carbon fibers having a fiber diameter of from 0.5 to 500 nm and a fiber length of at most 1,000 ?m and having a hollow-structured central axis and a titanium powder or a titanium oxide powder, with aluminum or an aluminum alloy by molten metal forging.

Abstract: An earth-boring rotary drill bit includes a bit body configured to carry one or more cutters for engaging a subterranean earth formation, the bit body comprising a particle-matrix composite material having a plurality of hard particles dispersed throughout a matrix material, the matrix material comprising a shape memory alloy. The matrix material comprises a metal alloy configured to undergo a reversible phase transformation between an austenitic phase and a martensitic phase. The matrix material may include an Ni-based alloy, Cu-based alloy, Co-based alloy, Fe-based alloy or Ti-based alloy.

Abstract: The invention provides a method of forming a metal matrix composite (MMC) comprising a metal matrix and a fibrous material embedded therein, the method comprising bringing the metal matrix into the molten state and contacting the fibrous material with the metal matrix in the molten state in a directionally controlled manner, whereby the Young's modulus of the resultant cooled MMC is controlled in one or more particular direction and optionally at one or more particular location.

Abstract: An apparatus for fabrication of a magnesium-based carbon nanotube composite material, the apparatus includes a thixomolding machine, and a feeding device. The thixomolding machine includes a heating barrel, a feeding inlet, a nozzle, a heating portion, and a plunger. The heating barrel includes a first end and a second end. The feeding inlet is disposed at the first end. The nozzle is disposed at the second end. The heating portion is disposed around the heating barrel. The plunger is disposed at a center of the heating barrel. The feeding device includes a hopper; an aspirator connected to the hopper, a first container, and a second container. The hopper is in communication with the first container and the second container. A method for fabricating a magnesium-based carbon nanotube composite material is also provided.

Abstract: A drill collar formed substantially entirely from a metal matrix material and one or more metal alloys is provided, the drill collar being produced through a molding process. The metal matrix material of the drill collar minimizes lateral movement and vibration during drilling operations, while providing a weight greater than that of conventional drill collar materials, thereby enabling construction of drill collars and bottom hole assemblies having a reduced length.

Abstract: A method for fabricating a magnesium-based composite material, the method includes the steps of: (a) providing a magnesium-based melt and a plurality of carbon nanotubes, mixing the carbon nanotubes with the magnesium-based melt to achieve a mixture; (b) injecting the mixture into at least one mold to achieve a preform; and (c) extruding the preform to achieve the magnesium-based carbon nanotube composite material.

Abstract: Earth-boring drill bits include a bit body including a blockage-resistant internal fluid passageway. The blockage-resistant internal fluid passageway includes at least one internal fluid passageway formed in the bit body and a cuttings filtering feature formed in the at least one internal fluid passageway configured to prevent at least some cuttings from flowing through the at least one internal fluid passageway. In one embodiment, the cuttings filtering feature includes at least one lateral member extending transversely across the at least one internal fluid passageway. In another embodiment, the cuttings filtering feature includes forming a central portion of the at least one internal fluid passageway with a width along a lateral axis thereof less than an average width of a fluid path extending through a nozzle disposed at least partially within the at least one internal fluid passageway. Methods of forming the blockage-resistant internal fluid passageway are also disclosed.

Abstract: The invention discloses the internal structures and processes to synthesize the structure of self-healing materials, specially metallic materials, metal matrix micro and nanocomposites. Self healing is imparted by incorporation of macro, micro or nanosize hollow reinforcements including nanotubes, filled with low melting healing material or incorporation of healing material in pockets within the metallic matrix; the healing material melts and fills the crack. In another concept, macro, micro and nanosize solid reinforcements including ceramic and metallic particles, and shape memory alloys are incorporated into alloy matrices, specially nanostructured alloy matrices, to impart self healing by applying compressive stresses on the crack or diffusing material into voids to fill them.

Abstract: A method of making a treating wash includes mixing brass granules with acetone, mixing carbon nanotube material, iron pyrite granules and copper granules in the acetone brass mixture, and straining the liquid from the remaining solid material. Methods of treating materials such as brass granules, iron pyrite granules, carbon nanotube material, and brass granules comprises washing the materials in the treating wash, followed by straining and drying the materials.

Abstract: An article in the form of one of a plate, a sheet, a cylinder, and a portion of a cylinder, which is adapted for use as at least a portion of a wear resistant working surface of a roll is disclosed. The article includes a metal matrix composite comprising a plurality of inorganic particles dispersed in a matrix material. The matrix material includes at least one of a metal and a metal alloy, wherein the melting temperature of the inorganic particles is greater than the melting temperature of the matrix material. A plurality of hard elements are embedded in the metal matrix composite. The wear resistance of the metal matrix composite is less than the wear resistance of the hard elements, and the metal matrix composite preferentially wears away when the article is in use, thereby providing or preserving gaps between each of the plurality of hard elements at a working surface of the article.

Abstract: A method of making a treating wash includes mixing brass granules with acetone, mixing carbon nanotube material, iron pyrite granules and copper granules in the acetone brass mixture, and straining the liquid from the remaining solid material. Methods of treating materials such as brass granules, iron pyrite granules, carbon nanotube material, and brass granules comprises washing the materials in the treating wash, followed by straining and drying the materials.

Abstract: A method of making a treating wash includes mixing brass granules with acetone, mixing carbon nanotube material, iron pyrite granules and copper granules in the acetone brass mixture, and straining the liquid from the remaining solid material. Methods of treating materials such as brass granules, iron pyrite granules, carbon nanotube material, and brass granules comprises washing the materials in the treating wash, followed by straining and drying the materials.

Abstract: The present invention relates to a magnesium-based composite material includes at least two magnesium-based metallic layers; and at least one magnesium-based composite layer respectively sandwiched by the at least two magnesium-based metallic layers. The present invention also relates to a method for fabricating a magnesium-based composite material, the method includes the steps of: (a) providing at least two magnesium-based plates; (b) providing a plurality of nanoscale reinforcements; (c) sandwiching the nanoscale reinforcements between the at least two magnesium-based plates to form a preform; and (d) hot pressing the preform to achieve the magnesium-based composite material.

Abstract: A method of producing a composite material which includes a carbon-based material and a particulate or fibrous metal material Z. The method includes steps (a) to (c). In the step (a), at least a first carbon material and the metal material Z mixed into an elastomer, and dispersing the first carbon material and the metal material Z by applying a shear force to obtain a composite elastomer, the metal material Z having a melting point lower than a melting point of the first carbon material. In the step (b), the composite elastomer is heat-treated to vaporize the elastomer to obtain an intermediate composite material including a second carbon material and the metal material Z. In the step (c), the intermediate composite material is heat-treated together with a substance including an element Y having a melting point lower than the melting point of the metal material Z to vaporize the substance including the element Y.

Abstract: The present invention relates to a metal matrix composite (MMC) and the method of manufacturing the MMC. The MMC includes a preform formed from a composition having ceramic particles and ceramic fibers. The metal matrix composite also includes a support element formed from a metal where the metal impregnates through the preform. The method of forming the MMC includes the step of extruding the composition through a multi-screw extruder to form an extrudate. The method also includes the step of heating the preform and positioning the preform within a mold. The method further includes the step of heating the metal for forming a molten metal and injecting the molten metal into a cavity of the mold under pressure for infiltrating the preform with the molten metal. The method also includes cooling the molten metal to solidify the molten metal and form the metal matrix composite and removing the metal matrix composite from the mold.