Abstract: A method for producing an aluminum nitride/aluminum base composite material comprising the steps of; (A) charging aluminum nitride powder into a container provided in a molten metal pressure apparatus, (B) applying pressure to the aluminum nitride powder in the container, (C) pouring a molten aluminum base material into the container, and, (D) applying pressure to the molten aluminum base material in the container to fill the aluminum base material in space between the aluminum nitride powder particles.

Abstract: An intermediate material is formed by coating at least a half of the surface of a function selecting material having at least one of physical property values that are different from those of a casting metal material forming a cast product with a coating metal material and the casting metal material is cast together with the intermediate material to form a composite body in casting the product.

Abstract: A method and apparatus for manufacturing composite materials. 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: This invention relates to the synthesis of a new generation of metastable aluminum-titanium (Al—Ti) alloys and the process of making them. The preparation method used is a combination process incorporating the advantages of conventional casting and spray techniques. The process is a low cost process. The aluminum-titanium materials made in this invention contain titanium in both the reacted and unreacted form. The results were confirmed using microstructural and x-ray diffraction studies. The presence of phases clearly indicate the metastable nature of these materials in accordance with the equilibrium phase diagram established for Al—Ti system. The Al—Ti materials can be made in the dimensions suitable for structural applications at ambient and elevated temperatures and as control materials for synthesis of more dilute equilibrium Al—Ti materials using conventional techniques such as 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: This invention relates to methods and apparatus useful in the ceramics industry. More specifically, this invention relates to the fabrication of high melting, wear-resistant ceramics and ceramic composites at low temperatures. The method involves reacting (1) a fluid formed from melting a metal alloy, comprising at least one reactive metal and at least one non-reactive metal, and having a melting temperature substantially below the product material melting point, typically below about 1500 C., with (2) a rigid, porous material. The reaction should occur for a sufficient time to allow the liquid to infiltrate the porous material and allow the active metal(s) to react with the porous material so as to form a ceramic or ceramic composite having a melting temperature substantially higher than 1500 C.

Abstract: A method of casting a siliconized silicon carbide part. The method includes providing a pre-casting mix comprised of a silicon carbide powder having a maximum particle size within a range of about 1000 to 2000 microns, and water having a percentage by weight of no more than about 9.5% of the mix. A slurry is formed from the mix and poured into a mold. The water is then removed from the mold within a predetermined period of time to form a solid porous green part. The green part is surrounded with silicon metal, and heated to a predetermined temperature above the melting point of the silicon metal. The silicon metal then siliconizes the green part to form a siliconized silicon carbide part.

Abstract: A composite material 5 in which a dispersing material 7 is dispersed in a matrix 6 is provided.

Abstract: The invention is to offer a composite material with least uneven distribution of a mechanical strength resulted from dispersing conditions of an inorganic filler and having a by far high mechanical strength in comparison with conventional composite materials, as well as to offer a method of making the same. Inorganic hollow particles and at least one of inorganic fiber sheets are accommodated in a stacked manner within a casting mold, and a molten metal is poured into a casting mold while pressurizing it, followed by cooling, whereby it is possible to produce such a composite material where a first composite layer and a second composite layer continuously exist in a metal matrix, so as to compose a composite material being a single body as a whole, the first composite layer containing at least one of inorganic fiber sheets and the second composite layer containing inorganic hollow particles.

Abstract: A method of manufacturing a preform for compounding use which, is to be impregnated with a molten metal to be compounded with a matrix material, is provided. The method includes the step of mixing short fibers, ceramic particles and a binder material together to make a mixture. The average of lengths of the short fibers is 100 to 200 &mgr;m while the volumetric percentage of the short fibers is 1 to 7%. The content of the binder material in the mixture is 0.3 to 5.0 mass %. The method includes also the steps of forming the mixture so as to have a predetermined shape, and sintering the mixture at a temperature of 1000 to 1150° C. to form the preform. Thus, it is restrained that the preform is deformed or an un-reinforced region is formed in the compounded portion.

Abstract: A method of preparing a metal alloy comprising a dispersion of particles of a first metallic material consisting of one or more refractory hard metals in a matrix of a second metallic material includes establishing a molten body of the second metallic material and introducing solid particles of the first metallic material into the molten body. Alternatively solid particles of a metalloid which reacts with the second metallic material to form particles of the first metallic material may be introduced into the molten body. The first metallic material has a higher melting point than the second metallic material and is substantially insoluble therein. The molten body is then stirred at a rate sufficient to effect shearing of the surfaces of the particles such that the surfaces are wetted by the molten body, and the molten body containing the resultant dispersion is cast in any desired manner.

Abstract: A metal-based composite material is formed by impregnating a matrix metal of Al or Al alloy into ores of a porous preform of a hydrogenatable metal having a metal hydride in at least a part of its surface.

Abstract: The present invention relates to a manufacturing method for a composite material comprising two or more metals or nonmetals and compounds thereof and, more particularly, to a manufacturing method in which a dispersion material can be dispersed very homogeneously into a base material of the composite material independently of the composition of the composite material.

Abstract: A porous preform includes at least one kind of preform-forming materials of ceramic particles, ceramic fibers and ceramic whiskers, and a film of a binder formed on a surface of said at least one kind of the preform-forming materials and comprising magnesium or a magnesium alloy. The preform is used for producing a metal matrix composite material.

Abstract: A method for producing metal/ceramic composite materials includes an injection plunger; a casting chamber having an opening through which casting metal is poured in and a ceramic precursor product is shot in; and a die having a runner and a die cavity. A shot head is used to shoot ceramic powder into a die, so that the powder is compacted to form a porous preform. The preform is infiltrated with liquid metal under pressure in the die.

Abstract: Composite wear component produced by casting and consisting of a metal matrix whose working face or faces include inserts which have a very high wear resistance, characterized in that the inserts consist of a ceramic pad, this ceramic pad consisting of a homogeneous solid solution of 20 to 80% of Al2O3 and 80 to 20% of ZrO2, the percentages being expressed by weights of the constituents, and the pad then being impregnated with a liquid metal during the casting.

Abstract: A system using fiber reinforced metal matrix wire in castings increases the tensile strength of and/or the rigidity the resultant casting. Because the fiber reinforced metal matrix wire is formed by a method that limits the exposure of the fiber to excessive heat, the fiber retains its strength more than conventionally formed wires. This system is applicable to castings for preferential reinforcement—increasing tensile strength and rigidity, and to sandwich structures wherein the composite wires bracket and internal matrix or a metallic layer surrounds and is strengthened by a central composite wire.

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: Disclosed are methods and materials for preparing metal matrix composite (MMC) components that have low weight, good thermal conductivity and a controllable in-plane coefficient of thermal expansion. One embodiment of the invention features a metal matrix composite that includes a metal alloy and random in-plane discontinuous fibers. In some embodiments, the metal alloy includes aluminum, copper or magnesium. In certain embodiments, the metal matrix composite includes additives that enable solution hardening. In other embodiments, the metal matrix composite includes additives that enable precipitation hardening. Another embodiment of the invention features a method of manufacturing a metal matrix composite. The method includes contacting random in-plane discontinuous fibers with a binder, and pressurizing the random in-plane discontinuous fibers and the binder to form a bound preform. The preform is pressurized to a pressure greater than the molten metal capillary breakthrough pressure of the bound preform.

Abstract: A process for making a metal-matrix composite (MMC), includes a mixture of particulate ceramic powder with a liquid carrier, without addition of a binder, to prepare a slip having thixotropic properties. The slip is introduced in a substantially dense consistency into a casting mold which is then subjected to vibrations so as to separate the carrier from the ceramic particles and to allow the carrier to float upon the ceramic particles while at the same time compacting the slip to realize a ceramic preform of porous consistency having pores. After terminating the exposure of the casting mold to vibrations, the liquid carrier is removed and the preform is allowed to solidify in the casting mold, without exposure to any further compaction measures, such as sintering, pressing or the like, and the casting mold is maintained in a position of rest. Subsequently, matrix metal is poured into the casting mold to fill the pores of the preform.

Abstract: A device for producing metal/ceramic composite materials includes (1) an injection plunger; (2) a casting chamber having an opening through which casting metal is poured in and a ceramic precursor product is shot in; and (3) a die having a runner and a die cavity. A shot head is used to shoot ceramic powder into a die, so that the powder is compacted to form a porous preform. The preform is infiltrated with liquid metal under pressure in the die.

Abstract: A method of adding boron to a tungsten, or tantalum, containing titanium aluminide alloy to form a boride dispersion in the tungsten, or tantalum, containing titanium aluminide. A molten tungsten, or tantalum, containing titanium aluminide alloy is formed and tungsten, or tantalum, boride is added to the molten tungsten, or tantalum, containing titanium aluminide alloy to form a molten mixture. The molten mixture is cooled and solidified to form a tungsten, or tantalum, containing titanium aluminide alloy having a uniform dispersion of tungsten, or tantalum, boride particles substantially without the formation of clusters of tungsten, or tantalum, boride. The titanium aluminide alloy comprises between 0.5 at % and 2.0 at % boron.

Abstract: The present invention provides improved heated manifolds, heaters and nozzles for injection molding, having a high strength metal skeleton infiltrated with a second phase metal having higher thermal conductivity. Also disclosed is method of forming a manifold, heater or nozzle preform and infiltrating the preform with a highly thermally conductive material The invention also provides a method of simultaneously infiltrating and brazing injection molding components of similar or dissimilar materials together.

Abstract: Method of making articles comprising polycrystalline &agr;-Al2O3 fibers within a matrix of aluminum, or an alloy of aluminum and up to about 2% copper.

Abstract: Nucleated casting systems and methods comprise the addition of powders into a liquidus portion of the casting. The casting system forms a casting comprising a liquidus portion that receives the refined liquid metal and a solidified portion, the casting further comprising a fine-grain, homogeneous microstructure that is essentially oxide- and sulfide-free and segregation defect free. The casting system comprises a source of refined liquid metal, the refined liquid metal having oxides and sulfides refined out of the metal; a solid metal particle addition system that adds solid metal particles to a surface of the liquidus portion of the casting; and a nucleated casting system for forming the casting. The solid metal particle addition system adds solid metal particles that serve as nucleation centers during solidification of the casting.

Abstract: A method of manufacturing a preform for compounding use which, is to be impregnated with a molten metal to be compounded with a matrix material, is provided. The method includes the step of mixing short fibers, ceramic particles and a binder material together to make a mixture. The average of lengths of the short fibers is 100 to 200 &mgr;m while the volumetric percentage of the short fibers is 1 to 7 %. The content of the binder material in the mixture is 0.3 to 5.0 mass %. The method includes also the steps of forming the mixture so as to have a predetermined shape, and sintering the mixture at a temperature of 1000 to 1150° C. to form the preform. Thus, it is restrained that the preform is deformed or an un-reinforced region is formed in the compounded portion.

Abstract: A superabrasive containing layered composite is provided which comprises a substrate block consisting of either ceramic material and metallic or several metallic materials, and a superabrasive containing body adjacent said substrate block. The superabrasive contains superabrasive particles, and a metallic ingredient which is distributed in the superabrasive containing layer, including a working surface. The superabrasive material may be formed using a compression cell wherein the compression cell comprises a die defined by a vertical wall and a flat closed bottom. Placed in the die, in order from bottom upward, comprises a formed pallet of single body or layers of mixed powder forming a refractory compound, a material mass of a working layer containing diamond particles, a mass of ignition material comprising an SHS composition, and an electrical heating element.

Abstract: Ceramic oxide pre-forms comprising substantially continuous, ceramic oxide fibers, and methods for making the same. The ceramic oxide pre-forms are useful, for example, as in making metal matrix composites reinforced with substantially continuous, ceramic oxide fibers.

Abstract: Solid objects are made by means of a novel multi-step forming, debinding, sintering and infiltrating process, using a metal-ceramic composition. In this process, the mixture is held for a period of time to degas and settle the powdered material from a liquid binder. The packed geometry is then heated to above the melting temperature of the binder to remove the binder portion of the solid geometry. Upon removal of the binder the binder-free solid geometry is raised to a temperature where the metal pre-sinters together into a three-dimensional rigid matrix with interconnected porosity to form a solid precursor. The porous matrix includes the particulate ceramic material and a first metal, which are at least partially sintered. A molten second metal is then introduced to the fill the porous matrix and form an infiltrated matrix.

Abstract: A dental material and method for forming a laminated structure having at least three layers with at least one layer composed of a base material composition containing high fusing temperature metal particles and another layer composed of a filler material composition of low fusing temperature metal particles. The layers are arranged in tandem adjacent to one another in an alternating sequence such that upon firing of the laminated structure in a furnace at a temperature at least equal to the melting temperature of the low fusing temperature metal particles but below the melting temperature of the high fusing temperature metal particles diffusion occurs from the filler layers into the base layers to bring the base layers together and to form a solid structure.

Abstract: A metal matrix composite includes a plurality of fibers having an average diameter of about eight micrometers with a coating, and a metal or alloy distributed with said fibers, a fibers-to-metal or alloy ratio has a range is has a range of about 9:1 to less than about 1:1.

Abstract: Disclosed are economical methods and apparatus for high throughput pressure infiltration casting. Methods of the invention use a mold vessel as an evacuation chamber along with an evacuation cap to produce superior quality near-net shape finished cast parts with low porosity. Other methods of the invention use an improved heat transfer technique for directionally solidifying molten infiltrant at an increased rate to increase further the throughput of the pressure infiltration casting cycle. The invention also provides apparatus for practicing methods for high throughput pressure infiltration casting. One embodiment of an apparatus of the invention is a removable evacuation cap, often used in conjunction with a fill tube. Another apparatus embodiment is an evacuation cap coupled to a mold vessel which is used as an evacuation chamber.

Abstract: A method of making metal/refractory composites includes bubbling a reactive gas through a melt to form a foam including refractory particles. In continuous mode, the foam is separated from the melt and the melt replenished. Composites of lightweight metals reinforced with discontinuous refractory ceramic particles can be efficiently and economically produced.

Abstract: Metal matrix composite wires that include at least one tow comprising a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The fibers are selected from the group of ceramic fibers carbon fibers, and mixtures thereof. The wires have certain specified characteristics such as roundness values, roundness uniformity values, and/or diameter uniformity values.

Abstract: A device for producing metal/ceramic composite materials includes (1) an injection plunger; (2) a casting chamber having an opening through which casting metal is poured in and a ceramic precursor product is shot in; and (3) a die having a runner and a die cavity. A shot head is used to shoot ceramic powder into a die, so that the powder is compacted to form a porous preform. The preform is infiltrated with liquid metal under pressure in the die.

Abstract: Method of making wire comprising polycrystalline &agr;-Al2O3 fibers within a matrix of substantially pure elemental aluminum, or an alloy elemental aluminum and up to about 2% copper.

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: Metal matrix composite wires that include a plurality of substantially continuous, longitudinally positioned fibers in a metal matrix. The wire exhibits zero breaks over a length of at least 300 meters when tested according to a specified test.

Abstract: A process for sealing a ceramic filter by infiltrating a metal into an end of the filter. The process includes the steps of contacting the end of a porous ceramic filter with a molten metal, whereby the metal enters into the ceramic matrix to substantially fill the void space. The ceramic filter is cooled to form a filter having a ceramic-metal composite portion. The present invention also provides a filter having an infiltrated metal seal. Methods for joining infiltrated ends are also provided.

Abstract: A method of high throughput pressure casting involving the steps of providing a mold vessel containing an infiltrant and a mold cavity; evacuating the mold cavity, and heating the infiltrant to form a molten infiltrant which isolates a reduced pressure in the mold cavity; transferring the mold vessel containing the molten infiltrant to a pressure vessel; applying pressure to the molten infiltrant to move it into the mold cavity; and cooling the molten infiltrant in the mold cavity to solidify the molten infiltrant. The mold cavity may contain a preform to produce a metal matrix composite.

Abstract: A method of producing a silicon based alloy is described which comprises melting a silicon alloy containing greater than 50 wt. % silicon and preferably including aluminium. The melted alloy is then inert gas atomized to produce powder or a spray formed deposit in which the silicon forms a substantially continuous phase made up of fine, randomly oriented crystals in the microstructure. The alloy produced by the method has particularly useful application in electronics packaging materials and a typical example comprises an alloy of 70 wt. % silicon and 30 wt. % aluminium. Such an alloy is an engineering material which, for example, is machinable.

Abstract: A carbide dispersed, strengthened copper alloy includes copper as a major constituent, carbide particles, and a dispersing agent. The carbide particles consist of one or more carbides selected from chromium carbide, tungsten carbide, molybdenum carbide, and tantalum carbide. The dispersing agent consists of one or more elements selected from magnesium, chromium, silicon, and aluminum.

Abstract: A ceramic-metal composite that is tough and stiff has been prepared and is comprised of an inert ceramic (e.g., alumina) embedded and dispersed in a matrix comprised of a metal (e.g., aluminum), a reactive ceramic (e.g., boron carbide) and a reactive ceramic-metal reaction product (e.g., AlB2, Al4BC, Al3B48C2, AlB12, Al4C3, AlB24C4 or mixtures thereof) wherein grains of the inert ceramic have an average grain size greater than or equal to the average grain size of grains of the reactive ceramic. The ceramic-metal composite may be prepared by forming a mixture comprised of an inert ceramic powder (e.g., alumina) and a reactive ceramic powder (e.g., boron carbide), the inert ceramic powder having an average particle size equal to or greater than the average particle size of the reactive ceramic powder, forming the mixture into a porous body and consolidating the porous body in the presence of a metal (e.g., aluminum) to form the ceramic-metal composite.

Abstract: A casting includes a heat transfer surface having a plurality of cavities. The plurality of cavities include a density of at least about 25 cavities per square centimeter to about 1,100 cavities per square centimeter resulting in increased surface area and therefore enhanced heat transfer capability. Also disclosed is a mold for forming a pattern for molding the casting. The mold includes a surface defining a portion of a chamber to which are attached a plurality of particles having an average particle size in a range of about 300 microns to about 2,000 microns.

Abstract: A composite material having less than about 25 volume percent refractory particles in a metal matrix is concentrated to have about 37-45 volume percent refractory particles. The concentrating is accomplished by heating the composite material to melt the matrix, and then contacting the molten composite material to a porous element having an average pore size greater than that of the average particle size. A small pressure differential, on the order of about one atmosphere, is applied across the porous element, so that metal matrix material separates from the composite material and flows through the porous element. The particulate volume fraction in the composite material gradually increases. When the particulate volume fraction exceeds about 37 volume percent, the mass of composite material becomes semi-solid and freestanding. The resulting composite material may be further processed, as by forming to a useful shape or diluting with another matrix material.

Abstract: A casting process for producing a metal matrix composite comprising a first phase or a matrix of a metal or metal alloy and a second phase of particles dispersed in the matrix, comprising the steps of: preparing a melt of the metal or metal alloy in a vessel; feeding the particles to the melt; applying ultrasonic vibration to the melt while electromagnetically stirring the melt; and then causing solidification of the melt. The process preferably further comprises the step of applying ultrasonic vibration to the melt while electromagnetically stirring the melt during the solidification of the melt.

Abstract: A metal-based composite material is formed by impregnating a matrix metal of Al or Al alloy into ores of a porous preform of a hydrogenatable metal having a metal hydride in at least a part of its surface.

Abstract: A composite material is rapidly melted by furnishing a pre-wetted composite material in the form of granules, placing the granules into an induction coil, and powering the induction heater to melt the metal matrix portion of the granules to form a molten mixture. High power inputs to the induction coil may be used, so that the granules are rapidly heated to their melting point and to temperatures above the melting point, from which the molten mixture may be cast. Because of the rapid heating, otherwise-reactive composite materials may be prepared by melting in air.

Abstract: A dispersion strengthening method for metallic melts that are used to form large articles. The method comprises adding nanophase particles into a molten metallic melt and dispersing the nanophase particles in the metallic melt. The nanophase particles comprising particles with diameters in the range of about 5 nanometers to about 100 nanometers. The step of dispersing the nanophase particles in the metallic melt spaces the particles from each other with an average interparticle spacing (IPS) in a range from about 10 nanometers to about 500 nanometers.

Abstract: The present invention relates to a process for the formation of components for use in a disk drive having graded properties. Particularly, the invention provides a method for forming a metal matrix composite components having graded properties. The graded properties are achieved by, for example, locating differing amounts of reinforcement material in different portions of a component and/or locating different compositions of reinforcement material in different portions of a component. Silicon carbide particles, for example, provide a low density reinforcement to an aluminum metal matrix creating a metal matrix composite having greater strength stiffness and damping.