US2004173291A1PendingUtilityA1

Metal matrix composite

30
Priority: Nov 18, 2002Filed: Nov 18, 2003Published: Sep 9, 2004
Est. expiryNov 18, 2022(expired)· nominal 20-yr term from priority
Inventors:Boris Y. RozenoyerWilliam AltergottUday Kashalikar
C04B 2235/404C04B 2235/77F01L 1/46C04B 2235/407F02F 7/0087C04B 2235/80C04B 2235/401C04B 2235/9607C04B 38/0058C04B 35/653F01L 2303/00F02F 1/38F01L 3/02F01L 2301/02C04B 2235/96F02B 53/00C04B 41/88C04B 35/117C04B 2111/00931F01L 2301/00C22C 9/00C22C 23/00C04B 41/5155C04B 35/565C04B 2235/402C04B 41/009C22C 1/1073C22C 1/1021C22C 1/1036
30
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Claims

Abstract

A metal matrix composite and method wherein a reinforcement preform is made by partially sintering ceramic particles and a metal matrix material is used into the preform. In one example, the resulting isotropic metal matrix composite has an ultimate tensile strength of at least 80 ksi in all directions, a high temperature strength retention of at least 85% up to 500° F., and a high temperature stiffness retention of at least 95% at temperatures up to 500° F. Preferably, the preform has an average pore size of 1-5 microns, an average interconnected porosity 35-45 vol. %, a 100% open porosity, and a flexure strength of greater than 7 ksi.

Claims

exact text as granted — not AI-modified
What is claimed is:  
     
         1 . A metal matrix composite comprising: 
 an isotropic reinforcement preform made by partially sintering ceramic particles; and    a metal matrix infused into the preform yielding an isotropic metal matrix composite having an ultimate tensile strength of at least 80 ksi in all directions.    
     
     
         2 . The metal matrix composite of  claim 1  in which the tensile strength is greater than or equal to 100 ksi.  
     
     
         3 . The metal matrix composite of  claim 1  in which the metal matrix composite has an isotropic high temperature strength retention of at least 85% up to 500° F.  
     
     
         4 . The metal matrix composite of  claim 1  in which the metal matrix composite has an isotropic high temperature stiffness retention of at least 95% at temperatures up to 500° F.  
     
     
         5 . The metal matrix composite of  claim 1  in which the preform has an average pore size of 1-5 microns, an average interconnected porosity 35-45 vol. %, a 100% open porosity, and a flexure strength of greater than 7 ksi.  
     
     
         6 . The metal matrix composite of  claim 1  in which the ceramic particles are substantially pure.  
     
     
         7 . The metal matrix composite of  claim 6  in which the ceramic particles are at least 99.0% pure.  
     
     
         8 . The metal matrix composite of  claim 1  in which the metal matrix material is selected to prevent chemical reaction with the preform.  
     
     
         9 . The metal matrix composite of  claim 1  in which the particles of the preform are selected from the group consisting of alumina and silicon carbide.  
     
     
         10 . The metal matrix composite of  claim 1  in which the metal matrix material is selected from the group consisting of aluminum, aluminum alloys, magnesium, magnesium alloys, copper, and copper alloys.  
     
     
         11 . The metal matrix composite of  claim 10  in which the aluminum is substantially pure aluminum.  
     
     
         12 . The metal matrix composite of  claim 11  in which the aluminum is 99.999% pure aluminum.  
     
     
         13 . The metal matrix composite of  claim 10  in which the aluminum alloy is aluminum alloy No. 201.  
     
     
         14 . The metal matrix composite of  claim 1  in which the metal matrix composite has a coefficient of thermal expansion of less than 7.0 ppm/° F.  
     
     
         15 . A metal matrix composite comprising: 
 a partially sintered reinforcement preform made of ceramic particles; and    a metal matrix infused into the preform yielding an isotropic metal matrix composite having a high temperature strength retention of at least 85% up to 500° F.    
     
     
         16 . The metal matrix composite of  claim 15  in which the ultimate tensile strength of the metal matrix composite is at least 80 ksi in all directions.  
     
     
         17 . The metal matrix composite of  claim 15  in which the metal matrix composite has a high temperature stiffness retention of at least 95% at temperatures up to 500° F.  
     
     
         18 . The metal matrix composite of  claim 15  in which the preform has an average pore size of 1-5 microns, an average interconnected porosity 35-45 vol. %, a 100% open porosity, and a flexure strength of greater than 7 ksi.  
     
     
         19 . A metal matrix composite comprising: 
 a partially sintered reinforcement preform made of ceramic particles; and    a metal matrix infused into the preform yielding an isotropic metal matrix composite with a high temperature stiffness retention of at least 95% at temperatures up to 500° F.    
     
     
         20 . The metal matrix composite of  claim 19  in which the metal matrix composite has a high temperature strength retention of at least 85% up to 500° F.  
     
     
         21 . The metal matrix composite of  claim 19  in which the preform has an average pore size of 1-5 microns, an average interconnected porosity of between 35-45 vol. %, approximately 100% open porosity, and a flexure strength of greater than 7 ksi.  
     
     
         22 . The metal matrix composite of  claim 19  in which the ultimate tensile strength of the metal matrix composite is at least 80 ksi in all directions.  
     
     
         23 . A metal matrix composite comprising: 
 a reinforcement preform made by partially sintering ceramic particles to have an average pore size of between 1-5 microns, an average interconnected porosity of between 35-45 vol. %, approximately 100% open porosity, and a flexure strength of greater than 7 ksi, and isotropic properties; and    a metal matrix infused into the preform.    
     
     
         24 . The metal matrix composite of  claim 23  in which the metal matrix composite has a high temperature strength retention of at least 85% up to 500° F.  
     
     
         25 . The metal matrix composite of  claim 23  in which the ultimate tensile strength of the metal matrix composite is at least 80 ksi in all directions.  
     
     
         26 . The metal matrix composite of  claim 23  in which the metal matrix composite has a high temperature stiffness retention of at least 95% at temperatures up to 500° F.  
     
     
         27 . A metal matrix composite comprising: 
 a preform made by partially sintering ceramic particles to have an average pore size of between 1-5 microns, an average interconnected porosity of between 35-45 vol. %, approximately 100% open porosity, a flexure strength of greater than 7 ksi, and isotropic properties; and    a metal matrix infused into the preform yielding an isotropic metal matrix composite with a high temperature strength retention of at least 85% up to 500° F., high temperature stiffness retention of at least 95% up to 500° F., and an ultimate tensile strength of at least 80 ksi in all directions.    
     
     
         28 . A method of making a metal matrix composite, the method comprising: 
 partially sintering ceramic particles to form a reinforcement preform having an average pore size of between 1-5 microns, an average interconnected porosity of between 35-45 vol. %, an approximately 100% open porosity, and a flexure strength of greater than 7 ksi; and    infusing the partially sintered preform with a metal matrix material.    
     
     
         29 . The method of  claim 28  in which infusion includes subjecting the preform to the molten metal matrix material under pressure.  
     
     
         30 . The method of  claim 29  in which infusion includes pressure casting.  
     
     
         31 . The method of  claim 29  in which infusion includes squeeze casting.  
     
     
         32 . The method of  claim 28  in which the resulting metal matrix composite has a high temperature stiffness retention of at least 95% at temperatures up to 500° F.  
     
     
         33 . The method of  claim 28  in which the resulting metal matrix composite has a high temperature strength retention of at least 85% up to 500° F.  
     
     
         34 . The method of  claim 28  in which the ultimate tensile strength of the resulting metal matrix composite is at least 80 ksi in all directions.  
     
     
         35 . The method of  claim 28  in which the ceramic particles are substantially pure.  
     
     
         36 . The method of  claim 35  in which the ceramic particles are at least 99.0% pure.  
     
     
         37 . The method of  claim 28  in which the metal matrix material is selected to prevent chemical reaction with the preform.  
     
     
         38 . The method of  claim 28  in which the particles of the preform are selected from the group consisting of alumina and silicon carbide.  
     
     
         39 . The method of  claim 28  in which the metal matrix material is selected from the group consisting of aluminum, aluminum alloys, magnesium, magnesium alloys, copper, and copper alloys.  
     
     
         40 . The method of  claim 39  in which the aluminum is substantially pure aluminum

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