Method of manufacturing composite material

Abstract

A method of manufacturing metal matrix composite with ceramic particles as a disperse phase includes the steps of holding the single metal matrix composite or the plurality of layered metal matrix composites between a pair of pressing dies, pressing the metal matrix composite by the pressing dies, and heating the metal matrix composite.

1 . A method of manufacturing metal matrix composite with ceramic particles as a disperse phase, comprising the steps of: 
 holding a single metal matrix composite or a plurality of layered metal matrix composites, each having a distortion, between a pair of pressing dies;    pressing the metal matrix composite by the pressing dies; and    heating the metal matrix composite.    
   
   
       2 . The method according to  claim 1 , further comprising the steps of: 
 placing ceramic particles in a forming die;    injecting pressurized molten matrix metal into the forming die; and    solidifying the matrix metal.    
   
   
       3 . The method according to  claim 2 , wherein the molten metal matrix is premixed with other ceramic particles.  
   
   
       4 . The method according to  claim 3 , wherein other ceramic particles are the same as the ceramic particles placed in the forming die.  
   
   
       5 . The method according to  claim 3 , wherein other ceramic particles are different from the ceramic particles placed in the forming die.  
   
   
       6 . The method according to  claim 1 , wherein the holding step includes alternately layering an intervening die and the plurality of metal matrix composites.  
   
   
       7 . The method according to  claim 6 , wherein the intervening die is formed in the same shape as the pressing die as seen in the pressing direction.  
   
   
       8 . The method according to  claim 6 , wherein the intervening die is formed larger than the pressing die as seen in the pressing direction.  
   
   
       9 . The method according to  claim 6 , wherein the intervening die is formed smaller than the pressing die as seen in the pressing direction and the intervening die is not smaller than the metal matrix composites as seen in the pressing direction.  
   
   
       10 . The method according to  claim 6 , wherein the intervening die has a fin at its end.  
   
   
       11 . The method according to  claim 6 , wherein the intervening die includes a built-in heater.  
   
   
       12 . The method according to  claim 1 , wherein the heating step is performed at a temperature of ((Tm+273)/2−273) to (Tm−10)° C., where Tm is the melting point of the matrix metal.  
   
   
       13 . The method according to  claim 1 , wherein the heating step is performed at a temperature of 10 to 150° C. lower than the melting point of the matrix metal.  
   
   
       14 . The method according to  claim 1 , wherein the pressing step includes applying a pressure of 1.5 to 65 MPa on the pressing dies.  
   
   
       15 . The method according to  claim 1 , wherein the matrix metal is selected from the group consisting of aluminum, aluminum alloy, copper, copper alloy, magnesium and magnesium alloy.  
   
   
       16 . The method according to  claim 1 , wherein the ceramic is selected from the group consisting of silicon carbide, aluminum nitride, boron nitride, carbon and zirconia, either alone or in mixture.  
   
   
       17 . The method according to  claim 1 , wherein the heating step includes putting the pressing dies that holds the metal matrix composite therebetween in a furnace for heating.  
   
   
       18 . The method according to  claim 1 , wherein the pressing die includes a built-in heater.  
   
   
       19 . The method according to  claim 1 , further comprising the step of cooling the pressing dies.  
   
   
       20 . The method according to  claim 1 , further comprising the step of fastening the pressing dies.  
   
   
       21 . The method according to  claim 1 , wherein the pressing die is made of iron.