Continuous Metal Matrix Composite Consolidation

Abstract

A method for the fabrication of large metal matrix composite structures comprising the continuous joining by brazing or welding of aluminum matrix tape using an infrared laser to melt the surface of the tape while applying pressure to the tape and simultaneously contacting it with previously applied tape layers on a rotating mandrel. The apparatus utilized to accomplish this fabrication process may include a variety of pre and post-contact heaters and preferably includes instruments for the continuous monitoring and control of the process.

1 .- 13 . (canceled)  
   
   
       14 . An apparatus for the fabrication of structural members of metal matrix composites comprising: 
 a removable rotating mandrel having a peripheral surface;    a carriage mechanism;    a compaction device attached to said carriage mechanism so as to permit controlled traverse of said compaction device across said peripheral surface;    a metal matrix composite prepeg tape feeding mechanism that supplies metal matrix tape that addresses said peripheral surface to a junction between said peripheral surface and said compaction device; and    a fusing device generating a fusing beam that impacts said metal matrix tape in said junction causing it to fuse as said metal matrix tape passes under said compaction wheel.    
   
   
       15 . The apparatus of  claim 14  wherein said prepeg tape comprises a matrix of aluminum or an aluminum alloy encompassing ceramic fibers.  
   
   
       16 . The apparatus of  claim 15  wherein said laser comprises a stacked multi-bar infrared laser.  
   
   
       17 . The apparatus of  claim 16  wherein said stacked multi-bar infrared laser comprises optical lenses that shape the infrared beam into a pattern that matches the cross sectional dimensions of said prepeg tape.  
   
   
       18 . The apparatus of  claim 14  wherein said mandrel is collapsible so as to permit removal of multiple layers of applied prepeg tape therefrom when fabrication is complete.  
   
   
       19 . The apparatus of  claim 14  wherein said peripheral surface and said compaction wheel comprise ceramic materials.  
   
   
       20 . The apparatus of  claim 14  further comprising preheaters that heat said prepeg tape prior to entering said junction.  
   
   
       21 . The apparatus of  claim 20  wherein said preheaters comprise infrared reflector lamps.  
   
   
       22 . The apparatus of  claim 14  further comprising an optical pyrometer that addresses said junction and views said metal matrix prepeg tape in said junction and provides temperature feedback information for controlling the power of said laser or the rotation speed of said mandrel.  
   
   
       23 . The apparatus of  claim 14  further comprising a mechanism for inducing vibratory energy to said prepeg tape prior to entry into said junction at a frequency of between about 1000 and 15000 vibration per minute.