Processing of Single-Walled Carbon Nanotube Metal-Matrix Composites Manufactured by an Induction Heating Method

Abstract

In some embodiments, the present invention is directed to a new composition of matter. Such a composition generally comprises a functionalized single-wall carbon nanotube (SWNT) which is coated with a metal that would not react with carbon at elevated temperatures. The metal-coated tube is incorporated into a metal matrix that could potentially form carbides. In some or other embodiments, the present invention is directed to methods of making such compositions.

1 . A composition comprising:
 single-wall carbon nanotubes coated with a first metal; and   a second metal within which the single-wall carbon nanotubes coated with a first metal are dispersed,   wherein the first metal is a non-carbide forming metal, and wherein the second metal, which serves as a matrix, is selected from the group consisting of carbide-forming metals and non-carbide forming metals.   
     
     
         2 . The composition of  claim 1 , wherein the single-wall carbon nanotubes are functionalized. 
     
     
         3 . The composition of  claim 2 , wherein the functionalized single-wall carbon nanotubes are fluorinated. 
     
     
         4 . The composition of  claim 1 , wherein the first metal comprises nickel. 
     
     
         5 . The composition of  claim 1 , wherein the second metal comprises titanium. 
     
     
         6 . The composition of  claim 1 , wherein the second metal comprises titanium alloy. 
     
     
         7 . A method of forming a composite comprising:
 a) electrolessly-coating single-wall carbon nanotubes with a first metal to form metal-coated carbon nanotubes;   b) mixing the metal-coated carbon nanotubes with a second metal to form a mixture; and   c) heating the mixture to form a composite,   wherein the first metal is a non-carbide forming metal, and wherein the second metal, which serves as a matrix, is selected from the group consisting of carbide-forming metals and non-carbide forming metals.   
     
     
         8 . The method of  claim 7 , wherein the single wall carbon nanotubes are functionalized prior to electroless coating with the first metal. 
     
     
         9 . The method of  claim 8 , wherein the single-wall carbon nanotubes are fluorinated. 
     
     
         10 . The method of  claim 7 , wherein the mixing involves ball milling. 
     
     
         11 . The method of  claim 7 , wherein the step of heating comprises at least one selected from the group consisting of forging, sintering, induction heating, electromagnetic levitation, and electric welding. 
     
     
         12 . The method of  claim 11 , wherein the step of heating the mixture comprises induction heating. 
     
     
         13 . The method of  claim 7 , wherein the step of heating the mixture to form a composite minimizes structural damage to the single wall carbon nanotube structure. 
     
     
         14 . The method of  claim 7 , wherein the first metal comprises nickel. 
     
     
         15 . The method of  claim 7 , wherein the second metal comprises titanium. 
     
     
         16 . The method of  claim 7 , wherein the second metal comprises titanium alloy.