Method of making a metal matrix composite material

Abstract

Described herein is a method for making a metal matrix composite material comprising: (a) forming a metal box comprising a bottom forming plate having a length and a width, a first pair of side forming plates having a length and a height, and a second pair of side forming plates having a width and a height; (b) mixing a metal powder and a ceramic powder to prepare a mixed powder; (c) filling the metal box with the mixed powder; (d) compacting the mixed powder in the metal box to provide the metal box comprising a compacted powder preform; (e) disposing a top forming plate onto the metal box in solid abutment against the metal box comprising the compacted powder preform and sealing around its edges to produce a pre-rolling assembly; and (f) performing hot working on the pre-rolling assembly to obtain the metal matrix composite material with a metal cladding.

1 . A method for making a metal matrix composite material comprising:
 (a) forming a metal box comprising a bottom forming plate having a length and a width, a first pair of side forming plates having a length and a height, and a second pair of side forming plates having a width and a height;   (b) mixing a metal powder and a ceramic powder to prepare a mixed powder;   (c) filling the metal box with the mixed powder;   (d) compacting the mixed powder in the metal box to provide the metal box comprising a compacted powder preform;   (e) disposing a top forming plate onto the metal box in solid abutment against the metal box comprising the compacted powder preform and sealing around its edges to produce a pre-rolling assembly: and   (f) performing hot working on the pre-rolling assembly to obtain the metal matrix composite material with a metal cladding.   
     
     
         2 . The method of  claim 1 , wherein the compacted powder preform has a density ratio of at least 0.65. 
     
     
         3 . The method of  claim 1 , wherein the compacting step is preformed using at least one of: solid compaction, cold isostatic press, and cold uniaxial press. 
     
     
         4 . The method of  claim 1 , wherein ratio of the height to the width of the metal box is at least 1:2.5. 
     
     
         5 . The method of  claim 1 , wherein the metal box is selected from at least one of aluminum, magnesium, and stainless steel. 
     
     
         6 . The method of  claim 1 , wherein the metal powder is selected from at least one of aluminum, magnesium, and stainless steel. 
     
     
         7 . The method of  claim 1 , wherein the ceramic powder comprises boron carbide. 
     
     
         8 . The method of  claim 1 , wherein the bottom forming plate, top forming plate, side forming plates, and end forming plates have a thickness of at least 2 mm. 
     
     
         9 . The method of  claim 1 , wherein the thickness of the pre-rolling assembly is reduced by rolling to at least ¼ th  of its original thickness. 
     
     
         10 . The method of  claim 1 , wherein the pre-rolling assembly is heated within at least 90% of the melting temperature of the metal powder. 
     
     
         11 . The method of  claim 1 , wherein the pre-rolling assembly is pre-heated prior to the hot working. 
     
     
         12 . The method of  claim 1 , wherein the hot working is selected from at least one of hot rolling, hot extrusion, and hot forging.