Equipartition of Nano Particles in a Metallic Matrix to Form a Metal Matrix Composite (MMC)

Abstract

A metal matrix composite with a uniformly distributed ceramic component is made by mixing nano size ceramic particles with a surfactant and/or dispersing agent in a polar liquid to produce a colloidal solution, blending the ceramic particles with micron or sub-micron size metallic particles, and then compacting the blended ceramic and metallic particles into a solid mass.

What is claimed is: 
     
         1 . A method of making a metal matrix composite comprising:
 mixing ceramic particles with a surfactant in a polar liquid solvent to produce a colloidal solution;   blending metallic particles with the ceramic particles in the colloidal solution;   removing the solvent;   compacting the blended ceramic and metallic particles into a solid mass.   
     
     
         2 . The method of  claim 1  wherein the ceramic particles are in the range of approximately 5 to 1000 nanometers in diameter. 
     
     
         3 . The method of  claim 1  wherein the metallic particles are less than approximately 2 microns in size. 
     
     
         4 . The method of  claim 1  wherein the polar liquid is an alcohol. 
     
     
         5 . The method of  claim 4  wherein the polar liquid is isopropyl alcohol. 
     
     
         6 . The method of  claim 1  wherein the surfactant is a phosphonic acid. 
     
     
         7 . The method of  claim 6  wherein the surfactant is hexylphosphonic acid. 
     
     
         8 . The method of  claim 1  further comprising adding a soluble polymer dispersing agent to the polar liquid solvent. 
     
     
         9 . The method of  claim 8  wherein the soluble polymer dispersing agent is poly vinyl pirrolidone. 
     
     
         10 . The method of  claim 1  wherein the ceramic and metallic particles are blended ultrasonically. 
     
     
         11 . The method of  claim 1  wherein the ceramic and metallic particles are blended in a dry state. 
     
     
         12 . The method of  claim 1  wherein the ceramic and metallic particles are blended in a polar liquid. 
     
     
         13 . The method of  claim 12  wherein the ceramic and metallic particles are blended with a high shear blender. 
     
     
         14 . The method of  claim 1  wherein the blended ceramic and metallic particles are compacted by cold isostatic pressing and sintering. 
     
     
         15 . The method of  claim 1  wherein the blended ceramic and metallic particles are compacted by vacuum hot pressing. 
     
     
         16 . The method of  claim 1  wherein the blended ceramic and metallic particles are compacted by hot powder forging. 
     
     
         17 . The method of  claim 1  further comprising extruding the solid mass. 
     
     
         18 . The method of  claim 1  further comprising rolling the solid mass. 
     
     
         19 . The method of  claim 1  wherein the metallic particles are aluminum. 
     
     
         20 . The method of  claim 19  wherein the ceramic is alumina. 
     
     
         21 . The method of  claim 20  wherein the alumina particles are one of alpha-phase, gamma-phase, or a combination of alpha-phase and gamma-phase.