Abstract Light weight composite refractory articles comprising a plurality of metal or alloy coated carbon fibers bonded together by an aluminum base matrix are provided. The coating metal or alloy can be any material selected from the group consisting of silver, silver-aluminum base alloys and mixtures thereof. The preferred process for producing such composites comprises contacting silver coated carbon fibers with an aluminum base material followed by hot pressing the so-contacted fibers at the solidus temperature of the aluminum base material to infiltrate aluminum around the silver-coated fibers and then cooling the resultant article to a completely solidified state. Such composite articles are characterized by a high tensile strength coupled with a high modulus of elasticity and are especially suited as materials of construction for aerospace and hydrospace vehicles and systems.
The method of claim 1 wherein said aluminum base material is an alloy consisting essentially of 4.5 weight percent copper, 0.6 weight percent manganese, 1.5 weight percent magnesium with the remainder being essentially aluminum.
Claim 2
Independent Claim
102 words
A method of producing an aluminum-bonded silver-coated carbon fiber composite article comprising: a. forming an assembly comprising alternate layers of silver coated carbon fibers and aluminum base foil, said fibers being positioned thereon in a parallel manner; b. placing the so-formed assembly in mold and heating it in an inert atmosphere to a temperature approximately equal to the solidus temperature of said aluminum base foil while exerting a sufficient pressure on said assembly to cause said aluminum base foil material to be infiltrated around said silver-coated carbon fibers; and c. cooling the resultant assembly to produce an aluminum-bonded silver-coated carbon fiber composite.
Claim 3
Dependent Claim
52 words
The method of claim 3 wherein: a. said aluminum base foil material consists essentially of 4.5 weight percent copper, 0.6 weight percent manganese, 1.5 weight percent magnesium with the remainder being essentially aluminum; and b. said heating in step (b) is accomplished in a vacuum at a temperature of about 550* C.
Claim 4
Dependent Claim
50 words
The method of claim 1 wherein said aluminum-bonded silver-coated carbon fiber composite article is heated to a temperature sufficient to cause at least some said silver to alloy with at least some of said aluminum to form at least a partial coating of a silver-aluminum base alloy on said fibers.