Method for bonding composite materials

Claim 1

A process for rapidly densifying and diffusion bonding plasma sprayed aluminum matrix composites reinforced with a plurality of filaments comprising placing at least one composite tape having a plurality of unidirectional filaments selected from the group consisting of boron, silicon carbide, silicon carbide coated boron, boron carbide, alumina and carbon embedded in a plasma sprayed aluminum matrix between platens heated to a predetermined temperature, pressing said composite in air for 2-40 minutes between said heated platens at a pressure of 100-10,000 psi to densify said aluminum matrix, said temperature being at or below the solidus temperature of said aluminum matrix when said pressure is 2,000-10,000 psi and between the solidus and the liquidus temperature of said aluminum matrix when said pressure is 100-2,000 psi, said temperature and pressing time being sufficiently high, in combination with said pressure, to cause bonding of the aluminum matrix to said filaments without degradation.

Claim 4

A method for rapidly manufacturing high strength aluminum matrix composites reinforced with a plurality of parallel layers of filaments comprising: positioning a plurality of filament reinforced aluminum matrix tapes in a stack, each tape comprising a plurality of unidirectional filaments selected from the group consisting of boron, silicon carbide, silicon carbide coated boron, boron carbide, alumina and carbon embedded in a plasma sprayed aluminum matrix; heating hot press platens to a predetermined temperature; placing said stacked tapes between said platens; pressing said tapes in air for approximately 2-15 minutes between said platens at a pressure of 100-10,000 psi to reduce their thickness and cause densification, said temperature being at or below the solidus temperature of said aluminum matrix when said pressure is 2,000-10,000 psi and between the solidus and the liquidus temperature of said aluminum matrix when said pressure is 100-2,000 psi, said temperature and pressing time being sufficiently high, in combination with said pressure, to cause bonding of said matrix to said filaments and to contiguous portions of adjacent tapes without filament degradation; and removing said densified composites from between said platens.

Claim 5

A method for rapidly manufacturing high strength aluminum matrix composites reinforced with a plurality of parallel layers of filaments comprising: positioning a plurality of filament reinforced aluminum matrix tapes in a stack, each tape comprising a plurality of unidirectional filaments selected from the group consisting of boron, silicon carbide, silicon carbide coated boron, boron carbide, alumina and carbon embedded in a plasma sprayed aluminum matrix; heating hot press platens to a predetermined temperature; placing said stacked tapes between said platens; pressing said tapes in air for approximately 2-15 minutes between said platens at a pressure of 100-10,000 psi to reduce their thickness and cause densification, said temperature being at or below the solidus temperature of said aluminum matrix when said pressure is 2,000-10,000 psi and between the solidus and the liquidus temperature of said aluminum matrix when said pressure is 100-2,000 psi, said temperature and pressing time being sufficiently high, in combination with said pressure, to cause bonding of said matrix to said filaments and to contiguous portions of adjacent tapes without filament degradation; and removing said densified composites from between said platens.

Claim 8

A method for rapidly manufacturing high strength 6061 aluminum matrix composites reinforced with a plurality of parallel layers of unidirectional filaments selected from the group consisting of boron, silicon carbide coated boron and silicon carbide filaments comprising: positioning a plurality of filament reinforced aluminum matrix tapes in a stack, said tapes comprising a plurality of unidirectional filaments embedded in a plasma sprayed 6061 aluminum matrix; placing said stacked tapes between platens heated to a temperature of approximately 570°-635°C; pressing said tapes in air for approximately 2-15 minutes between said platens at a pressure of 200-5,000 psi to reduce their thickness until fully densified, said temperature being 570°-582°C when said pressure is 2,000-5,000 psi and 582°-635°C when said pressure is 200-2,000 psi, said temperature and pressing time being sufficiently high, in combination with said pressure, to cause bonding of said matrix to said filaments and to contiguous portions of adjacent tapes without filament degradation; and removing said densified composites from between platens.

Claim 9

A method for rapidly manufacturing high strength 6061 aluminum matrix composites reinforced with a plurality of parallel layers of unidirectional filaments selected from the group consisting of boron, silicon carbide coated boron and silicon carbide filaments comprising: positioning a plurality of filament reinforced aluminum matrix tapes in a stack, said tapes comprising a plurality of unidirectional filaments embedded in a plasma sprayed 6061 aluminum matrix; placing said stacked tapes between platens heated to a temperature of approximately 570°-635°C; pressing said tapes in air for approximately 2-15 minutes between said platens at a pressure of 200-5,000 psi to reduce their thickness until fully densified, said temperature being 570°-582°C when said pressure is 2,000-5,000 psi and 582°-635°C when said pressure is 200-2,000 psi, said temperature and pressing time being sufficiently high, in combination with said pressure, to cause bonding of said matrix to said filaments and to contiguous portions of adjacent tapes without filament degradation; and removing said densified composites from between platens.