US4828008A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Metal matrix composites
Assignee: Lanxide Technology Co LP
•
Filing: 1987-05-13
•
Granted: 1989-05-09
•
Expires: 2007-05-13
Abstract
Abstract A ceramic-reinforced aluminum matrix composite is formed by contacting a molten aluminum-magnesium alloy with a permeable mass of ceramic material in the presence of a gas comprising from about 10 to 100% nitrogen, by volume, balance non-oxidizing gas, e.g., hydrogen or argon. Under these conditions, the molten alloy spontaneously infiltrates the ceramic mass under normal atmospheric pressures. A solid body of the alloy can be placed adjacent a permeable bedding of ceramic material, and brought to the molten state, preferably to at least about 700° C., in order to form the aluminum matrix composite by infiltration. In addition to magnesium, auxiliary alloying elements may be employed with aluminum. The resulting composite products may contain a discontinuous aluminum nitride phase in the aluminum matrix and/or an aluminum nitride external surface layer.
Inventors
- 👤 Danny R. White
- 👤 Andrew W. Urquhart
- 👤 Michael K. Aghajanian
- 👤 Dave K. Creber
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-10-24 20:52
CPC Classifications
C; C22; C22C; C22C29/00; C22C1/00; C22C1/10; C22C1/1036; C22C1/1057; C22C1/1063; C22C21/00; C22C21/06; C22C32/00; C22C32/001; C22C32/0047; C22C47/00; C22C47/08; C22C49/00; C22C49/14; B; B22; B22F; B22F2998/00; B22F2999/00; Y; Y10; Y10T; Y10T428/00; Y10T428/12; Y10T428/12007; Y10T428/12486
Claims Analysis
Total Claims: 25
Claim 1
Independent Claim
111 words
A method of producing a metal matrix composite comprising: (a) providing an aluminum alloy comprising aluminum and at least about 1 weight percent magnesium and a permeable mass of ceramic filler material; (b) in the presence of a gas comprising about from 10 to 100 volume percent nitrogen, balance non-oxidizing gas, contacting said aluminum alloy in a molten state with said permeable mass, and infiltrating said permeable mass with said molten aluminum alloy, said infiltration of said permeable mass occurring spontaneously; and (c) after a desired amount of infiltration of said mass, allowing said molten aluminum alloy to solidify to form a solid metal matrix structure embedding said ceramic filler material.
Claim 2
Independent Claim
111 words
A method of producing a metal matrix composite comprising: (a) providing an aluminum alloy comprising aluminum and at least about 1 weight percent magnesium and a permeable mass of ceramic filler material; (b) in the presence of a gas comprising about from 10 to 100 volume percent nitrogen, balance non-oxidizing gas, contacting said aluminum alloy in a molten state with said permeable mass, and infiltrating said permeable mass with said molten aluminum alloy, said infiltration of said permeable mass occurring spontaneously; and (c) after a desired amount of infiltration of said mass, allowing said molten aluminum alloy to solidify to form a solid metal matrix structure embedding said ceramic filler material.
Claim 3
Dependent Claim
24 words
The method of claim 1 wherein a temperature at which said aluminum alloy is contacted with said mass is at least about 700° C.
Claim 4
Dependent Claim
14 words
The method of claim 2 wherein said temperature is at least about 800° C.
Claim 5
Dependent Claim
19 words
The method of claim 3 wherein said temperature is in the range of about from 800° to 1200° C.
Claim 6
Independent Claim
18 words
The method of any one of claims 2, 3, or 4 wherein said gas is substantially all nitrogen.
Claim 7
Independent Claim
27 words
The method of any one of claims 2, 3, or 4 wherein said gas comprises at least 50% by volume nitrogen and the balance argon or hydrogen.
Claim 8
Dependent Claim
17 words
The method of claim 6 wherein said aluminum alloy comprises at least about 3% magnesium by weight.
Claim 9
Independent Claim
25 words
The method of any one of claims 2, 3, or 4 wherein said aluminum alloy comprises at least one alloying element in addition to magnesium.
Claim 10
Independent Claim
30 words
The method of any one of claims 2, 3, or 4 wherein said ceramic filler material comprises a material selected from the group consisting of oxides, carbides, borides, and nitrides.
Claim 11
Dependent Claim
21 words
The method of claim 9 wherein said ceramic filler material comprises alumina, and said temperature is up to about 1000° C.
Claim 12
Dependent Claim
22 words
The method of claim 9 wherein said ceramic filler material comprises silicon carbide, and said temperature is up to about 1200° C.
Claim 13
Dependent Claim
13 words
The method of claim 9 wherein said ceramic filler material comprises zirconium oxide.
Claim 14
Dependent Claim
13 words
The method of claim 9 wherein said ceramic filler material comprises titanium diboride.
Claim 15
Dependent Claim
13 words
The method of claim 9 wherein said ceramic filler material comprises aluminum nitride.
Claim 16
Independent Claim
24 words
The method of any one of claims 2, 3, or 4 wherein aluminum nitride is formed as a discontinuous phase in the metal matrix.
Claim 17
Dependent Claim
22 words
The method of claim 15 wherein the amount of aluminum nitride present in said matrix is increased as said temperature is increased.
Claim 18
Independent Claim
41 words
The method of any one of claims 2, 3, or 4 wherein said ceramic filler is comprised of a filler substrate and a ceramic coating, which coating comprises a material selected from the group consisting of oxides, carbides, borides, and nitrides.
Claim 19
Dependent Claim
13 words
The method of claim 17 wherein said filler substrate is comprised of carbon.
Claim 20
Dependent Claim
14 words
The method of claim 17 wherein said filler substrate is comprised of carbon fiber.
Claim 21
Independent Claim
158 words
A method of making an aluminum alloy matrix composite bearing a layer of aluminum nitride on said composite, said method comprising: (a) positioning an aluminum alloy comprising aluminum and at least 1 weight percent magnesium adjacent a permeable mass of ceramic filler material; (b) in the presence of a gas comprising about from 10 to 100 volume percent nitrogen, balance non-oxidizing gas, melting and contacting said aluminum alloy with said permeable mass, and infiltrating said permeable mass with said molten aluminum alloy, said infiltration of said permeable mass occurring spontaneously; and (c) after a desired amount of said mass has been infiltrated, maintaining said aluminum alloy molten while in the presence of said gas to form aluminum nitride on at least one surface of said mass, and then allowing said aluminum alloy to solidify to form a solid aluminum alloy matrix structure embedding said ceramic filler material, and containing aluminum nitride on or adjacent at least one surface.
Claim 22
Independent Claim
158 words
A method of making an aluminum alloy matrix composite bearing a layer of aluminum nitride on said composite, said method comprising: (a) positioning an aluminum alloy comprising aluminum and at least 1 weight percent magnesium adjacent a permeable mass of ceramic filler material; (b) in the presence of a gas comprising about from 10 to 100 volume percent nitrogen, balance non-oxidizing gas, melting and contacting said aluminum alloy with said permeable mass, and infiltrating said permeable mass with said molten aluminum alloy, said infiltration of said permeable mass occurring spontaneously; and (c) after a desired amount of said mass has been infiltrated, maintaining said aluminum alloy molten while in the presence of said gas to form aluminum nitride on at least one surface of said mass, and then allowing said aluminum alloy to solidify to form a solid aluminum alloy matrix structure embedding said ceramic filler material, and containing aluminum nitride on or adjacent at least one surface.
Claim 23
Dependent Claim
42 words
The method of claim 20 wherein a layer of aluminum nitride is formed on said at least one surface and a thickness of said layer of aluminum nitride is increased as an exposure time of molten aluminum to said gas is increased.
Claim 24
Dependent Claim
40 words
The method of claim 20 wherein a layer of aluminum nitride is formed on said at least one surface and a thickness of said layer of aluminum nitride is increased as a temperature of said molten aluminum alloy is increased.
Claim 25
Dependent Claim
26 words
The method of claim 21 wherein the thickness of said layer of aluminum nitride is increased as a temperature of said molten aluminum alloy is increased.
References Cited (Backward Citations)
US3364976A
Cited
US3547180A
Cited
US3718441A
Cited
US3970136A
Cited
US3864154A
Cited
US4232091A
Cited
US4473103A
Cited
EP0094353A2
Cited
US4450207A
Cited
EP0115742A1
Cited
US4630665A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1992-05-08 | 1992-11-07 | 1993-05-09 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1996-05-08 | 1996-11-07 | 1997-05-09 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2000-05-08 | 2000-11-07 | 2001-05-09 | $7700.00 | Window Closed / Lapsed |