Method of making metal matrix composites

Claim 1

A method of producing a metal matrix composite, comprising: (a) forming a substantially impervious mold by the steps comprising of: (i) providing a permeable preform having a cavity and comprised of a first filler material; (ii) contacting a molten parent metal with said preform and with an oxidant to react molten parent metal with said oxidant to form an oxidation reaction product within a temperature range extending from a temperature above the melting point of said parent metal to a temperature below the melting point of said oxidation reaction product; (iii) maintaining at least a portion of said oxidation reaction product in contact with and extending between said molten parent metal and said oxidant to progressively draw molten parent metal through the oxidation reaction product towards the oxidant and into said preform so that the oxidation reaction product continues to form within said preform at the interface between said oxidant and previously formed oxidation reaction product; (iv) continuing said oxidation reaction within said temperature range to embed at least a portion of said preform within said oxidation reaction product by growth of the oxidation reaction product to thereby provide an impervious mold with said cavity; and (v) removing at least a portion of excess metal from said cavity which has not reacted with said oxidant to form oxidation reaction product; (b) emplacing a permeable mass of a second filler material within said cavity of said impervious mold, and contacting said mass of second filler with at least one molten metal selected from the group consisting of aluminum and magnesium. (c) hermetically sealing the mold contents for a period of time sufficient to spontaneously infiltrate said mass of second filler with said at least one molten metal; and (d) upon completion of step (c), solidifying said at least one molten metal to provide said metal matrix composite.

Claim 2

A method of producing a metal matrix composite, comprising: (a) forming a substantially impervious mold by the steps comprising of: (i) providing a permeable preform having a cavity and comprised of a first filler material; (ii) contacting a molten parent metal with said preform and with an oxidant to react molten parent metal with said oxidant to form an oxidation reaction product within a temperature range extending from a temperature above the melting point of said parent metal to a temperature below the melting point of said oxidation reaction product; (iii) maintaining at least a portion of said oxidation reaction product in contact with and extending between said molten parent metal and said oxidant to progressively draw molten parent metal through the oxidation reaction product towards the oxidant and into said preform so that the oxidation reaction product continues to form within said preform at the interface between said oxidant and previously formed oxidation reaction product; (iv) continuing said oxidation reaction within said temperature range to embed at least a portion of said preform within said oxidation reaction product by growth of the oxidation reaction product to thereby provide an impervious mold with said cavity; and (v) removing at least a portion of excess metal from said cavity which has not reacted with said oxidant to form oxidation reaction product; (b) emplacing a permeable mass of a second filler material within said cavity of said impervious mold, and contacting said mass of second filler with at least one molten metal selected from the group consisting of aluminum and magnesium. (c) hermetically sealing the mold contents for a period of time sufficient to spontaneously infiltrate said mass of second filler with said at least one molten metal; and (d) upon completion of step (c), solidifying said at least one molten metal to provide said metal matrix composite.

Claim 4

A method of producing a metal matrix composite, comprising: (a) forming a substantially impervious mold by the steps comprising: (i) providing a permeable preform comprised of a first filler material, and having therein a cavity and at least one opening at an exterior surface thereof; (ii) contacting a molten parent metal with said preform and with an oxidant to react molten parent metal with said oxidant within a temperature range extending from a temperature above the melting point of said parent metal to a temperature below the melting point of said oxidation reaction product; (iii) maintaining at least a portion of said oxidation reaction product in contact with and extending between said molten parent metal and said oxidant to progressively draw molten parent metal through the oxidation reaction product towards the oxidant and into said preform so that the oxidation reaction product continues to form within said preform at the interface between said oxidant and previously formed oxidation reaction product; and (iv) continuing said oxidation reaction within said temperature range to embed at least a portion of said preform which encloses said cavity within said oxidation reaction product by growth of the oxidation reaction product to thereby provide said impervious mold having said cavity and said at least one opening; (v) removing at least a portion of excess metal from said cavity which has not reacted with said oxidant to form oxidation reaction product; (b) emplacing a permeable mass of a second filler material within said cavity of said impervious mold; (c) introducing at least one molten metal selected from the group consisting of aluminum and magnesium into said at least one opening to hermetically seal said mass of second filler material within said cavity and therein contact said second filler material with said at least one molten metal for a period of time sufficient to spontaneously infiltrate said mass of second filler material with said at least one molten metal and thereby provide a molten material containing said second filler material dispersed therein; and (d) upon completion of step (c), solidifying said at least one molten metal to provide said metal matrix composite.

Claim 5

A method of producing a metal matrix composite, comprising: (a) forming a substantially impervious mold by the steps comprising: (i) providing a permeable preform comprised of a first filler material, and having therein a cavity and at least one opening at an exterior surface thereof; (ii) contacting a molten parent metal with said preform and with an oxidant to react molten parent metal with said oxidant within a temperature range extending from a temperature above the melting point of said parent metal to a temperature below the melting point of said oxidation reaction product; (iii) maintaining at least a portion of said oxidation reaction product in contact with and extending between said molten parent metal and said oxidant to progressively draw molten parent metal through the oxidation reaction product towards the oxidant and into said preform so that the oxidation reaction product continues to form within said preform at the interface between said oxidant and previously formed oxidation reaction product; and (iv) continuing said oxidation reaction within said temperature range to embed at least a portion of said preform which encloses said cavity within said oxidation reaction product by growth of the oxidation reaction product to thereby provide said impervious mold having said cavity and said at least one opening; (v) removing at least a portion of excess metal from said cavity which has not reacted with said oxidant to form oxidation reaction product; (b) emplacing a permeable mass of a second filler material within said cavity of said impervious mold; (c) introducing at least one molten metal selected from the group consisting of aluminum and magnesium into said at least one opening to hermetically seal said mass of second filler material within said cavity and therein contact said second filler material with said at least one molten metal for a period of time sufficient to spontaneously infiltrate said mass of second filler material with said at least one molten metal and thereby provide a molten material containing said second filler material dispersed therein; and (d) upon completion of step (c), solidifying said at least one molten metal to provide said metal matrix composite.

Claim 6

The method of any of claims 1, 2, or 3, wherein said first filler material comprises a material selected from the group consisting of alumina and silicon carbide, said parent metal comprises aluminum, said second filler material comprises silicon carbide and said at least one molten metal in step (b) comprises aluminum.

Claim 7

The method of any of claims 1, 2 or 3, including, in step (a)(iv), embedding within said oxidation reaction product at least that portion of said preform which defines said cavity.

Claim 8

The method of any of claims 1, 2 or 3, wherein the contacting of step (a)(ii) is effected within said cavity of said permeable preform.

Claim 9

The method of any of claims 1, 2 or 3, wherein in step (a) (v), said excess metal is removed from said cavity as molten parent metal.

Claim 10

The method of any of claims 1, 2 or 3, including defining at least a portion of the geometry of said substantially impervious mold by associating at least one barrier means with said mass of first filler material to define at least one boundary of growth of said oxidation reaction product.

Claim 12

The method of any of claims 1, 2 or 3, wherein said mass of first filler material comprises a permeable bed of moldable filler material; and said cavity within said bed is formed by providing a shaped parent metal having a positive pattern section which is shaped so that inverse shape replication thereof defines a desired geometry of said mold cavity, and embedding at least said positive pattern section within said bed of moldable filler material; and thereafter heating the embedded parent metal to within said temperature range to form therefrom said molten parent metal in contact with a wall of said cavity.

Claim 13

The method of any of claims 1, 2 or 3, wherein said mass of first filler material comprises a permeable bed of moldable filler material; and said cavity within said bed is formed by providing an expendable pattern body which is shaped so that inverse replication thereof defines a desired geometry of said mold cavity, and embedding said expendable pattern body within said bed of moldable filler material; and thereafter replacing said embedded expendable pattern body with molten parent metal in contact with a wall of said cavity.

Claim 16

The method of any of claims 1, 2 or 3, including separating said metal matrix composite from said mold.

Claim 18

The method of any of claims 1, 2 or 3, including carrying out the solidification of step (d) under bonding conditions including maintaining the solidifying molten material in contact with at least a portion of said impervious mold, thereby forming said metal matrix composite integrally with said at least a portion of said impervious mold.

Claim 19

The method of any of claims 1, 2 or 3, wherein said cavity is shaped to have a selected geometry which is inversely replicated by the metal matrix composite.

Claim 20

The method of any of claims 1, 2 or 3, wherein said second filler material is selected from the group consisting of at least one oxide, carbide, boride and nitride.

Claim 21

The method of any of claims 1, 2 or 3, wherein said parent metal comprises an aluminum parent metal.

Claim 24

The method of any of claims 1, 2 or 3, wherein contact of said molten aluminum with said second filler is at a temperature of from about 700° C. to 1000° C.

Claim 27

The method of any of claims 1, 2 or 3, wherein said molten parent metal comprises aluminum, said second filler material comprises silicon carbide particles and said silicon carbide particles are coated with Na 2 O.