US5020583A
Expired / Lapsed
US
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Directional solidification of metal matrix composites
Assignee: Lanxide Technology Co LP
•
Filing: 1988-11-10
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Granted: 1991-06-04
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Expires: 2008-11-10
Abstract
Abstract A metal matrix composite is formed by contacting a molten matrix alloy with a permeable mass of filler material or preform in the presence of an infiltrating atmosphere. Under these conditions, the molten matrix alloy will spontaneously infiltrate the permeable mass of filler material or preform under normal atmospheric pressures. Once a desired amount of spontaneous infiltration has been achieved, or during the spontaneous infiltration step, the matrix metal which has infiltrated the permeable mass of filler material or preform is directionally solidified. This technique allows the production of spontaneously infiltrated metal matrix composites having improved microstructures and properties.
Inventors
- 👤 Michael K. Aghajanian
- 👤 Robert C. Kantner
- 👤 John P. Biel, Jr.
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-04 12:22
CPC Classifications
C; C04; C04B; C04B41/00; C04B41/009; C04B41/45; C04B41/50; C04B41/51; C04B41/515; C04B41/5155; C04B41/80; C04B41/81; C04B41/85; C04B41/88; C22; C22C; C22C1/00; C22C1/10; C22C1/1036; C22C1/1057; C22C1/1063; B; B22; B22F; B22F3/00; B22F3/10; B22F3/1003; B22F2003/1014; C04B2111/00; C04B2111/00474; C04B2111/00905; C04B2111/00913; C04B2111/00931
Claims Analysis
Total Claims: 47
Claim 1
Independent Claim
58 words
A method for making a metal matrix composite, comprising: providing a substantially non-reactive filler; providing an infiltration enhancer precursor in at least a portion of said filler; spontaneously infiltrating at least a portion of the filler with molten matrix metal to form a spontaneously infiltrated mass; and directionally solidifying at least a portion of said spontaneously infiltrated mass.
Claim 2
Independent Claim
58 words
A method for making a metal matrix composite, comprising: providing a substantially non-reactive filler; providing an infiltration enhancer precursor in at least a portion of said filler; spontaneously infiltrating at least a portion of the filler with molten matrix metal to form a spontaneously infiltrated mass; and directionally solidifying at least a portion of said spontaneously infiltrated mass.
Claim 3
Dependent Claim
11 words
The method of claim 1, wherein the filler comprises a preform.
Claim 4
Dependent Claim
37 words
The method of claim 1, wherein the filler comprises at least one material selected from the group consisting of powders, flakes, platelets, microspheres, whiskers, bubbles, fibers, particulates, fiber mats, chopped fibers, spheres, pellets, tubules and refractory cloths.
Claim 5
Dependent Claim
17 words
The method of claim 1, wherein the filler is of limited solubility in the molten matrix metal.
Claim 6
Dependent Claim
14 words
The method of claim 1, wherein the filler comprises at least one ceramic material.
Claim 7
Dependent Claim
16 words
The method of claim 1, wherein additional infiltration enhancer precursor is alloyed in said matrix metal.
Claim 8
Dependent Claim
34 words
The method of claim 1, wherein said matrix metal comprises aluminum and contains at least one alloying element selected from the group consisting of silicon, iron, copper, manganese, chromium, zinc, calcium, magnesium and strontium.
Claim 9
Dependent Claim
38 words
The method of claim 1, wherein the temperature during spontaneous infiltration is greater than the melting point of the matrix metal, but lower than the volatilization temperature of the matrix metal and the melting point of the filler.
Claim 10
Independent Claim
87 words
A method for making a metal matrix composite, comprising: providing a molten matrix metal; contacting said molten matrix metal with a permeable mass comprising a substantially non-reactive filler; supplying a material comprising an infiltration enhancer precursor to at least said permeable mass; spontaneously infiltrating at least a portion of said permeable mass; and after a desired amount of infiltration of said permeable mass has occurred, contacting said infiltrated mass with a directional solidification means thereby causing said molten matrix metal to solidify directionally within said permeable mass.
Claim 11
Independent Claim
87 words
A method for making a metal matrix composite, comprising: providing a molten matrix metal; contacting said molten matrix metal with a permeable mass comprising a substantially non-reactive filler; supplying a material comprising an infiltration enhancer precursor to at least said permeable mass; spontaneously infiltrating at least a portion of said permeable mass; and after a desired amount of infiltration of said permeable mass has occurred, contacting said infiltrated mass with a directional solidification means thereby causing said molten matrix metal to solidify directionally within said permeable mass.
Claim 12
Independent Claim
33 words
The method of claims 1 or 9, wherein an infiltrating atmosphere communicates with at least one of the filler and the matrix metal for at least a portion of the period of infiltration.
Claim 13
Dependent Claim
35 words
The method of claim 10, further comprising the step of supplying at least one of an infiltration enhancer precursor and an infiltration enhancer to at least one of the matrix metal and the infiltrating atmosphere.
Claim 14
Dependent Claim
23 words
The method of claim 11, wherein at least one of the infiltration enhancer precursor and infiltration enhancer is supplied from an external source.
Claim 15
Dependent Claim
21 words
The method of claim 11, wherein infiltration enhancer is provided in more than one of said matrix metal and said filler.
Claim 16
Dependent Claim
21 words
The method of claim 10, wherein the infiltrating atmosphere comprises an atmosphere selected from the group consisting of oxygen and nitrogen.
Claim 17
Independent Claim
29 words
The method of claims 1 or 9, further comprising the step of supplying at least one of an infiltration enhancer precursor and an infiltration enhancer to the matrix metal.
Claim 18
Independent Claim
34 words
The method of claims 1 or 9, further comprising the step of contacting at least a portion of the filler with an infiltration enhancer during at least a portion of the period of infiltration.
Claim 19
Independent Claim
40 words
The method of claims 1 or 9, wherein an infiltration enhancer is formed by reacting the infiltration enhancer precursor and at least one species selected from the group consisting of the infiltrating atmosphere and a material added to the filler.
Claim 20
Dependent Claim
13 words
The method of claim 17, wherein during infiltration, the infiltration enhancer precursor volatilizes.
Claim 21
Dependent Claim
25 words
The method of claim 18, wherein the volatilized infiltration enhancer precursor reacts to form a reaction product in at least a portion of the filler.
Claim 22
Dependent Claim
19 words
The method of claim 19, wherein said reaction product is at least partially reducible by said molten matrix metal.
Claim 23
Dependent Claim
17 words
The method of claim 20, wherein said reaction product coats at least a portion of said filler.
Claim 24
Dependent Claim
14 words
The method of claim 19, wherein said reaction product comprises a nitride of magnesium.
Claim 25
Independent Claim
32 words
The method of claims 1 or 9, further comprising the step of defining a surface boundary of the filler with a barrier, wherein the matrix metal spontaneously infiltrates up to the barrier.
Claim 26
Dependent Claim
22 words
The method of claim 23, wherein the barrier comprises a material selected from the group consisting of carbon, graphite and titanium diboride.
Claim 27
Dependent Claim
15 words
The method of claim 23, wherein said barrier is substantially non-wettable by said matrix metal.
Claim 28
Dependent Claim
35 words
The method of claim 23, wherein said barrier comprises at least one material which permits communication between an infiltrating atmosphere and at least one of the matrix metal, filler, infiltration enhancer and infiltration enhancer precursor.
Claim 29
Independent Claim
25 words
The method of claims 1 or 9, wherein the matrix metal comprises aluminum, the infiltration enhancer precursor comprises magnesium and the infiltrating atmosphere comprises nitrogen.
Claim 30
Independent Claim
25 words
The method of claims 1 or 9, wherein the matrix metal comprises aluminum, the infiltration enhancer precursor comprises zinc, and the infiltrating atmosphere comprises oxygen.
Claim 31
Independent Claim
32 words
The method of claims 1 or 9, wherein at least one of infiltration enhancer and additional infiltration enhancer precursor is further provided at a boundary between said filler and said matrix metal.
Claim 32
Independent Claim
23 words
The method of claims 1 or 9, wherein said infiltration enhancer precursor is provided in both of said matrix metal and said filler.
Claim 33
Independent Claim
27 words
The method of claims 1 or 9, wherein the infiltration enhancer precursor comprises at least one material selected from the group consisting of magnesium, strontium and calcium.
Claim 34
Independent Claim
32 words
The method of claims 1 or 9, wherein the matrix metal comprises aluminum and the filler comprises at least one material selected from the group consisting of oxides, carbides, borides and nitrides.
Claim 35
Independent Claim
20 words
The method of claims 1 or 9, wherein said directional solidification step is performed after spontaneous infiltration is substantially completed.
Claim 36
Independent Claim
20 words
The method of claims 1 or 9, wherein said directional solidification step is performed during the period of spontaneous infiltration.
Claim 37
Independent Claim
25 words
The method of claims 1 or 9, wherein said directional solidification step comprises contacting a surface of the spontaneously infiltrated mass with a heat sink.
Claim 38
Dependent Claim
13 words
The method of claim 35, wherein said heat sink comprises a chill plate.
Claim 39
Independent Claim
25 words
The method of claims 1 or 9, wherein said directional solidification step comprises contacting a surface of the spontaneously infiltrated mass with a fluid body.
Claim 40
Dependent Claim
13 words
The method of claim 37, wherein said fluid body comprises a flowing fluid.
Claim 41
Dependent Claim
12 words
The method of claim 37, wherein said fluid body is substantially stationary.
Claim 42
Dependent Claim
19 words
The method of claim 37, wherein said spontaneously infiltrated mass is at least partially immersed in said fluid body.
Claim 43
Independent Claim
23 words
The method of claims 1 or 9, wherein said directional solidification step comprises sequentially removing said spontaneously infiltrated mass from a heat source.
Claim 44
Independent Claim
28 words
The method of claims 1 or 9, wherein said directional solidification step comprises hot-topping at least a portion of at least one surface of the spontaneously infiltrated mass.
Claim 45
Independent Claim
40 words
The method of claims 1 or 9, wherein said directional solidification step comprises heating at least a portion of at least one surface of the spontaneously infiltrated mass while permitting the portion of said mass not being heated to cool.
Claim 46
Independent Claim
25 words
The method of claims 1 or 9, wherein the matrix metal comprises aluminum, the infiltration enhancer precursor comprises strontium, and the infiltrating atmosphere comprises nitrogen.
Claim 47
Independent Claim
25 words
The method of claims 1 or 9, wherein the matrix metal comprises aluminum, the infiltration enhancer precursor comprises calcium, and the infiltrating atmosphere comprises nitrogen.
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USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-06-03 | 1994-12-03 | 1995-06-04 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-06-03 | 1998-12-03 | 1999-06-04 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-06-03 | 2002-12-03 | 2003-06-04 | $7700.00 | Window Closed / Lapsed |