Patent US5289967A successfully refreshed from Google Patents.
US5289967A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Synthesis of metal matrix composites by transient liquid consolidation
Assignee: Boeing North American Inc
•
Filing: 1992-08-26
•
Granted: 1994-03-01
•
Expires: 2012-08-26
Abstract
Abstract A method is provided for fabricating metal matrix composites. Optical or reinforcing fibers, which may be in the form of monofilaments, mats, or tow, are consolidated into a metal matrix alloy. Grooves may be provided in the metal matrix material for holding and positioning the fibers. A transient liquid diffusion bonding agent in the form of a powder may be blended with powdered filler material, such as powdered matrix material, to provide a vehicle for consolidating the fibers into the metal matrix. The fibers and the blended powder are placed between layers of the metal matrix material and the whole structure is heated under minimal pressure to liquefy the bonding agent. The liquid bonding agent wets each fiber and interdiffuses with the matrix material, resulting in rapid isothermal solidification of the alloy and consolidation of the fibers in the matrix.
Inventors
- 👤 Clifford C. Bampton
- 👤 Michael A. Cunningham
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-09 08:51
CPC Classifications
B; B23; B23K; B23K35/00; B23K35/22; B23K35/24; B23K35/32; B23K35/327; B23K35/001; B23K35/004; C; C22; C22C; C22C47/00; C22C47/20; C22C49/00; C22C49/02; C22C49/04; B22; B22F; B22F2998/00; B22F2998/10
Claims Analysis
Total Claims: 20
Claim 1
Independent Claim
149 words
A method of forming a metal matrix composite, comprising the steps of: providing fibers for consolidation within a matrix of metallic material selected from the group of materials consisting of titanium aluminide alloys, superalloys, iron-aluminide and nickel-aluminide alloys, and aluminum alloys; selecting a transient liquid diffusion bonding agent from the group of materials consisting of Ag, Cu, Al, Ag-Al, Cu-Al, and Ti-Cu-Ni for titanium aluminide matrix materials; B, Si, P, and alloys thereof for superalloy, iron-aluminide, and nickel-aluminide matrix materials; and Zn, Mg, Zn-Al, Si-Al, and Mg-Al for aluminum alloy matrix materials; disposing said fibers and said bonding agent between layers of said matrix material to form a layered structure; heating said layered structure to liquefy said bonding agent; wetting said fibers with said liquefied bonding agent; and isothermally solidifying said bonding agent upon interdiffusion with elements of said matrix material to consolidate said fibers in said metal matrix.
Claim 2
Independent Claim
149 words
A method of forming a metal matrix composite, comprising the steps of: providing fibers for consolidation within a matrix of metallic material selected from the group of materials consisting of titanium aluminide alloys, superalloys, iron-aluminide and nickel-aluminide alloys, and aluminum alloys; selecting a transient liquid diffusion bonding agent from the group of materials consisting of Ag, Cu, Al, Ag-Al, Cu-Al, and Ti-Cu-Ni for titanium aluminide matrix materials; B, Si, P, and alloys thereof for superalloy, iron-aluminide, and nickel-aluminide matrix materials; and Zn, Mg, Zn-Al, Si-Al, and Mg-Al for aluminum alloy matrix materials; disposing said fibers and said bonding agent between layers of said matrix material to form a layered structure; heating said layered structure to liquefy said bonding agent; wetting said fibers with said liquefied bonding agent; and isothermally solidifying said bonding agent upon interdiffusion with elements of said matrix material to consolidate said fibers in said metal matrix.
Claim 3
Dependent Claim
28 words
The method of claim 1, wherein the step of selecting said transient liquid diffusion bonding agent further comprises the step of providing said bonding agent in powder form.
Claim 4
Dependent Claim
31 words
The method of claim 2, wherein the step of providing said bonding agent in powder form further comprises the step of blending said bonding agent powder with a powdered filler material.
Claim 5
Dependent Claim
29 words
The method of claim 3, wherein the step of blending said bonding agent powder with a powdered filler material comprises blending said bonding agent powder with powdered matrix material.
Claim 6
Dependent Claim
39 words
The method of claim 1, wherein the step of providing fibers further comprises the step of selecting fibers from the group of fibrous materials consisting of alumina (Al 2 O 3 ), TiB 2 , SiC, and optical fibers.
Claim 7
Dependent Claim
43 words
The method of claim 5, further comprising the step of coating said fibers with a protective coating selected from the group of materials consisting of Nb, Mo, Ta, W, Re, TiB 2 , Y 2 O 3 and Er 2 O 3 .
Claim 8
Dependent Claim
22 words
The method of claim 1, further comprising the step of providing grooves in said matrix material for holding and positioning said fibers.
Claim 9
Dependent Claim
20 words
The method of claim 7, further comprising the step of placing said fibers in said grooves of said matrix material.
Claim 10
Dependent Claim
22 words
The method of claim 8, wherein the step of placing said fibers in said grooves comprises winding said fibers into said grooves.
Claim 11
Independent Claim
179 words
A method of forming a metal matrix composite, comprising the steps of: providing at least two layers of metallic matrix material selected from the group consisting of titanium aluminide alloys, superalloys, iron-aluminide and nickel-aluminide intermetallic alloys, and aluminum alloys; providing fibers for consolidation within said metallic matrix material; providing at least one of said layers of metallic matrix material with grooves for positioning and holding said fibers; providing a transient liquid diffusion bonding agent selected from the group of materials consisting of Ag, Cu, Al, Ti-Cu-Ni, Ag-Al, and Cu-Al for titanium aluminide matrix materials; B, Si, P, and alloys thereof for superalloy, iron-aluminide, and nickel-aluminide matrix materials; and Zn, Mg, Zn-Al, and Mg-Al for aluminum alloy matrix materials; disposing said bonding agent and said fibers in said grooves between layers of said matrix material to form a layered structure; heating said layered structure to liquefy said bonding agent; wetting said fibers with said liquefied bonding agent; and isothermally solidifying said bonding agent upon interdiffusion with elements of said metallic matrix material to consolidate said fibers in said metal matrix.
Claim 12
Independent Claim
179 words
A method of forming a metal matrix composite, comprising the steps of: providing at least two layers of metallic matrix material selected from the group consisting of titanium aluminide alloys, superalloys, iron-aluminide and nickel-aluminide intermetallic alloys, and aluminum alloys; providing fibers for consolidation within said metallic matrix material; providing at least one of said layers of metallic matrix material with grooves for positioning and holding said fibers; providing a transient liquid diffusion bonding agent selected from the group of materials consisting of Ag, Cu, Al, Ti-Cu-Ni, Ag-Al, and Cu-Al for titanium aluminide matrix materials; B, Si, P, and alloys thereof for superalloy, iron-aluminide, and nickel-aluminide matrix materials; and Zn, Mg, Zn-Al, and Mg-Al for aluminum alloy matrix materials; disposing said bonding agent and said fibers in said grooves between layers of said matrix material to form a layered structure; heating said layered structure to liquefy said bonding agent; wetting said fibers with said liquefied bonding agent; and isothermally solidifying said bonding agent upon interdiffusion with elements of said metallic matrix material to consolidate said fibers in said metal matrix.
Claim 13
Dependent Claim
25 words
The method of claim 10, wherein the step of providing said bonding agent comprises providing a bonding agent powder blended with a powdered filler material.
Claim 14
Dependent Claim
30 words
The method of claim 11, further comprising the steps of providing powdered metallic matrix material as said filler material and blending said powdered matrix material with said bonding agent powder.
Claim 15
Dependent Claim
39 words
The method of claim 10, wherein the step of providing fibers further comprises the step of selecting fibers from the group of fibrous material consisting of alumina (Al 2 O 3 ), TiB 2 , SiC, and optical fibers.
Claim 16
Dependent Claim
44 words
The method of claim 13, wherein the step of providing fibers comprises providing fibers having a coating selected from the group of materials consisting of Nb, Mo, Ta, W, Re, TiB 2 , Y 2 O 3 , and Er 2 O 3 .
Claim 17
Independent Claim
182 words
A method of forming a metal matrix composite, comprising the steps of: providing layers of a metallic matrix material selected from the group of materials consisting of titanium aluminide alloys, superalloys, iron-aluminide and nickel-aluminide intermetallic alloys, and aluminum alloys; providing fibers for consolidation within said layers of matrix material; providing a powdered transient liquid diffusion bonding agent selected from the group of materials consisting of Ag, Cu, Al, Ti-Cu-Ni, Ag-Al, and Cu-Al for titanium aluminide matrix materials; B, Si, P, and alloys thereof for superalloy, iron-aluminide, and nickel-aluminide matrix materials; and Zn, Mg, Zn-Al, and Mg-Al for aluminum alloy matrix materials; blending said powdered bonding agent with a powdered filler material to form a blended powder; disposing said fibers and blended powder between layers of said matrix material to form a layered structure; heating said layered structure to liquefy said bonding agent; infiltrating said fibers and said powdered filler material with said liquefied bonding agent; forming a bonding alloy by interdiffusion of elements of said bonding agent and said metallic matrix material; and isothermally solidifying said bonding alloy to consolidate said fibers.
Claim 18
Independent Claim
182 words
A method of forming a metal matrix composite, comprising the steps of: providing layers of a metallic matrix material selected from the group of materials consisting of titanium aluminide alloys, superalloys, iron-aluminide and nickel-aluminide intermetallic alloys, and aluminum alloys; providing fibers for consolidation within said layers of matrix material; providing a powdered transient liquid diffusion bonding agent selected from the group of materials consisting of Ag, Cu, Al, Ti-Cu-Ni, Ag-Al, and Cu-Al for titanium aluminide matrix materials; B, Si, P, and alloys thereof for superalloy, iron-aluminide, and nickel-aluminide matrix materials; and Zn, Mg, Zn-Al, and Mg-Al for aluminum alloy matrix materials; blending said powdered bonding agent with a powdered filler material to form a blended powder; disposing said fibers and blended powder between layers of said matrix material to form a layered structure; heating said layered structure to liquefy said bonding agent; infiltrating said fibers and said powdered filler material with said liquefied bonding agent; forming a bonding alloy by interdiffusion of elements of said bonding agent and said metallic matrix material; and isothermally solidifying said bonding alloy to consolidate said fibers.
Claim 19
Dependent Claim
44 words
The method of claim 15, wherein the step of providing fibers comprises providing fibers having a coating selected from the group of materials consisting of Nb, Mo, Ta, W, Re, TiB 2 , Y 2 O 3 , and Er 2 O 3 .
Claim 20
Dependent Claim
42 words
The method of claim 16, further comprising the steps of providing grooves in at least one of said layers of said matrix material, and placing said fibers and said powdered bonding agent in said grooves, said grooves holding and positioning said fibers.
References Cited (Backward Citations)
US3419952A
Cited
US3609855A
Cited
US3894677A
Cited
US3678570A
Cited
DE2735638A1
Cited
US4934581A
Cited
US4614296A
Cited
US4710235A
Cited
US4762268A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1997-02-28 | 1997-08-30 | 1998-03-01 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 2001-02-28 | 2001-08-30 | 2002-03-01 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2005-02-28 | 2005-08-30 | 2006-03-01 | $7700.00 | Window Closed / Lapsed |