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Metalmatrixcomposites Publicationnumber US4828008A

US4828008A Publicationtype Grant
Applicationnumber US07/049,171
Publicationdate May9,1989
ABSTRACT
Filingdate May13,1987
Prioritydate May13,1987
Aceramicreinforcedaluminummatrixcompositeisformedbycontactinga
Feestatus Paid
moltenaluminummagnesiumalloywithapermeablemassofceramicmaterialin
Alsopublishedas CA1321905C,8More
thepresenceofagascomprisingfromabout10to100%nitrogen,byvolume,
balancenonoxidizinggas,e.g.,hydrogenorargon.Undertheseconditions,the Inventors DannyR.White,AndrewW.Urquhart,
MichaelK.Aghajanian,DaveK.Creber
moltenalloyspontaneouslyinfiltratestheceramicmassundernormal
OriginalAssignee LanxideTechnologyCompany,Lp
atmosphericpressures.Asolidbodyofthealloycanbeplacedadjacenta
permeablebeddingofceramicmaterial,andbroughttothemoltenstate, ExportCitation BiBTeX,EndNote,RefMan

preferablytoatleastabout700C.,inordertoformthealuminummatrix PatentCitations(12),Referencedby(144),Classifications(34),
LegalEvents(8)
compositebyinfiltration.Inadditiontomagnesium,auxiliaryalloyingelements
maybeemployedwithaluminum.Theresultingcompositeproductsmaycontain ExternalLinks:USPTO,USPTOAssignment,Espacenet
adiscontinuousaluminumnitridephaseinthealuminummatrixand/oran
aluminumnitrideexternalsurfacelayer.

IMAGES (2)

DESCRIPTION CLAIMS (23)

BACKGROUNDOFTHEINVENTION Whatisclaimedis:

1.FieldoftheInvention 1.Amethodofproducingametalmatrixcompositecomprising:

Thepresentinventionrelatestoamethodofmakingametalmatrixcompositeby
thespontaneousinfiltrationofapermeablemassofceramicfillermaterialwitha
moltenmetal,and,moreparticularly,withamoltenaluminumalloyinthe
presenceofnitrogen.Theinventionrelatesalsotoaluminummatrixcomposites
madebythemethod.
2.DescriptionofthePriorArt
Compositeproductscomprisingametalmatrixandastrengtheningorreinforcing
phasesuchasceramicparticulates,whiskers,fibersorthelike,showgreat
promiseforavarietyofapplicationsbecausetheycombinethestrengthand
hardnessofthestrengtheningphasewiththeductilityandtoughnessofthemetal
matrix.Generally,ametalmatrixcompositewillshowanimprovementinsuch
propertiesasstrength,stiffness,contactwearresistance,andelevated
temperaturestrengthretentionrelativetothematrixmetal,perse,butthedegree
towhichanygivenpropertymaybeimproveddependslargelyonthespecific
constituents,theirvolumeorweightfraction,andhowtheyareprocessedin
formingthecomposite.Insomeinstances,thecompositealsomaybelighterin
weight.Aluminummatrixcompositesreinforcedwithceramicssuchassilicon
carbideinparticulate,platelet,orwhiskerform,forexample,areofinterest
becauseoftheirhigherstiffness,wearresistanceandhightemperaturestrength
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(a)providinganaluminumalloycomprisingaluminumandatleastabout1
weightpercentmagnesiumandapermeablemassofceramicfillermaterial
(b)inthepresenceofagascomprisingaboutfrom10to100volumepercent
nitrogen,balancenonoxidizinggas,contactingsaidaluminumalloyina
moltenstatewithsaidpermeablemass,andinfiltratingsaidpermeablemass
withsaidmoltenaluminumalloy,saidinfiltrationofsaidpermeablemass
occurringspontaneouslyand
(c)afteradesiredamountofinfiltrationofsaidmass,allowingsaidmolten
aluminumalloytosolidifytoformasolidmetalmatrixstructureembedding
saidceramicfillermaterial.
2.Themethodofclaim1whereinatemperatureatwhichsaidaluminum
alloyiscontactedwithsaidmassisatleastabout700C.
3.Themethodofclaim2whereinsaidtemperatureisatleastabout
800C.
4.Themethodofclaim3whereinsaidtemperatureisintherangeof
aboutfrom800to1200C.

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relativetoaluminum.
Variousmetallurgicalprocesseshavebeendescribedforthefabricationof
aluminummatrixcomposites,rangingfrommethodsbasedonpowdermetallurgy
techniquestothoseinvolvingliquidmetalinfiltrationsuchasbypressurecasting.
Withpowdermetallurgytechniques,themetalintheformofapowderandthe
reinforcingmaterialintheformofapowder,whiskers,choppedfibers,etc.,are
admixedandtheneithercoldpressedandsintered,orhotpressed.The
maximumceramicvolumefractioninsiliconcarbidereinforcedaluminummatrix
compositesproducedbythismethodhasbeenreportedtobe25volumepercent
inthecaseofwhiskers,and40volumepercentinthecaseofparticulates.
5.Themethodofanyoneofclaims2,3,or4whereinsaidgasis
substantiallyallnitrogen.
6.Themethodofanyoneofclaims2,3,or4whereinsaidgas
comprisesatleast50%byvolumenitrogenandthebalanceargonor
hydrogen.
7.Themethodofclaim6whereinsaidaluminumalloycomprisesat
leastabout3%magnesiumbyweight.
8.Themethodofanyoneofclaims2,3,or4whereinsaidaluminum
alloycomprisesatleastonealloyingelementinadditiontomagnesium.

Theproductionofmetalmatrixcompositesbypowdermetallurgyutilizing
conventionalprocessesimposescertainlimitationswithrespecttothe
characteristicsoftheproductsattainable.Thevolumefractionoftheceramic
phaseinthecompositeislimitedtypicallytoabout40percent.Also,thepressing
operationposesalimitonthepracticalsizeattainable.Onlyrelativelysimple
productshapesarepossiblewithoutsubsequentprocessing(e.g.,formingor
machining)orwithoutresortingtocomplexpresses.Also,nonuniformshrinkage
duringsinteringcanoccur,aswellasnonuniformityofmicrostructuredueto
segregationinthecompactsandgraingrowth.
U.S.Pat.No.3,970,136,grantedJuly20,1976,toJ.C.Cannelletal.,describes
aprocessforformingametalmatrixcompositeincorporatingafibrous
reinforcement,e.g.siliconcarbideoraluminawhiskers,havingapredetermined
patternoffiberorientation.Thecompositeismadebyplacingparallelmatsor
feltsofcoplanarfibersinamoldwithareservoirofmoltenmatrixmetal,e.g.,
aluminum,betweenatleastsomeofthemats,andapplyingpressuretoforce
moltenmetaltopenetratethematsandsurroundtheorientedfibers.Molten
metalmaybepouredontothestackofmatswhilebeingforcedunderpressureto
flowbetweenthemats.Loadingsofuptoabout50%byvolumeofreinforcing
fiberinthecompositehavebeenreported.
Theabovedescribedinfiltrationprocess,inviewofitsdependenceonoutside
pressuretoforcethemoltenmatrixmetalthroughthestackoffibrousmats,is
subjecttothevagariesofpressureinducedflowprocesses,i.e.possiblenon
uniformityofmatrixformation,porosity,etc.Nonuniformityofpropertiesis
possibleeventhoughmoltenmetalmaybeintroducedatamultiplicityofsites
withinthefibrousarray.Consequently,complicatedmat/reservoirarraysand
flowpathwaysneedtobeprovidedtoachieveadequateanduniformpenetration
ofthestackoffibermats.Also,theaforesaidpressureinfiltrationmethodallows
9.Themethodofanyoneofclaims2,3,or4whereinsaidceramicfiller
materialcomprisesamaterialselectedfromthegroupconsistingof
oxides,carbides,borides,andnitrides.
10.Themethodofclaim9whereinsaidceramicfillermaterial
comprisesalumina,andsaidtemperatureisuptoabout1000C.
11.Themethodofclaim9whereinsaidceramicfillermaterial
comprisessiliconcarbide,andsaidtemperatureisuptoabout1200C.
12.Themethodofclaim9whereinsaidceramicfillermaterial
compriseszirconiumoxide.
13.Themethodofclaim9whereinsaidceramicfillermaterial
comprisestitaniumdiboride.
14.Themethodofclaim9whereinsaidceramicfillermaterial
comprisesaluminumnitride.
15.Themethodofanyoneofclaims2,3,or4whereinaluminumnitride
isformedasadiscontinuousphaseinthemetalmatrix.
16.Themethodofclaim15whereintheamountofaluminumnitride
presentinsaidmatrixisincreasedassaidtemperatureisincreased.
17.Themethodofanyoneofclaims2,3,or4whereinsaidceramic
filleriscomprisedofafillersubstrateandaceramiccoating,which
coatingcomprisesamaterialselectedfromthegroupconsistingof
oxides,carbides,borides,andnitrides.
18.Themethodofclaim17whereinsaidfillersubstrateiscomprisedof

foronlyarelativelylowreinforcementtomatrixvolumefractiontobeachieved carbon.

becauseofdifficultyofinfiltratingalargematvolume.Stillfurther,moldsare
19.Themethodofclaim17whereinsaidfillersubstrateiscomprisedof
requiredtocontainthemoltenmetalunderpressure,whichaddstotheexpense
carbonfiber.
oftheprocess.Finally,theaforesaidprocess,limitedtoinfiltratingaligned
particlesorfibers,isnotdirectedtoformationofaluminummetalmatrix 20.Amethodofmakinganaluminumalloymatrixcompositebearingalayerof
compositesreinforcedwithmaterialsintheformofrandomlyorientedparticles, aluminumnitrideonsaidcomposite,saidmethodcomprising:
whiskersorfibers.
(a)positioninganaluminumalloycomprisingaluminumandatleast1weight
Inthefabricationofaluminummatrixaluminafilledcomposites,aluminumdoes percentmagnesiumadjacentapermeablemassofceramicfillermaterial
notreadilywetalumina,therebymakingitdifficulttoformacoherentproduct.
(b)inthepresenceofagascomprisingaboutfrom10to100volumepercent
Thepriorartsuggestsvarioussolutionstothisproblem.Onesuchapproachisto
nitrogen,balancenonoxidizinggas,meltingandcontactingsaidaluminum
coatthealuminawithavolatilemetal(e.g.,nickelortungsten),whichisthenhot
alloywithsaidpermeablemass,andinfiltratingsaidpermeablemasswith
pressedalongwiththealuminum.Inanothertechnique,thealuminumisalloyed
saidmoltenaluminumalloy,saidinfiltrationofsaidpermeablemass
withlithium,andthealuminamaybecoatedwithsilica.However,these
occurringspontaneouslyand
compositesexhibitvariationsinproperties,orthecoatingscandegradethefiller,
orthematrixcontainslithiumwhichcanaffectthemetalproperties. (c)afteradesiredamountofsaidmasshasbeeninfiltrated,maintainingsaid
aluminumalloymoltenwhileinthepresenceofsaidgastoformaluminum
U.S.Pat.No.4,232,091toR.W.Grimshawetal.,overcomescertaindifficulties
nitrideonatleastonesurfaceofsaidmass,andthenallowingsaid
ofthepriorartintheproductionofaluminummatrixaluminacomposites.This
aluminumalloytosolidifytoformasolidaluminumalloymatrixstructure
patentdescribesapplyingpressuresof75375kg/cm2toforcealuminum(or
embeddingsaidceramicfillermaterial,andcontainingaluminumnitrideonor
aluminumalloy)intoafibrousorwhiskermatofaluminawhichhasbeen
adjacentatleastonesurface.
preheatedto700to1050C.Themaximumvolumeratioofaluminatometalin
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theresultingsolidcastingwas0.25/1.Becauseofitsdependencyonoutside 21.Themethodofclaim20whereinalayerofaluminumnitrideis
forcetoaccomplishinfiltration,thisprocessissubjecttomanyofthesame formedonsaidatleastonesurfaceandathicknessofsaidlayerof
deficienciesasthatofCannelletal. aluminumnitrideisincreasedasanexposuretimeofmoltenaluminum
tosaidgasisincreased.
EuropeanPatentApplicationPublicationNo.115,742describesmaking
aluminumaluminacomposites,especiallyusefulaselectrolyticcellcomponents, 22.Themethodofclaim20whereinalayerofaluminumnitrideis
byfillingthevoidsofapreformedaluminamatrixwithmoltenaluminum.The formedonsaidatleastonesurfaceandathicknessofsaidlayerof
applicationemphasizesthenonwettabilityofaluminabyaluminum,andtherefore aluminumnitrideisincreasedasatemperatureofsaidmoltenaluminum
varioustechniquesareemployedtowetthealuminathroughoutthepreform.For alloyisincreased.
example,thealuminaiscoatedwithawettingagentofadiborideoftitanium,
23.Themethodofclaim21whereinthethicknessofsaidlayerof
zirconium,hafnium,orniobium,orwithametal,i.e.,lithium,magnesium,
aluminumnitrideisincreasedasatemperatureofsaidmoltenaluminum
calcium,titanium,chromium,iron,cobalt,nickel,zirconium,orhafnium.Inert
alloyisincreased.
atmospheres,suchasargon,areemployedtofacilitatewettingandinfiltration.
Thisreferencealsoshowsapplyingpressuretocausemoltenaluminumto
penetrateanuncoatedpreform.Inthisaspect,infiltrationisaccomplishedby
evacuatingtheporesandthenapplyingpressuretothemoltenaluminuminaninertatmosphere,e.g.,argon.Alternatively,
thepreformcanbeinfiltratedbyvaporphasealuminumdepositiontowetthesurfacepriortofillingthevoidsbyinfiltration
withmoltenaluminum.Toassureretentionofthealuminumintheporesofthepreform,heattreatment,e.g.,at1400to
1800C.,ineitheravacuumorinargonisrequired.Otherwise,eitherexposureofthepressureinfiltratedmaterialtogasor
removaloftheinfiltrationpressurewillcauselossofaluminumfromthebody.

Theuseofwettingagentstoeffectinfiltrationofanaluminacomponentinanelectrolyticcellwithmoltenmetalisalso
showninEuropeanPatentApplicationPublicationNo.94353.Thispublicationdescribesproductionofaluminumby
electrowinningwithacellhavingacathodiccurrentfeederasacelllinerorsubstrate.Inordertoprotectthissubstratefrom
moltencryolite,athincoatingofamixtureofawettingagentandsolubilitysupressorisappliedtothealuminasubstrate
priortostartupofthecellorwhileimmersedinthemoltenaluminumproducedbytheelectrolyticprocess.Wettingagents
disclosedaretitanium,zirconium,hafnium,silicon,magnesium,vanadium,chromium,niobium,orcalcium,andtitaniumis
statedasthepreferredagent.Compoundsofboron,carbonandnitrogenaredescribedasbeingusefulinsuppressingthe
solubilityofthewettingagentsinmoltenaluminum.Thereference,however,doesnotsuggesttheproductionofmetal
matrixcomposites,nordoesitsuggesttheformationofsuchacompositeinanitrogenatmosphere.

Inadditiontoapplicationofpressureandwettingagents,ithasbeendisclosedthatanappliedvacuumwillaidthe
penetrationofmoltenaluminumintoaporousceramiccompact.Forexample,U.S.Pat.No.3,718,441,grantedFeb.27,
1973,toR.L.Landingham,reportsinfiltrationofaceramiccompact(e.g.,boroncarbide,aluminaandberyllia)witheither
moltenaluminum,beryllium,magnesium,titanium,vanadium,nickelorchromiumunderavacuumoflessthan106torr.A
vacuumof102to106torrresultedinpoorwettingoftheceramicbythemoltenmetaltotheextentthatthemetaldidnot
flowfreelyintotheceramicvoidspaces.However,wettingwassaidtohaveimprovedwhenthevacuumwasreducedto
lessthan106torr.

U.S.Pat.No.3,864,154,grantedFeb.4,1975,toG.E.Gazzaetal.,alsoshowstheuseofvacuumtoachieveinfiltration.
ThispatentdescribesloadingacoldpressedcompactofAlB12powderontoabedofcoldpressedaluminumpowder.
AdditionalaluminumwasthenpositionedontopoftheAlB12powdercompact.Thecrucible,loadedwiththeAlB12compact
"sandwiched"betweenthelayersofaluminumpowder,wasplacedinavacuumfurnace.Thefurnacewasevacuatedto
approximately105torrtopermitoutgassing.Thetemperaturewassubsequentlyraisedto1100C.andmaintainedfora
periodof3hours.Attheseconditions,themoltenaluminumpenetratedtheporousAlB12compact.

Asshownabove,thepriorartreliesontheuseofappliedpressure,vacuum,orwettingagentstoeffectinfiltrationofmetal
intoaceramicmass.Noneoftheartciteddiscussesorsuggestsspontaneousinfiltrationofceramicmaterialwithmolten
aluminumalloysunderatmosphericpressure.

SUMMARYOFTHEINVENTION

Thepresentmethodcomprisesproducingametalmatrixcompositebyinfiltratingapermeablemassofceramicfilleror
ceramiccoatedfillerwithmoltenaluminumcontainingatleastabout1%byweightmagnesium,andpreferablyatleastabout
3%byweight.Infiltrationoccursspontaneouslywithouttheneedofexternalpressureorhighvacuum.Asupplyofthe
moltenmetalalloyiscontactedwiththemassoffillermaterialatatemperatureofatleastabout700C.inthepresenceof
agascomprisingfromabout10to100%,andpreferablyatleastabout50%,nitrogenbyvolume,balancenonoxidizinggas,
e.g.,argon.Undertheseconditions,themoltenaluminumalloyinfiltratestheceramicmassundernormalatmospheric
pressurestoformanaluminummatrixcomposite.Whenthedesiredamountofceramicmaterialhasbeeninfiltratedwith
moltenalloy,thetemperatureisloweredtosolidifythealloy,therebyformingasolidmetalmatrixstructurethatembedsthe
reinforcingceramicmaterial.Usually,andpreferably,thesupplyofmoltenalloydeliveredwillbesufficienttoallowthe
infiltrationtoproceedessentiallytotheboundariesoftheceramicmass.Theamountofceramicfillerinthealuminummatrix
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compositesproducedaccordingtotheinventionmaybeexceedinglyhigh.Inthisrespectfillertoalloyratiosofgreaterthan
1:1maybeachieved.

Inoneembodiment,asupplyofmoltenaluminumalloyisdeliveredtotheceramicmassbypositioningabodyofthealloy
adjacenttoorincontactwithapermeablebedoftheceramicfillermaterial.Thealloyandbedareexposedtothenitrogen
containinggasatatemperatureabovethealloy'smeltingpoint,intheabsenceofappliedpressureorvacuum,wherebythe
moltenalloyspontaneouslyinfiltratestheadjacentorsurroundingbed.Uponreductionofthetemperaturetobelowthealloy's
meltingpoint,asolidmatrixofaluminumalloyembeddingtheceramicisobtained.Itshouldbeunderstoodthatasolidbody
ofthealuminumalloymaybepositionedadjacentthemassoffiller,andthemetalisthenmeltedandallowedtoinfiltratethe
mass,orthealloymaybemeltedseparatelyandthenpouredagainstthemassoffiller.

Thealuminummatrixcompositesproducedaccordingtothepresentinventiontypicallycontainaluminumnitrideinthe
aluminummatrixasadiscontinuousphase.Theamountofnitrideinthealuminummatrixmayvarydependingonsuch
factorsasthechoiceoftemperature,alloycomposition,gascompositionandceramicfiller.Stillfurther,ifelevated
temperatureexposureinthenitridingatmosphereiscontinuedafterinfiltrationiscomplete,aluminumnitridemayformonthe
exposedsurfacesofthecomposite.Theamountofdispersedaluminumnitrideaswellasthedepthofnitridationalongthe
outersurfacesmaybevariedbycontrollingoneormorefactorsinthesystem,e.g.temperature,therebymakingitpossible
totailorcertainpropertiesofthecompositeortoprovideanaluminummatrixcompositewithanaluminumnitrideskinasa
wearsurface,forexample.

Theexpression"balancenonoxidizinggas",asusedhereindenotesthatanygaspresentinadditiontoelementalnitrogenis
eitheraninertgasorreducinggaswhichissubstantiallynonreactivewiththealuminumundertheprocessconditions.Any
oxidizinggas(otherthannitrogen)whichmaybepresentasanimpurityinthegas(es)used,isinsufficienttooxidizethe
metaltoanysubstantialextent.

Itshouldbeunderstoodthattheterms"ceramic","ceramicmaterial","ceramicfiller"or"ceramicfillermaterial"areintended
toincludeceramicfillers,perse,suchasaluminaorsiliconcarbidefibers,andceramiccoatedfillermaterialssuchas
carbonfiberscoatedwithaluminaorsiliconcarbidetoprotectthecarbonfromattackbymoltenmetal.Further,itshouldbe
understoodthatthealuminumusedintheprocess,inadditiontobeingalloyedwithmagnesium,maybeessentiallypureor
commerciallypurealuminum,ormaybealloyedwithotherconstituentssuchasiron,silicon,copper,manganese,
chromium,andthelike.

BRIEFDESCRIPTIONOFTHEDRAWINGS

Intheaccompanyingdrawings,whichillustratethemicrostructuresofaluminummatrixcompositesmadeaccordingtothe
methodoftheinvention:

FIG.1isaphotomicrographtakenat400Xmagnificationofanaluminareinforcedaluminummatrixcompositeproducedat
850C.substantiallyinaccordancewithExample3

FIG.2isaphotomicrographtakenat400Xmagnificationofanaluminareinforcedaluminummatrixcompositeproduced
substantiallyinaccordancewithExample3a,butatatemperatureof900C.foratimeof24hoursand

FIG.3isaphotomicrographtakenat400Xmagnificationofanaluminumreinforcedaluminummatrixcomposite(using
somewhatcoarseraluminaparticles,i.e.90meshsizevs.220meshsize)producedsubstantiallyinaccordancewith
Example3b,butatatemperatureof1000C.andforatimeof24hours.

DETAILEDDESCRIPTION

Inaccordancewiththemethodofthisinvention,analuminummagnesiumalloyinthemoltenstateiscontactedwithor
deliveredtoasurfaceofapermeablemassofceramicmaterial,e.g.,ceramicparticles,whiskersorfibers,inthepresence
ofanitrogencontaininggas,andthemoltenaluminumalloyspontaneouslyandprogressivelyinfiltratesthepermeable
ceramicmass.Theextentofspontaneousinfiltrationandformationofthemetalmatrixwillvarywiththeprocessconditions,
asexplainedbelowingreaterdetail.Spontaneousinfiltrationofthealloyintothemassofceramicresultsinacomposite
productinwhichthealuminumalloymatrixembedstheceramicmaterial.

Accordingtocopending,coassignedU.S.patentapplicationSer.No.818,943,filedJan.15,1986,nowU.S.Pat.No.
4,713,360,byM.S.Newkirketal.,ithadpreviouslybeenfoundthataluminumnitrideformson,andgrowsfrom,thefree
surfaceofabodyofmoltenaluminumalloywhenthelatterisexposedtoanitridingatmosphere,e.g.,forminggas(a96/4
nitrogen/hydrogenmixture,byvolume).Moreover,accordingtocopending,coassignedU.S.patentapplicationSer.No.
819,397,filedJan.17,1986,byM.S.Newkirketal.,amatrixstructureofinterconnectedaluminumnitridecrystalliteshad
beenfoundtoformwithinaporousmassoffillerparticlespermeatedwithforminggaswhenthemasswasmaintainedin
contactwithamoltenaluminumalloy.Therefore,itwassurprisingtofindthat,inanitridingatmosphere,amoltenaluminum
magnesiumalloyspontaneouslyinfiltratesapermeablemassofceramicmaterialtoformametalmatrixcomposite.

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Undertheconditionsemployedinthemethodofthepresentinvention,theceramicmassorbodyissufficientlypermeableto
allowthegaseousnitrogentopenetratethebodyandcontactthemoltenmetalandtoaccommodatetheinfiltrationofmolten
metal,wherebythenitrogenpermeatedceramicmaterialisspontaneouslyinfiltratedwithmoltenaluminumalloytoforman
aluminummatrixcomposite.Theextentofspontaneousinfiltrationandformationofthemetalmatrixwillvarywithagiven
setofprocessconditions,i.e.,magnesiumcontentofthealuminumalloy,presenceofadditionalalloyingelements,size,
surfaceconditionandtypeoffillermaterial,nitrogenconcentrationofthegas,timeandtemperature.Forinfiltrationofmolten
aluminumtooccurspontaneously,thealuminumisalloyedwithatleastabout1%,andpreferablyatleastabout3%,
magnesium,basedonalloyweight.Oneormoreauxiliaryalloyingelements,e.g.silicon,zinc,oriron,maybeincludedin
thealloy,whichmayaffecttheminimumamountofmagnesiumthatcanbeusedinthealloy.Itisknownthatcertain
elementscanvolatizefromameltofaluminum,whichistimeandtemperaturedependent,andthereforeduringtheprocess
ofthisinvention,volatilizationofmagnesium,aswellaszinc,canoccur.Itisdesirable,therefore,toemployanalloyinitially
containingatleastabout1%byweightmagnesium.Theprocessisconductedinthepresenceofanitrogenatmosphere
containingatleastabout10volumepercentnitrogenandthebalanceanonoxidizinggasundertheprocessconditions.After
thesubstantiallycompleteinfiltrationoftheceramicmass,themetalissolidifiedasbycoolinginthenitrogenatmosphere,
therebyformingasolidmetalmatrixessentiallyembeddingtheceramicfillermaterial.Becausethealuminummagnesium
alloywetstheceramic,agoodbondistobeexpectedbetweenthemetalandtheceramic,whichinturnmayresultin
improvedpropertiesofthecomposite.

Theminimummagnesiumcontentofthealuminumalloyusefulinproducingaceramicfilledmetalmatrixcompositedepends
ononeormorevariablessuchastheprocessingtemperature,time,thepresenceofauxiliaryalloyingelementssuchas
siliconorzinc,thenatureoftheceramicfillermaterial,andthenitrogencontentofthegasstream.Lowertemperaturesor
shorterheatingtimescanbeusedasthemagnesiumcontentofthealloyisincreased.Also,foragivenmagnesiumcontent,
theadditionofcertainauxiliaryalloyingelementssuchaszincpermitstheuseoflowertemperatures.Forexample,a
magnesiumcontentatthelowerendoftheoperablerange,e.g.,fromabout1to3weightpercent,maybeusedin
conjunctionwithatleastoneofthefollowing:anaboveminimumprocessingtemperature,ahighnitrogenconcentration,or
oneormoreauxiliaryalloyingelements.Alloyscontainingfromabout3to5weightpercentmagnesiumarepreferredonthe
basisoftheirgeneralutilityoverawidevarietyofprocessconditions,withatleastabout5%beingpreferredwhenlower
temperaturesandshortertimesareemployed.Magnesiumcontentsinexcessofabout10%byweightofthealuminumalloy
maybeemployedtomoderatethetemperatureconditionsrequiredforinfiltration.Themagnesiumcontentmaybereduced
whenusedinconjunctionwithanauxiliaryalloyingelement,buttheseelementsserveanauxiliaryfunctiononlyandare
usedtogetherwiththeabovespecifiedamountofmagnesium.Forexample,therewassubstantiallynoinfiltrationof
nominallypurealuminumalloyedonlywith10%siliconat1000C./intoabeddingof500mesh,39Crystolon(99%pure
siliconcarbidefromNortonCo.).

Theuseofoneormoreauxiliaryalloyingelementsandtheconcentrationofnitrogeninthesurroundinggasalsoeffectsthe
extentofnitridingofthealloymatrixatagiventemperature.Forexample,increasingtheconcentrationofanauxiliary
alloyingelementsuchaszincorironinthealloymaybeusedtoreducetheinfiltrationtemperatureandtherebydecreasethe
nitrideformationwhereasincreasingtheconcentrationofnitrogeninthegasmaybeusedtopromotenitrideformation.

Theconcentrationofmagnesiuminthealloyalsotendstoaffecttheextentofinfiltrationatagiventemperature.
Consequently,itispreferredthatatleastaboutthreeweightpercentmagnesiumbeincludedinthealloy.Alloycontentof
lessthanthisamount,suchasoneweightpercentmagnesium,tendtorequirehigherprocesstemperaturesoranauxiliary
alloyingelementforinfiltration.Thetemperaturerequiredtoeffectthespontaneousinfiltrationprocessofthisinventionmay
belowerwhenthemagnesiumcontentofthealloyisincreased,e.g.toatleastabout5weightpercent,orwhenanother
elementsuchaszincorironispresentinthealuminumalloy.Thetemperaturealsomayvarywithdifferentceramic
materials.Ingeneral,spontaneousandprogressiveinfiltrationwilloccurataprocesstemperatureofatleastabout700C.,
andpreferablyofatleastabout800C.Temperaturesgenerallyinexcessof1200C.donotappeartobenefittheprocess,
andaparticularlyusefultemperaturerangehasbeenfoundtobeaboutfrom800to1200C.

Inthepresentmethod,moltenaluminumalloyisdeliveredtoamassofpermeableceramicmaterialinthepresenceofa
nitrogencontaininggasmaintainedfortheentiretimerequiredtoachieveinfiltration.Thisisaccomplishedbymaintaininga
continuousflowofgasintocontactwiththelayupofceramicmaterialandmoltenaluminumalloy.Althoughtheflowrateof
thenitrogencontaininggasisnotcritical,itispreferredthattheflowratebesufficienttocompensateforanynitrogenlost
fromtheatmosphereduetonitrideformationinthealloymatrix,andalsotopreventorinhibittheincursionofairwhichcan
haveanoxidizingeffectonthemoltenmetal.

Asstatedabove,thenitrogencontaininggascomprisesatleastabout10volumepercentnitrogen.Ithasbeenfoundthat
thenitrogenconcentrationcanaffecttherateofinfiltration.Moreparticularly,thetimeperiodsrequiredtoachieveinfiltration
tendtoincreaseasthenitrogenconcentrationdecreases.AsisshowninTableI(below)forExamples57,thetimerequired
toinfiltratealuminawithmoltenaluminumalloycontaining5%magnesiumand5%siliconat1000C.increasedasthe
concentrationofnitrogendecreased.Infiltrationwasaccomplishedinfivehoursusingagascomprising50volumepercent
nitrogen.Thistimeperiodincreasedto24hourswithagascomprising30volumepercentnitrogen,andto72hourswitha
gascomprising10volumepercentnitrogen.Preferably,thegascomprisesessentially100%nitrogen.Nitrogen
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concentrationsatthelowerendoftheeffectiverange,i.e.lessthanabout30volumepercent,generallyarenotpreferred
owingtothelongerheatingtimesrequiredtoachieveinfiltration.

Themethodofthisinventionisapplicabletoawidevarietyofceramicmaterials,andthechoiceoffillermaterialwilldepend
onsuchfactorsasthealuminumalloy,theprocessconditions,thereactivityofthemoltenaluminumwiththefillermaterial,
andthepropertiessoughtforthefinalcompositeproduct.Thesematerialsinclude(a)oxides,e.g.alumina,magnesia,
titania,zirconiaandhafnia(b)carbides,e.g.,siliconcarbideandtitaniumcarbide(c)borides,e.g.titaniumdiboride,
aluminumdodecaboride,and(d)nitrides,e.g.aluminumnitride,siliconnitride,andzirconiumnitride.Ifthereisatendencyfor
thefillermaterialtoreactwiththemoltenaluminumalloy,thismightbeaccommodatedbyminimizingtheinfiltrationtimeand
temperatureorbyprovidinganonreactivecoatingonthefiller.Thefillermaterialmaycompriseasubstrate,suchascarbon
orothernonceramicmaterial,bearingaceramiccoatingtoprotectthesubstratefromattackordegradation.Suitable
ceramiccoatingsincludetheoxides,carbides,boridesandnitrides.Ceramicswhicharepreferredforuseinthepresent
methodincludealuminaandsiliconcarbideintheformofparticles,platelets,whiskersandfibers.Thefiberscanbe
discontinuous(inchoppedform)ofintheformofcontinuousfilament,suchasmultifilamenttows.Further,theceramicmass
orpreformmaybehomogeneousorheterogeneous.

Siliconcarbidereactswithmoltenaluminumtoformaluminumcarbide,andifsiliconcarbideisusedasthefillermaterial,it
isdesirabletopreventorminimizethisreaction.Aluminumcarbideissusceptibletoattackbymoisture,whichpotentially
weakensthecomposite.Consequently,tominimizeorpreventthisreaction,thesiliconcarbideisprefiredinairtoforma
reactivesilicacoatingthereon,orthealuminumalloyisfurtheralloyedwithsilicon,orboth.Ineithercase,theeffectisto
increasethesiliconcontentinthealloytoeliminatethealuminumcarbideformation.Similarmethodscanbeusedtoprevent
undesirablereactionswithotherfillermaterials.

Thesizeandshapeoftheceramicmaterialcanbeanysizeandshapewhichmayberequiredtoachievetheproperties
desiredinthecomposite.Thus,thematerialmaybeintheformofparticles,whiskers,plateletsorfiberssinceinfiltrationis
notrestrictedbytheshapeofthefillermaterial.Othershapessuchasspheres,tubules,pellets,refractoryfibercloth,and
thelikemaybeemployed.Inaddition,thesizeofthematerialdoesnotlimitinfiltration,althoughahighertemperatureor
longertimeperiodmaybeneededforcompleteinfiltrationofamassofsmallerparticlesthanforlargerparticles.Further,the
massofceramicmaterialtobeinfiltratedispermeable,i.e.,permeabletomoltenaluminumalloysandtonitrogencontaining
gases.Theceramicmaterialcanbeeitheratitspourdensityorcompressedtoamodestdensity.

Themethodofthepresentinvention,notbeingdependentontheuseofpressuretoforcemoltenmetalintoamassof
ceramicmaterial,allowstheproductionofsubstantiallyuniformaluminumalloymatrixcompositeshavingahighvolume
fractionofceramicmaterialandlowporosity.Highervolumefractionsofceramicmaterialmaybeachievedbyusingalower
porosityinitialmassofceramicmaterial.Highervolumefractionsalsomaybeachievediftheceramicmassiscompacted
underpressureprovidedthatthemassisnotconvertedintoeitheracompactwithclosedcellporosityorintoafullydense
structurethatwouldpreventinfiltrationbythemoltenalloy.

Ithasbeenobservedthatforaluminuminfiltrationandmatrixformationwithagivenaluminumalloy/ceramicsystem,wetting
oftheceramicbythealuminumalloyisthepredominantinfiltrationmechanism.Atlowprocessingtemperatures,anegligible
orminimalamountofmetalnitridingoccursresultinginaminimaldiscontinuousphaseofaluminumnitridedispersedinthe
metalmatrix.Astheupperendofthetemperaturerangeisapproached,nitridationofthemetalismorelikelytooccur.Thus,
theamountofthenitridephaseinthemetalmatrixcanbecontrolledbyvaryingtheprocessingtemperature.Theprocess
temperatureatwhichnitrideformationbecomesmorepronouncedalsovarieswithsuchfactorsasthealuminumalloyused
anditsquantityrelativetothevolumeoffiller,theceramicmaterialtobeinfiltrated,andthenitrogenconcentrationofthegas
used.Forexample,theextentofaluminumnitrideformationatagivenprocesstemperatureisbelievedtoincreaseasthe
abilityofthealloytowettheceramicfillerdecreasesandasthenitrogenconcentrationofthegasincreases.

Itisthereforepossibletotailortheconstituencyofthemetalmatrixduringformationofthecompositetoimpartcertain
characteristicstotheresultingproduct.Foragivensystem,theprocesstemperaturecanbeselectedtocontrolthenitride
formation.Acompositeproductcontaininganaluminumnitridephasewillexhibitcertainpropertieswhichcanbefavorable
to,orimprovetheperformanceof,theproduct.Further,thetemperaturerangeforspontaneousinfiltrationwithaluminum
alloymayvarywiththeceramicmaterialused.Inthecaseofaluminaasthefillermaterial,thetemperatureforinfiltration
shouldpreferablynotexceedabout1000C.inordertoinsurethattheductilityofthematrixisnotreducedbythesignificant
formationofanynitride.However,temperaturesexceeding1000C.maybeemployedifitisdesiredtoproducea
compositewithalessductileandstiffermatrix.Toinfiltrateotherceramicssuchassiliconcarbide,highertemperaturesof
about1200C.maybeemployedsincethealuminumalloynitridestoalesserextent,relativetotheuseofaluminaasfiller,
whensiliconcarbideisemployedasafillermaterial.

Inaccordancewithanotherembodimentoftheinvention,thecompositeisprovidedwithanaluminumnitrideskinorsurface.
Generally,theamountofthealloyissufficienttoinfiltrateessentiallytheentirebedofceramicmaterial,thatis,tothe
definedboundaries.However,ifthesupplyofmoltenalloybecomesdepletedbeforetheentirebedorpreformhasbeen
infiltrated,andthetemperaturehasnotbeenreducedtosolidifythealloy,analuminumnitridelayerorzonemayformonor
alongtheoutersurfaceofthecompositeduetonitridingofthesurfaceregionsoftheinfiltratingfrontofaluminumalloy.That
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portionofthebednotembeddedbythematrixisreadilyremovedasbygritblasting.Also,anitrideskincanbeformedat
thesurfaceofthebedorpreforminfiltratedtoitsboundarybyprolongingtheprocessconditions.Forexample,anopen
vesselwhichisnonwettablebythemoltenaluminumalloyisfilledwiththepermeableceramicfiller,andthetopsurfaceof
theceramicbedisexposedtothenitrogengas.Uponmetalinfiltrationofthebedtothevesselwallsandtopsurface,ifthe
temperatureandflowofnitrogengasarecontinued,themoltenaluminumattheexposedsurfacewillnitride.Thedegreeof
nitridationcanbecontrolled,andmaybeformedaseitheracontinuousphaseoradiscontinuousphaseintheskinlayer.It
thereforeispossibletotailorthecompositeforspecificapplicationsbycontrollingoftheextentofnitrideformationonthe
surfaceofthecomposite.Forexample,aluminummatrixcompositesbearingasurfacelayerofaluminumnitridemaybe
producedexhibitingimprovedwearresistancerelativetothemetalmatrix.

Asisshowninthefollowingexamples,moltenaluminummagnesiumalloysspontaneouslyinfiltratethepermeablemassof
ceramicmaterialduetotheirtendencytowetaceramicmaterialpermeatedwithnitrogengas.Auxiliaryalloyingelements
suchassiliconandzincmaybeincludedinthealuminumalloystopermittheuseoflowertemperaturesandlower
magnesiumconcentrations.Aluminummagnesiumalloyswhichinclude1020%ormoreofsiliconthereinarepreferredfor
infiltratingunfiredsiliconcarbidesincesilicontendstominimizereactionofthemoltenalloywithsiliconcarbidetoform
aluminumcarbide.Inaddition,thealuminumalloysemployedintheinventionmayincludevariousotheralloyingelementsto
providespecificallydesiredmechanicalandphysicalpropertiesinthealloymatrix.Forexample,copperadditivesmaybe
includedinthealloytoprovideamatrixwhichmaybeheattreatedtoincreasehardnessandstrength.EXAMPLES110

Theseexamplesillustrateformingaluminumalloymatrixcompositesusingvariouscombinationsofaluminummagnesium
alloys,alumina,nitrogencontaininggases,andtemperaturetimeconditions.ThespecificcombinationsareshowninTableI,
below.

InExamples19,moltenAlMgalloyscontainingatleast1%byweightmagnesium,andoneormoreauxiliaryalloying
elements,weredeliveredtothesurfaceofapermeablemassofloosealuminaparticles,bycontactingasolidbodyofthe
alloywiththealuminamass.Thealuminaparticleswerecontainedinarefractoryboatatpourdensity.Thesizeofthealloy
bodywas2.551.3cm.Thealloyceramicassemblywasthenheatedinafurnaceinthepresenceofanitrogencontaining
gasflowingattherateof200300cubiccentimetersperminute.UndertheconditionsofTableI,themoltenalloy
spontaneouslyinfiltratedthebedofaluminamaterial,withtheexceptionofExample2wherepartialinfiltrationoccurred.It
wasfoundthatalloybodiesweighing4345gramswereusuallysufficienttocompletelyinfiltrateceramicmassesof3040
grams.

Duringinfiltrationofthealuminafiller,aluminumnitridemayforminthematrixalloy,asexplainedabove.Theextentof
formationofaluminumnitridecanbedeterminedbythepercentweightgainofthealloy,i.e.,theincreaseinweightofthe
alloyrelativetotheamountofalloyusedtoeffectinfiltration.Weightlosscanalsooccurduetovolatilizationofthe
magnesiumorzincwhichislargelyafunctionoftimeandtemperature.Suchvolatilizationeffectswerenotmeasured
directlyandthenitridationmeasurementsdidnottakethisfactorintoaccount.Thetheoreticalpercentweightgaincanbeas
highas52,basedonthecompleteconversionofaluminumtoaluminumnitride.Usingthisstandard,nitrideformationinthe
aluminumalloymatrixwasfoundtoincreasewithincreasingtemperature.Forinstance,thepercentweightgainof5Mg10
SialloyofExample8(inTableI,below)was10.7%at1000C.,butwhensubstantiallythissameexperiment(notshownin
TableI)wasrepeatedexceptat900C.,thepercentweightgainwas3.4%.SimilarresultsarealsoreportedforExample
14,below.Itthereforeispossibletopreselectortailorthecompositionofthematrix,andhencethepropertiesofthe
composite,byoperatingwithincertaintemperatureintervals.

Inadditiontoinfiltratingpermeablebodiesofceramicparticulatematerialtoformcomposites,itispossibletoproduce
compositesbyinfiltratingfabricsoffibrousmaterial.AsshowninExample10,acylinderofAl3%Mgalloymeasuring2.2
cminlengthand2.5cmindiameterandweighing29gramswaswrappedinafabricmadeofduPontFPaluminafiberand
weighing3.27grams.Thealloyfabricassemblywasthenheatedinthepresenceofforminggas.Undertheseconditions,
thealloyspontaneouslyinfiltratedthealuminafabrictoyieldacompositeproduct.

Withoutintendingtobeboundbyanyspecifictheoryorexplanation,itappearsthatthenitrogenatmosphereinduces
spontaneousinfiltrationofthealloyintothemassofceramicmaterial.Todeterminetheimportanceofnitrogen,acontrol
experimentwasdoneinwhichanitrogenfreegaswasemployed.AsshowninTableI,ControlExperimentNo.1was
conductedinthesamemannerasExample8exceptforuseofanitrogenfreegas.Undertheseconditions,itwasfound
thatthemoltenaluminumalloydidnotinfiltratethealuminabedding.

Analysisofscanningelectronmicroscopeimagesofsomeofthealuminumalloymatrixcompositeswasdonetodetermine
thevolumefractionsofceramicfiller,alloymatrixandporosityinthecomposite.Theresultsindicatedthatthevolumeratio
ofceramicfillertoalloymatrixistypicallygreaterthanabout1:1.Forinstance,inthecaseofExample3itwasfoundthat
thecompositecontained60%alumina,39.7%metalalloymatrixanda0.3%porosity,byvolume.

ThephotomicrographofFIG.1isforacompositemadesubstantiallyaccordingtoExample3.Aluminaparticles10areseen
embeddedinamatrix12ofthealuminumalloy.Ascanbeseenbyinspectionofthephaseboundaries,thereisintimate
contactbetweenthealuminaparticlesandthematrixalloy.Minimalnitridingofthealloymatrixoccurredduringinfiltrationat
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850C.aswillbecomeevidentbycomparisonwithFIGS.2and3.Theamountofnitrideinthemetalmatrixwasconfirmed
byxraydiffractionanalysiswhichrevealedmajorpeaksforaluminumandaluminaandonlyminorpeaksforaluminum
nitride.

Theextentofnitridingforagivenaluminumalloyceramicnitridinggassystemwillincreasewithincreasingtemperaturefora
giventimeperiod.Thus,usingtheparametersthatproducedthecompositeofFIG.1exceptforatemperatureof900C.
andforatimeof24hours,theextentofnitridingwasfoundtoincreasesignificantly,ascanbeseenbyreferencetoFIG.2.
ThisexperimentwillberegardedasExample3abelow.Thegreaterextentofnitrideformation,asshownbythedarkgray
areas14,isreadilyapparentbycomparisonofFIG.1withFIG.2.

Ithasbeenfoundthatthepropertiesofthecompositecanbetailoredbythechoiceoftypeandsizeoffillerandbythe
selectionofprocessconditions.Todemonstratethiscapability,acompositewasmadewiththealloyandprocessconditions
employedinExample3,exceptat1000C.for24hoursandusinga90meshaluminafillerratherthana220meshfiller.
ThedensitiesandelasticmoduliofthiscompositeasExample3b,andthatofExample3aareshownbelow

______________________________________ExampleTemp.DensityYoung'sModulusNumber(C.)(g/cc)
(GPa)______________________________________3a9003.061543b10003.13
184______________________________________

Theresultsshownaboveillustratethatthechoiceoffillerandprocessconditionsmaybeusedtomodifythepropertiesof
thecomposite.Incontrasttotheresultsshown,theYoung'sModulusforaluminumis70GPa.Also,acomparisonofFIGS.
2and3showsthatamuchhigherconcentrationofAINformedinExample3bthanin3a.Althoughthesizeofthefiller
particlesisdifferentinthetwoexamples,thehigherAINconcentrationisbelievedtobearesultofthehigherprocessing
temperatureandisregardedastheprimaryreasonforthehigherYoung'sModulusofthecompositeofExample3b(the
Young'sModulusforAINis345GPa).

TABLEI__________________________________________________________________________ALUMINUMMATRIX
ALUMINACOMPOSITESControlInfilt.Infilt.ExampleExpt.AluminumAlloyAl2O3GasTemp.TimeNo.No.Compositiona
(%)ParticleSizeComposition(%)(C.)
(hr)__________________________________________________________________________13Mg5Si220mesh.sup.
Forminggasb1000521Mg5Si220meshForminggas1000533Mg5Si6Zn220meshForminggas8501845Mg5
Si220meshForminggas900555Mg5Si90mesh50/50N2/Ar1000565Mg5Si90mesh30/70N2/Ar10002475
Mg5Si90mesh10/90N2/Ar10007285Mg10Si220meshForminggas10001095Mg10Si220meshN210001010
3MgFabricForminggas11002120015Mg10Si220mesh96/4Ar/H21000

10__________________________________________________________________________aBalancealuminumb96%N2
/4%H2

EXAMPLES1121

Ceramicmaterialsotherthanaluminamaybeemployedintheinvention.AsshowninExamples1121ofTableII,aluminum
alloymatrixcompositesreinforcedwithsiliconcarbidemaybeproduced.Variouscombinationsofmagnesiumcontaining
aluminumalloys,siliconcarbidereinforcingmaterials,nitrogencontaininggases,andtemperature/timeconditionsmaybe
employedtoprovidethesecomposites.TheproceduredescribedinExamples19wasfollowedwiththeexceptionthat
siliconcarbidewassubstitutedforalumina.Gasflowrateswere200350cc/min.UndertheconditionssetforthinExamples
1121ofTableII,itwasfoundthatthealloyspontaneouslyinfiltratedthemassofsiliconcarbide.

Thevolumeratiosofsiliconcarbidetoaluminumalloyinthecompositesproducedbytheseexamplesweretypicallygreater
than1:1.Forexample,imageanalysis(asdescribedabove)oftheproductofExample13indicatedthattheproduct
comprised57.4%siliconcarbide,40.5%metal(aluminumalloyandsilicon)and2.1%porosity,allbyvolume.

Themagnesiumcontentofthealloyemployedtoeffectspontaneousinfiltrationisimportant.Inthisconnection,experiments
utilizingtheconditionsofControlExperiments2and3ofTableIIwereperformedtodeterminetheeffectoftheabsenceof
magnesiumontheabilityofaluminumalloystospontaneouslyinfiltratesiliconcarbide.Undertheconditionsofthesecontrol
experiments,itwasfoundthatspontaneousinfiltrationdidnotoccurwhenmagnesiumwasnotincludedinthealloy.

Thepresenceofnitrogengasisalsoimportant.Accordingly,ControlExperimentNo.4wasperformedinwhichthe
conditionsofExample17wereemployedexceptforuseofanitrogenfreegas,i.e.,argon.Undertheseconditions,itwas
foundthatthemoltenalloydidnotinfiltratethemassofsiliconcarbide.

Asexplainedabove,temperaturecanaffecttheextentofnitriding,aswasillustratedbyrepeatingExample14atfive
differenttemperatures.TableII,below,showsExample14conductedat800C.,andtheweightgainwas1.8%,butwhen
therunwasrepeatedattemperaturesof900,1000and1100C.,theweightgainswere2.5%,2.8%and3.5%,
respectively,andtherewasamarkedincreaseto14.9%forarunconductedat1200C.Itshouldbeobservedthatthe
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Variousmaterialsotherthanaluminaandsiliconcarbidemaybeemployedasceramicfillermaterialsinthecompositesof
thepresentinvention.Thesematerials,whichincludezirconia,aluminumnitrideandtitaniumdiborideareshownin
Examples2224,respectively.

TABLEII__________________________________________________________________________ALUMINUMMATRIX
SILICONCARBIDECOMPOSITESControlExampleExpt.AluminumAlloyGasTemp.TimeNo.No.CompositionSiCType
Composition(C.)(hr)__________________________________________________________________________113Mg
500meshparticlesa,bForminggas100024123Mg10Si"Forminggas1000242PureAl"Forminggas100024310Si
"Forminggas100024133Mg15Si500meshparticlesbForminggas95024145Mg15Si500meshparticlesa,b
Forminggas80010155Mg15Si500meshparticlesbForminggas100010165Mg15Si"N210001045Mg15
Si"Argon100010175Mg17Si"Forminggas100010181Mg3Si"Forminggas120010195Mg15SiLoose
SiCfibersc Forminggas950185.6mils205Mg15SiSiCwhiskersdForminggas85024215Mg15SiChoppedSiC
fiberseForminggas90024__________________________________________________________________________a
Prefiredat1250C.for24hrs.b39Crystolon(99+%pureSiCNortonCompany)c FromAvcoSpecialtyMaterialsCo.dIn
apressedpreformplacedonZrO2beddinginAl2O3boat,whiskersfromNipponLightMetalsCo.,Ltd.eNicalonfibersfrom
NipponCarbonCo.,Ltd.

EXAMPLE22

Analuminumalloycontaining5%magnesiumand10%siliconwasmeltedincontactwiththesurfaceofazirconiaparticle
bedding(220mesh,SCMg3fromMagnesiumElektron,Inc.)inanatmosphereofforminggasat900C.Underthese
conditions,themoltenalloyspontaneouslyinfiltratedthezirconiabedding,yieldingametalmatrixcomposite.

EXAMPLE23

TheproceduredescribedinExamples19wasemployedfortworunswiththeexceptionthataluminumnitridepowderof
lessthan10micronsparticlesize(fromElektroschmelzwerkKemptonGmbH)wassubstitutedforthealumina.The
assembledalloyandbeddingwereheatedinanitrogenatmosphereat1200C.for12hours.Thealloyspontaneously
infiltratedthealuminumnitridebedding,yieldingametalmatrixcomposite.Asdeterminedbypercentweightgain
measurements,minimalnitrideformation,togetherwithexcellentinfiltrationandmetalmatrixformation,wereachievedwith
3Mgand3Mg10Sialloys.Unitweightgainsofonly9.5%and6.9%,respectively,werefound.

EXAMPLE24

TheproceduredescribedinExample23wasrepeatedwiththeexceptionthattitaniumdiboridepowderhavingamean
particlesizeof56microns(GradeHTCfromUnionCarbideCo.)wassubstitutedforthealuminumnitridepowder.
AluminumalloysofthesamecompositionasinExample23spontaneouslyinfiltratedthepowderandformedauniform
metalmatrixbondingthepowdertogether,withminimalnitrideformationinthealloy.Unitweightgainsof11.3%and4.9%
wereobtainedforAl3MgandAl3Mg10Sialloys,respectively.

Incomparisonwithconventionalmetalmatrixcompositetechnology,theinventionobviatestheneedforhighpressuresor
vacuums,providesfortheproductionofaluminummatrixcompositeswithawiderangeofceramicloadingsandwithlow
porosity,andfurtherprovidesforcompositeshavingtailoredproperties.

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CLASSIFICATIONS

U.S.
164/66.1,164/97
Classification
International C22C29/00,C22C47/00,C22C29/02,C22C29/16,C22C29/12,C22C47/10,C22C32/00,C22C47/04,C22C1/10,C22C49/14,C22C47/02,
Classification C22C49/06,C04B35/58,C22C47/08,C22C21/00,C22C29/14,C22C101/10
Cooperative Y10T428/12486,Y10T428/12007,C22C49/14,C22C47/08,B22F2998/00,C22C32/00,C22C2001/1063,C22C1/1036,C22C29/00,
Classification B22F2999/00
European
C22C29/00,C22C32/00,C22C49/14,C22C47/08,C22C1/10D
Classification

LEGALEVENTS
Date Code Event Description
Ownername:LANXIDECORPORATION,TRALEEINDUSTRIALPARK,NEWAR
Freeformattext:ASSIGNMENTOFASSIGNORSINTEREST.ASSIGNORS:WHITE,DANNY
Jun25,1987 AS Assignment
R.URQUHART,ANDREWW.AGHAJANIAN,MICHAELK.AND
OTHERSREEL/FRAME:004733/0487SIGNINGDATESFROM19870615TO19870619
Ownername:LANXIDETECHNOLOGYCOMPANY,LP,DELAWARE
Freeformattext:ASSIGNMENTOFASSIGNORSINTEREST.ASSIGNOR:LANXIDE
Feb13,1989 AS Assignment CORPORATIONREEL/FRAME:005013/0531
Effectivedate:19890210
Fee Yearoffeepayment:4
May26,1992 FPAY
payment
Certificate
Apr27,1993 CC
ofcorrection
Fee Yearoffeepayment:8
Nov8,1996 FPAY
payment
Maintenance
Nov28,2000 REMI feereminder
mailed
Fee Yearoffeepayment:12
May2,2001 FPAY
payment
Surcharge
May2,2001 SULP forlate Yearoffeepayment:11
payment

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