1882 results about "Metal matrix composite" patented technology

Embodiments of the present invention provide a cost effective electrostatic chuck assembly capable of operating over a wide temperature range in an ultra-high vacuum environment while minimizing thermo-mechanical stresses within the electrostatic chuck assembly. In one embodiment, the electrostatic chuck assembly includes a dielectric body having chucking electrodes which comprise a metal matrix composite material with a coefficient of thermal expansion (CTE) that is matched to the CTE of the dielectric body.

Novel composite disc brake rotor assemblies are provided, along with novel and efficient methods for manufacturing them. Preferably, the rotor assemblies comprise annular wear plates formed of particle reinforced aluminum-based metal matrix composite (MMC), ceramic matrix composite (CMC), or of ‘carbon graphite foam.’ The wear plates, made of a first material, are attached to annular surfaces of a central rotor, made of a second material, by fusing bonding layers between the wear plates and the rotor surfaces. The bonding layers are comprised of at least one of a metal alloy having a melting temperature lower than that of either the first or second materials, and a high-temperature adhesive. Preferably, the wear plates comprise projections that are positioned within adjacent receiving recesses in the center rotor. The bonding layers and projections enhance thermal and acoustical transference between the wear plates and the center rotor section. Carbon graphite foam provides for substantially enhanced heat transference. Use of the fusable binding layer, or adhesive provides for an efficient, low cost method of manufacturing for composite disc brake rotor assemblies.

Embodiments of the present invention provide a cost effective electrostatic chuck assembly capable of operating over a wide temperature range in an ultra-high vacuum environment while minimizing thermo-mechanical stresses within the electrostatic chuck assembly. In one embodiment, the electrostatic chuck assembly includes a dielectric body having chucking electrodes which comprise a metal matrix composite material with a coefficient of thermal expansion (CTE) that is matched to the CTE of the dielectric body.

The invention discloses a preparation method of a graphene reinforced metal-matrix composite, which comprises the following steps of: firstly, dispersing the graphene oxide on the surface of the flaky metal powder; and then obtaining the graphene / metal composite powder through the reducing treatment; and at last, carrying out densification treatment by adopting a powder metallurgic technology to obtain the compact graphene reinforced metal-matrix composite. The flaky metal powder has the plane two-dimensional form, is inclined to the directional piling to form a laminated structure, and is helpful for inducing the graphene orientation distribution and giving play to the reinforcing effect. The preparation method disclosed by the invention is simple and feasible, is capable of regulating the graphene content and is suitable for preparing the massive composite.

The lightweight bulletproof metal matrix macrocomposites (MMMC) contain (a) 10-99 vol. % of permeable skeleton structure of titanium, titanium aluminide, Ti-based alloys, and / or mixtures thereof infiltrated with low-melting metal selected from Al, Mg, or their alloys, and (b) 1-90 vol. % of ceramic and / or metal inserts positioned within said skeleton, whereby a normal projection area of each of said inserts is equal to or larger than the cross-section area of a bullet or a projectile body. The MMMC are manufactured as flat or solid-shaped, double-layer, or multi-layer articles containing the same inserts or different inserts in each layer, whereby insert projections of each layer cover spaces between inserts of the underlying layer. The infiltrated metal contains 1-70 wt. % of Al and Mg in the balance, optionally, alloyed with Ti, Si, Zr, Nb, V, as well as with 0-3 wt. % of TiB2, SiC, or Si3N4 sub-micron powders, to promote infiltrating and wetting by Al-containing alloys. The manufacture includes (a) forming the permeable metal powder and inserts into the skeleton-structured preform by positioning inserts in the powder followed by loose sintering in vacuum to provide the average porosity of 20-70%, (b) heating and infiltrating the porous preform with molten infiltrating metal for 10-40 min at 450-750° C., (c) hot isostatic pressing of the infiltrated composite, and (d) re-sintering or diffusion annealing.

Objects comprising Al-7.5 Mg particulate having pressure consolidated nanocrystalline coating material are formed. Oxides of the coating material, in particulate form, may become dispersed in the pressure consolidated, thereby increasing its strength.

A lightweight armor system may comprise multiple reinforcement materials layered within a single metal matrix casting. These reinforcement materials may comprise ceramics, metals, or other composites with microstructures that may be porous, dense, fibrous or particulate. Various geometries of flat plates, and combinations of reinforcement materials may be utilized. These reinforcement materials are infiltrated with liquid metal, the liquid metal solidifies within the material layers of open porosity forming a dense hermetic metal matrix composite armor in the desired product shape geometry. The metal infiltration process allows for metal to penetrate throughout the overall structure extending from one layer to the next, thereby binding the layers together and integrating the structure.

The invention discloses a preparation method of a copper-plated graphene reinforced metal-based composite. The preparation method comprises the following steps: firstly, chemically plating the surfaces of oxidized graphene powder with copper to obtain copper-plated graphene powder; ball-grinding and mixing the copper-plated graphene powder and metal powder to obtain copper-plated graphene / metal mixed powder; and performing warm-pressing forming to the copper-plated graphene / metal mixed powder by adopting powder metallurgy warm-pressing technology, sintering, and performing composite processing and forming by adopting extrusion, forging, rolling and other technologies. The copper-plated graphene powder is adopted as a reinforcing body, the preparation method is simple, the cost is low, the designability is strong, and the copper-plated graphene reinforced metal-based composite which is good in interface binding, high in compactness and good in mechanical performance and thermophysical performance can be obtained.

A method for forming a vehicular brake rotor involving loading a shaped metal substrate with a mixture of metal alloying components and ceramic particles in a dieheating the contents of the die while applying pressure to melt at least one of the metal components of the alloying mixture whereby to densify the contents of the die and form a ceramic particle-containing metal matrix composite coating on the metallic substrate; and cooling the resulting coated product.

The invention discloses a foam skeleton structure reinforced metal-matrix composite material and a preparation method thereof. The composite material comprises a foam skeleton, a surface strengthening material and a matrix, wherein the foam skeleton is made of foam metal, foamed ceramics or foamy carbon; the surface strengthening material is a high heat conduction material adopting a diamond film, a graphene film, a carbon nanotube and the like; the metal matrix material adopts one of copper, aluminum, a copper alloy, an aluminum alloy and the like. A reinforcing phase and a matrix phase of the prepared composite material keep continuous distribution in three-dimensional space, an interpenetrating network structure is formed, the influence of a composite interface on the thermal properties of the material can be weakened effectively, good plasticity and toughness of the metal matrix are not reduced, the reinforcing phase can become a whole, the heat conduction efficiency of a reinforcing body is realized to the greatest extent, the heat conductivity, the electric conductivity and the mechanical strength of the composite material are greatly improved compared with the traditional composite material, and the composite material is a multifunctional composite material with great potential.

The invention relates to a method for preparing a particulate reinforced metallic matrix composite material. The method is characterized in that: metal powder and hard phase powder are mechanically mixed and the mixture is added into a high-energy globe mill container for ball milling; powder after ball milling is sieved; sandblasting coarsing pretreatment is performed on the matrix surface and the ball milling powder is sprayed on a matrix by adoption of the cold spraying method, and then the particulate reinforced metallic matrix composite material is obtained. The preparation method adopts the high-energy ball milling method to prepare and spray the powder, and can make distribution of hard phases more uniform on one hand and thin metallic matrix crystal grains through ball milling on the other hand, thereby the performance of the MMC material prepared is further improved. The particulate reinforced metallic matrix composite material prepared by the method has compact tissue and excellent performance, and not only can prepare a coating but also can realize near-net forming of parts. The method has simple technique, good controllability, low production cost and high production efficiency, and is favorable for realizing industrialized application.

A low-temperature friction-based coating method termed friction stir fabrication (FSF) is disclosed, in which material is deposited onto a substrate and subsequently stirred into the substrate using friction stir processing to homogenize and refine the microstructure. This solid-state process is capable of depositing coatings, including nanocrystalline aluminum and / or metal matrix composites and the like, onto substrates such as aluminum at relatively low temperatures. A method of making rod stock for use in the FSF process is also disclosed.

The invention discloses a graphene and carbon nanotube mixed enhanced metal-matrix composite material and a preparation method thereof. The graphene and carbon nanotube mixed enhanced metal-matrix composite material is characterized in that graphene and a carbon nanotube are mutually connected to constitute an enhanced network in a metal matrix, wherein the graphene is few-layer graphene with 10 layers or less, the radius-thickness ratio of the graphene is larger than 200, and the volume fraction of the graphene is 0.1-1%; and the carbon nanotube is a single-wall, double-wall or multi-wall carbon nanotube, the length-diameter ratio of the carbon nanotube is larger than 20, and the volume fraction of the carbon nanotube is 0.5-5%. Compared with the composite material enhanced only by the carbon nanotube, the graphene and carbon nanotube mixed enhanced metal-matrix composite material disclosed by the invention not only has greatly improved mechanical properties, but also has more excellent electric conduction and heat conduction properties, and is a multi-purpose structure and function integrated material. In addition, the preparation method provided by the invention based on slurry blending and graphene oxide reduction is simple and efficient and is easy for large-scale production.

A metal matrix composite casting comprises a metal matrix composite and a processed member inserted in the metal matrix composite by enveloped casting. By the processed member which is easier to process than the metal matrix composite, a processed portion of a predetermined shape can be formed in the metal matrix composite. That is, by a simple processing such that the processed member is removed from the metal matrix composite or the processed portion is formed in the processed member itself, the processed portion having a desired shape can be easily formed in the metal matrix composite.

A cast article from an aluminum alloy has improved mechanical properties at elevated temperatures. The cast article has the following composition in weight percent: Silicon 6.0-25.0, Copper 5.0-8.0, Iron 0.05-1.2, Magnesium 0.5-1.5, Nickel 0.05-0.9, Manganese 0.05-1.2, Titanium 0.05-1.2, Zirconium 0.05-1.2, Vanadium 0.05-1.2, Zinc 0.05-0.9, Strontium 0.001-0.1, Phosphorus 0.001-0.1, and the balance is Aluminum, wherein the silicon-to-magnesium ratio is 10-25, and the copper-to-magnesium ratio is 4-15. The aluminum alloy contains a simultaneous dispersion of three types of Al3X compound particles (X=Ti, V, Zr) having a L12 crystal structure, and their lattice parameters are coherent to the aluminum matrix lattice. A process for producing this cast article is also disclosed, as well as a metal matrix composite, which includes the aluminum alloy serving as a matrix containing up to about 60% by volume of a secondary filler material.

An extrudable and weldable matrix alloy composite comprising: a) a base material metal of about 50 to 99.9% by weight, b) boron carbide or silicon carbide of about 0.1 to 50% by weight, c) less than about 3.0% by weight of at least one metal having an intermetallic phase temperature lower than the melting point of the base material metal, and d) a reinforcement agent of up to about 5% by weight.

An electric submersible pump and pump system including additively manufactures structures and method of manufacture are disclosed. The pump system including the electric submersible pump and an electric motor configured to operate the electric submersible pump. The electric submersible pump including a housing, at least one impeller and at least one diffuser disposed within the housing in cooperative engagement. The housing, the at least one impeller, and the at least one diffuser defining an internal volume configured to receive a fluid. At least one of the at least one impeller and the at least one diffuser configured as a monolithic additively manufactured structure comprised of a metal matrix composite. Also provided is an electric submersible pump including an impeller and a diffuser, wherein at least one of the impeller and the diffuser is configured as a monolithic additively manufactured structure comprised of a tungsten carbide (WC) dispersed in a metal matrix.

The invention relates to a method for preparing endogenetic particle reinforced metal matrix composites under the coupling effect of a magnetic field and supersonic waves. The method comprises: adjusting the temperature of a metal matrix fused mass to the reaction initial temperature after refining, adding a reactant which can generate a particle phase with the fused mass through the reaction in situ for implementing the synthesis reaction, standing the mixture after the reaction is over, and cooling the mixture to the pouring temperature for pouring; and the method is characterized in that: the magnetic field and the high-intensity ultrasonic field are simultaneously exerted in the reaction synthesis process to realize the synthesis of endogenetic particle reinforced metal matrix composites under the coupling effect of the magnetic field and the high-intensity ultrasonic field. The magnetic field can be an intense pulse magnetic field, a high frequency oscillation magnetic field or a low frequency alternating magnetic field. In the method, the coupling effect of the magnetic field and the ultrasonic field makes the particle sizes be thinned and dispersed evenly; the ultrasonic vibration agitation and electromagnetic stirring functions improve the composite dynamic condition, and the compounding of the particle phase and a base metal interface is better; and the co-action of magnetochemistry and sonochemistry improves the thermodynamic condition of the reaction in situ, as well as speeding up the reaction in situ and controlling the growth of the particle phase.

Metal-cladded metal matrix composite wires that include a hot worked metal cladding associated with the exterior surface of a metal matrix composite wire comprising a plurality of continuous, longitudinally positioned fibers in a metal matrix.

The invention provides a powder metallurgy preparation method for a nano-particle reinforced ultra-fine grain metal-matrix composite. According to the method, a metal-matrix grain refining process and a nano-particle dispersing process are carried out in steps. The method comprises the steps that firstly, micro-nano flaky metal-matrix powder is prepared in advance; nano-particles and the flaky metal-matrix powder are stirred and mixed in a stirrer at the high speed under protective atmosphere, and by means of high shear force and pressure generated between stirring blades and a tank body, the nano-particles are uniformly dispersed to the surface of the micro-nano flaky metal-matrix powder; through short-time mechanical ball-milling treatment, the nano metal particles are embedded into the micro-nano flaky metal-matrix powder, so that composite powder of nano-particle reinforced metal is obtained; and compression moulding, sintering and compacting treatment are conducted, so that the ultra-fine grain metal-matrix composite with the nano-particles uniformly dispersed is obtained. By means of the powder metallurgy preparation method, time and energy are saved; cost is low; the application range is wide; and the prepared material is high in comprehensive mechanical performance and has large-scale application potential.

It is the object of the present invention to provide a low weight, compact, low vertical profile thermal management system for removing heat from electronic components. The thermal management system comprises of a plurality of “flow-through” type cooling devices, a source of filtered pressurized fluid suitable for use as a coolant, and a fluid delivering device that supplies the cooling devices with fluid. A preferred fluid is air, such as a filtered pressurized air. The cooling device is comprised of a high conductivity metal matrix composite heat spreader, a miniature heat sink, preferably of the same material, a permeable heat exchanger with high specific surface, and a closure that provides structural integrity of the cooling device.

Titanium based metal matrix composites reinforced with ceramic particulate are well known, based on a blend of titanium alloy powders with ceramic powders, e.g., aluminum oxide powders, utilizing a low energy ball milling process, followed by cold compacting and sintering to produce an appropriate composite. This prior art process is disadvantaged from the point of view that there are virtually no particles in the blend below the micrometer size range, which lack has a deleterious effect on the subsequent processing of the composite. This problem has been overcome by utilizing dry high energy intensive milling in the process, which has the effect of providing the necessary number of small particles below the micrometer size range as well as enhancing the reactivity of different particles with one another. In order to produce a titanium base alloy alumina metal matrix composite, titanium dioxide powder is blended with aluminum powder and subjected to dry high energy intensive milling until the separate particle phases achieve a size of 500 nanometers maximum. The intermediate powder product is then heated to form the titanium alloy / amumina metal matrix composite in which the ceramic particles have an average diameter of no more than 3 mu, and the oxide consists of more than 10% and less than 60% by volume fraction of the total composite. The composites have extensive application to tough and strong engineering alloys.

(a) The metal matrix composite is suitable for the manufacture of flat or shaped titanium aluminide, zirconium aluminide, or niobium aluminide articles and layered metal composites having improved mechanical properties such as lightweight plates and sheets for aircraft and automotive applications, thin cross-section vanes and airfoils, heat-sinking lightweight electronic substrates, bulletproof structures for vests, partition walls and doors, as well as sporting goods such as helmets, golf clubs, sole plates, crown plates, etc. The composite material consists of a metal (e.g., Ti, Zr, or Nb-based alloy) matrix at least partially intercalated with a three-dimensional skeletal metal aluminide structure, whereby ductility of the matrix metal is higher than that of the metal aluminide skeleton. The method for manufacturing includes the following steps: (a) providing an aluminum skeleton structure having open porosity of 50-95 vol. %, (b) filling said skeleton structure with the powder of a reactive matrix metal, (c) compacting the aluminum skeleton / matrix powder composite preform by cold rolling, cold die pressing, cold isostatic pressing, and / or hot rolling, (d) consolidating the initial or compacted composite preform by sintering, hot pressing, hot rolling, hot isostatic pressing, and / or hot extrusion to provide, at least partially, a reaction between aluminum skeleton and matrix metal powder, and (e) diffusion annealing followed by any type of heat treatment needed to provide predetermined mechanical and surface properties of the resulting metal matrix composite. The combination of ductile matrix and metal aluminide skeletal structure results in significant improvement of mechanical properties of the composite material, especially hot strength. This high-strength aluminide-based material can also be used as a core component in multilayer metal matrix composites.

An article in the form of one of a plate, a sheet, a cylinder, and a portion of a cylinder, which is adapted for use as at least a portion of a wear resistant working surface of a roll is disclosed. The article includes a metal matrix composite comprising a plurality of inorganic particles dispersed in a matrix material. The matrix material includes at least one of a metal and a metal alloy, wherein the melting temperature of the inorganic particles is greater than the melting temperature of the matrix material. A plurality of hard elements are embedded in the metal matrix composite. The wear resistance of the metal matrix composite is less than the wear resistance of the hard elements, and the metal matrix composite preferentially wears away when the article is in use, thereby providing or preserving gaps between each of the plurality of hard elements at a working surface of the article.

The invention discloses a preparation method and application of a ceramic preform, belonging to the field of metal matrix composite. The preparation method comprises steps of mixing adhesive with ceramic particles, fully mixing powder of carbide such as silicon carbide and boron carbide with powder of oxide, then adding into adhesive coated ceramic particles to be mixed, filling the mixed material into a die so as to prepare the cellular porous ceramic preform, wherein a coating layer well wetted by molten metal is formed on the surface of the ceramic particle. The ceramic particles prepared by the method allow the ceramic particles of the metal matrix composite to be distributed more uniformly in the metal matrix, the composite layer is thick, the coated surface of the ceramic particle is easy to be wetted by molten metal, the bonding strength of the metal and the ceramic is greatly improved, and the service life of the composite is prolonged.

A method of fabricating microstructural components, microparts assemblies and microparts is disclosed. The method includes fabricating a unidirectional metal matrix composite made of materials selected to allow precise etching of different structural elements of the given composite without damage to each other. Cutting a composite to form slices or sections. Etching a matrix entirely out will produce wide assortment of microparts. Partial removal of matrix will form an array of microprotrusions protruding from a substrate. Etching out the microprotrusions cores will form hollow microprotrusions. The method of invention is suitable for fabricating of variety of microcomponents. For example: microneedles—a medical microdevice component having micron features, arrays of high strength micropins and micropunches, and precisely controlled unique microstructural surfaces.

A method for the local initial application of a thermal barrier coating layer (3), or for the local repair of coating defects and / or deteriorations of components (1) in the hot gas path of a gas turbine engine, which components are coated with a thermal barrier coating layer, includes at least the following steps:(I) in the case of repair, normally overall inspection of the whole component (1) for the determination of the location of defect / deterioration, as well as of corresponding type of defect / deterioration of each place for a multitude of locations of the component (1);(II) if needed, preparation of the surface in at least one location;(III) local application of a ceramic tissue together with a wet chemical thermal barrier coating layer deposition material for the formation of a patch (5) of ceramic matrix composite;(IV)a intermediate inspection of the patch and / or the surface;(IV)b in the case of a repetitive and / or multi-step repair method, subsequent layer application of a ceramic tissue together with a wet chemical thermal barrier coating layer deposition material for the formation of a patch (5) of ceramic matrix composite at this location;(V) if needed, surface finishing at the at least one location; and(VI) final inspection of the at least one location.Steps (IV)a, (V) and (VI) can be omitted with the provision that at least one of steps (IV)a or (VI) is carried out.

A highly abrasive wear metal matrix composite hardfacing material for downhole tools is disclosed. The hardfacing material may comprise a matrix of a softer material with high hardness, such as amorphous nanocomposite steel alloys, and one or more hard component materials. The hard component materials may comprise sintered tungsten carbide, monocrystalline WC, polycrystalline WC, and the additional component of spherical cast tungsten carbide. Alternatively, a matrix of softer material, hard component materials and crushed cast tungsten carbide may be used.

The invention relates to the technical field of graphene / metal matrix composite materials and in particular relates to a graphene / metal matrix composite material and a preparation method thereof. The preparation method of the graphene / metal matrix composite material is as follows: reduced graphene or high-quality graphene prepared by an electric discharge sintering method and nano metal powder are added into an ethanol solution, ultrasonic mixing is carried out, and then ball milling, drying and sintering are carried out, so that the graphene / metal matrix composite material is obtained. The preparation method of the graphene / metal matrix composite material has the advantages of simple process, wide applicability and high efficiency; the prepared graphene / metal matrix composite material has the advantages of high conductivity, high thermal conductivity and high strength; strength of a metal matrix composite material is improved while good electricity conducting and heat conducting properties of the metal matrix composite material are maintained.