CA2081555A1

CA2081555A1 - Porous metal matrix composites and production methods

Info

Publication number: CA2081555A1
Application number: CA002081555A
Authority: CA
Inventors: Marc Stevens Newkirk
Original assignee: Individual
Current assignee: Lanxide Technology Co LP
Priority date: 1990-05-09
Filing date: 1991-05-07
Publication date: 1992-11-08
Also published as: WO1991017275A1

Abstract

The present invention relates to a novel process for forming porous metal matrix composite bodies. Particularly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Such spontaneous infiltration occurs without the requirement for the application of pressure or vacuum.
However, the amount of matrix metal provided is insufficient to embed substantially completely the filler material or preform.

Description

~ w o 91/17275 P~/US91/03160 -l- 20815~5 DESCRIPTION
POROUS METAL MATRIX COMPOSITES AND PRODUCTION METHODS

Jechnical Field The present invention relates to a novel process for forming porous metal matrix composite bodies. Particultrly, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with a filler material or a preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform.
Such sp~ntan~nllc ;nfiltratinn occ~rs witho~t the req~irPment for the application of pressure or vacuum. However, the amount of matrix metal provided is insufficient to embed substantially completely the filler material or preform.

Backqround Art ; Composite products comprising a metal matrix and a strengthening or reinforcing phase such as ceramic particulates, whiskers, fibers or the like, show great promise for a variety of applications because they combine some of the stiffness and wear resistance of the reinforcing phase with the ductility and toughness of the metal matrix. Generally, a metal matrix composite will show an improvement in such properties as strength, stiffness, contact wear resistance, coefficient of thermal expansion (C.T.E.), density, thermal conductivity and elevated temperature strength retention relative to the matrix metal in monolithic form, but the degree to which any given property may be ; improved depends largely on the specific constituents, their volume or weight fraction, and how they are processed in forming the composite.
In some instances, the composite also may be lighter in weight than the matrix metal per se. Aluminum matrix composites reinforced with ceramics such as silicon carbide in particulate, platelet, or whisker form, for example, are of interest because of their higher specific stiffness (e.g., elastic modulus over density), wear resistance, thermal conductivity, low coefficient of thermal expansion (C.T.E.) and high temperature strength and/or specific strength (e.g., strength over density) relative to aluminum.

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w o ~1/17275 PCT/US91/031 r Various metallurgical processes have been described for the fabrication of aluminum matrix composites, including methods based on powder metallurgy techniques and liquid-metal infiltration techniques which make use of pressure casting, vacuum casting, stirring, and wetting agents. With powder metallurgy techniques, the metal in the form of a powder and the reinforcing material in the form of a powder, whiskers, chopped fibers, etc., are admixed and then either cold-pressed and sintered, or hot-pressed. The maximum ceramic volume fraction in silicon carbide reinforced aluminum matrix composites produced by this method has been reported to be about 25 volume percent in the case of whiskers, and about 40 volume percent in the case of particulates.
The production of metal matrix composites by powder metallurgy techniques utilizing conventional processes imposes certain limitations with respeet. to the çharactPristirs of the produrts attainahlp~ The volume fraction of the ceramic phase in the composite is limited typically, in the case of particulates, to about 40 percent. Also, the pressing operation poses a limit on the practical size attainable. Only relatively simple product shapes are possible without subsequent processing (e.g., forming or machining) or without resorting to complex presses. Also, nonuniform shrinkage during sintering can occur, as well as nonuniformity of microstructure due to segregation in the compacts and grain growth.
U.S. Patent No. 3,970,135, granted July 20, 1976, to J. C. Cannell et al., describes a process for forming a metal matrix composite incorporating a fibrous reinforcement, e.g. silicon carbide or alumina whiskers, having a predetermined pattern of fiber orientation. The ; composite is made by placing parallel mats or felts of coplanar fibers in a mold with a reservoir of molten matrix metal, e.g., aluminum, between at least some of the mats, and applying pressure to force molten metal to penetrate the mats and surround the oriented fibers. Molten metal may be poured onto the stack of mats while being forced under pressure to flow between the mats. Loadings of up to about 50% by volume of reinforcing fibers in the composite have been reported.
The above-described infiltration process, in view of its dependence on outside pressure to force the molten matrix metal through the stack of fibrous mats, is subject to the vagaries of pressure-induced flow processes, i.e., possible non-uniformity of matrix formation, porosity, etc. Non-uniformity of properties is possible even though molten metal may be introduced at a multiplicity of sites within .

20815~5 WO ~1/17275 PCl/US91/03160 the fibrous array. Consequently, complicated mat/reservoir arrays and flow pathways need to be provided to achieve adequate and uniform penetration of the stack of fiber mats. Also, the aforesaid pressure-infiltration method allows for only a relatively low reinforcement to matrix volume fraction to be achieved because of the difficulty inherent in infiltrating a large mat volume. Still further, molds are required to contain the molten metal under pressure, which adds to the expense of the process. Finally, the aforesaid process, limited to infiltrating aligned particles or fibers, is not directed to formation of aluminum metal matrix composites reinforced with materials in the form of randomly oriented particles, whiskers or fibers.
In the fabrication of aluminum matrix-alumina filled composites, aluminum does not readily wet alumina, thereby making it difficult to form a coher~nt prsduct. YariQus solutinns to this problem haYe been suggested. One such approach is to coat the alumina with a metal (e.g., nickel or tungsten), which is then hot-pressed along with the aluminum.
In another technique, the aluminum is alloyed with lithium, and the alumina may be coated with silica. However, these composites exhibit variations in properties, or the coatings can degrade the filler, or the matrix contains lithium which can affect the matrix properties.
U.S Patent No. 4,232,091 to R. W. Grimshaw et al., overcomes certain difficulties in the art which are encountered in the production of aluminum matrix-alumina composites. This patent describes applying pressures of 75-375 kg/cm2 to force molten aluminum (or molten aluminum alloy) into a fibrous or whisker mat of alumina which has been preheated to 700 to 1050C. The maximum volume ratio of alumina to metal in the resulting solid casting was 0.2~/1. Because of its dependency on outside force to accomplish infiltration, this process is subject to many of the same deficiencies as that of Cannell et al.
European Patent Application Publication No. 115,742 describes making aluminum-alumina composites, especially useful as electrolytic cell components, by filling the voids of a preformed alumina matrix with molten aluminum. The application emphasizes the non-wettability of alumina by aluminum, and therefore various techniques are employed to wet the alumina throughout the preform. For example, the alumina is coated with a wetting agent of a diboride of titanium, zirconium, hafnium, or niobium, or with a metal, i.e., lithium, magnesium, calcium, titanium, chromium, iron, cobalt, nickel, zirconium, or hafnium. Inert atmospheres, such as argon, are employed to facilitate wetting. This .
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WO 91/17275 PCI'/US91/0316 - reference also shows applying pressure to cause molten aluminum to penetrate an uncoated matrix. In this aspect, infiltra~ion is accomplished by evacuating the pores and then applying pressure to the molten aluminum in an inert atmosphere, e.g., argon. Alternatively, the preform can be infiltrated by vapor-phase aluminum deposition to wet the surface prior to filling the voids by infiltration with molten aluminum.
To assure retention of the aluminum in the pores of the preform, heat treatment, e.g., at 1400 to 1800-C, in either a vacuum or in argon is required. Otherwise, either exposure of the pressure infiltrated material to gas or removal of the infiltration pressure will cause loss of aluminum from the body.
The use of wetting agents to effect infiltration of an alumina component in an electrolytic cell with molten metal is also shown in European Patent. Annlication Publica~ion No. 94353. This publication describes production of aluminum by electrowinning with a cell having a cathodic current feeder as a cell`liner or substrate. In order to protect this substrate from molten cryolite, a thin coating of a mixture of a wetting agent and solubility suppressor is applied to the alumina substrate prior to start-up of the cell or while immersed in the molten aluminum produced by the electrolytic process. Wetting agents disclosed are titan~um, zirconium, hafnium, sllicon, magnesium, vanadium~
chromium, niobium, or calcium, and titanium is stated as the preferred agent. Compounds of boron, carbon and nitrogen are described as being useful in suppressing the solubility of the wetting agents in molten aluminum The reference, however, does not suggest the production of metal matrix composites, nor does it suggest the formation of such a composite in, for example, a nitrogen atmosphere.
In addition to application of pressure and wetting agents, it has been disclosed that an applied vacuum will aid the penetration of molten aluminum into a porous ceramic compact. For example, U.S. Patent No.
3,718,441, granted February 27, 1973, to R. L. Landingham, reports infiltration of a ceramic compact (e.g., boron carbide, alumina and beryllia) with either molten aluminum, beryllium, magnesium, titanium, vanadium, nickel or chromium under a vacuum of less than 10-6 torr. A
vacuum of 10-2 to lo-6 torr resulted in poor wetting of the ceramic by the molten metal to the extent that the metal did not flow freely into the ceramic void spaces. However, wetting was said to have improved when the vacuum was reduced to less than lo-6 torr.

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, 208i555 -w o 91/17275 P ~ /US91/0~160 U.S. Patent No. 3,864,154, granted February 4, 1975, to G. E.
Gazza et al., also shows the use of vacuum to achieve infiltration.
This patent describes loading a cold-pressed compact of AlB12 powder onto a bed of cold-pressed aluminum powder. Additional aluminum was then positioned on top of the AlB12 powder compact. The crucible, loaded with the AlB12 compact "sandwiched" between the layers of aluminum powder, was placed in a vacuum furnace. The furnace was evacuated to approximately 10-5 torr to permit outgassing. The temperature was subsequently raised to 1100-C and maintained for a period of 3 hours. At these conditions, the molten aluminum penetrated the porous AlB12 compact.
U.S. Patent No. 3,364,976, granted January 23, 1968 to John N.
Reding et al., discloses the concept of creating a self-generated vacuum in a body tn enhanne penetration of 2 molten metal into the hody.
Specifically, it is disclosed that a body, e.g., a graphite mold, a steel mold, or a porous refractory material, is entirely submerged in a molten metal. In the case of a mold, the mold cavity, which is filled with a gas reactive with the metal, communicates with the externally located molten metal through at least one or;fice ;n the mold. When the mold is immersed into the melt, filling of the cavity occurs as the self-generated vacuum is produced from the reaction between the gas in the cavity and the molten metal. Particularly, the vacuum is a result of the formation of a solid oxidized form of the metal. Thus, Reding et al. d;sclose that ;t ;s essential to induce a reaction between gas in the cavity and the molten metal. However, utilizing a mold to create a vacuum may be undesirable because of the inherent limitations associated with use of a mold. Molds must first be machined into a particular shape; then finished, machined to produce an acceptable casting surface on the mold; then assembled prior to their use; then disassembled after their use to remove the cast piece therefrom; and thereafter reclaim the mold, which most likely would include refinishing surfaces of the mold or discarding the mold if it is no longer acceptable for use. Machining of a mold into a complex shape can be very costly and time-consuming.
Moreover, removal of a formed piece from a complex-shaped mold can also be difficult (i.e., cast pieces having a complex shape could be broken when removed from the mold). Still further, while there is a suggestion that a porous refractory material can be immersed directly in a molten metal without the need for a mold, the refractory material would have to be an integral piece because there is no provision for infiltrating a .

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WO 91/17275 PCI`/US91/0?~1 loose or separated porous material absent the use of a container mold (i.e., it is generally believed that the particulate material would typically disassociate or float apart when placed in a molten metal).
Still further, if it was desired to infiltrate a particulate material or loosely formed preform, precautions should be taken so that the infiltrating metal does not displace at least portions of the particulate or preform resulting in a non-homogeneous microstructure.
Accordingly, there has been a long felt need for a simple and reliable process to produce shaped metal matrix composites which does not rely upon the use of applied pressure or vacuum (whether externally applied or internally created), or damaging wetting agents to create a metal matrix embedding another material such as a ceramic material.
; Moreover, there has been a long felt need to minimize the amount of final machining operatinns needed to prndl!re a metal ~atrix co~pnsite body. The present invention satisfies these needs by providing a spontaneous infiltration mechanism for infiltrating a material (e.g., a ceramic material), which can be formed into a preform, with molten matrix metal (e.g., aluminum) in the presence of an infiltrating atmosphere (e.g., nitrogen) under normal atmospheric pressures so long às an infiltration enhancer precursor and/or infiltràtion enhancer is present at least at some point during the process.

DescriDtion of Commonlv Owned U.S. Patents and Patent ADDlications The subject matter of this application ;s related to that of several other copending and co-owned patent applications and issued Patents. Particularly, these other copending patent applications and ; issued Patents describe novel methods for making metal matrix composite materials (hereinafter sometimes referred to as "Commonly Owned Metal Matrix Patents and Patent Applications").
A novel method of making a metal matrix composite material is disclosed in Commonly Owned U.S. Patent Application Serial No.
07/049,171, filed May 13, 1987, in the names of White et al., and entitled "Metal Matrix Composites", now United States Patent No.
4,828,008, which issued on May 9, 1989, and which published in the EPO
on November 17, 1988, as Publication No. 0291441. According to the method of this White et al. invention, a metal matrix composite is produced by infiltrating a permeable mass of filler material (e.g., a ceramic or a ceramic-coated material) with molten aluminum containing at least about 1 percent by weight magnesium, and preferably at least about ~, ~ . '-.. , . , ........ . . . : . .

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O'~I/17275 PCT/US91/0~160 3 percent by weight magnesium. Infiltration occurs spontaneously without the application of external pressure or vacuum. A supply of the molten metal alloy is contacted with the mass of filler material at a temperature of at least about 675-C in the presence of a gas comprising from about 10 to 100 percent, and preferably at least about 50 percent, nitrogen by volume, and a remainder of the gas, if any, being a nonoxidizing gas, e.g., argon. Under these conditions, the molten alum;num alloy infiltrates the ceramic mass under normal atmospheric pressures to form an aluminum (or aluminum alloy) matrix composite.
When the desired amount of filler material has been infiltrated with the molten aluminum alloy, the temperature is lowered to solidify the alloy, thereby forming a solid metal matrix structure that embeds the reinforcing filler material. Usually, and preferably, the supply of molten allny ~l~l;vere-l will ~e cuffirlpnt to per!nit the infiltr2tion to proceed essentially to the boundaries of the mass of filler material.
The amount of filler material in the aluminum matrix composites produced according to the White et al. invention may be exceedingly high. In this respect, filler to alloy volumetric ratios of greater than 1:1 may be achleved.
Under the process conditions in the aforesaid White et al.
;nvention, aluminum nitride can form as a discontinuous phase dispersed throughout the aluminum matrix. The amount of nitride in the aluminum matrix may vary depending on such factors as temperature, alloy composition, gas composition and filler material. Thus, by controlling ~ 25 one or more such factors in the system, it is possible to tailor certain ; properties of the composite. For some end use applications, however, it may be desirable that the composite contain little or substantially no aluminum nitride.
It has been observed that higher temperatures favor infiltration but render the process more conducive to nitride formation. The White et al. invention allows the choice of a balance between infiltration kinetics and nitride format;on.
An example of suitable barrier means for use with metal matrix composite formation is described in Commonly Owned U.S. Patent Application Serial No. 07/141,~42, filed January 7, 1988, in the names of Michael K. Aghajanian et al., and entitled "Method of Making Metal Matrix Composite with the Use of a Barrier," now U.S. Patent No.

4,935,055, which issued on June 19, 1990, and which published in the EPO
on July 12, 19~9, as Publication No. 0323945. According to the ~ethod .
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W o 91/17275 PCT/US91/~316 of this Aghajanian et al. invention, a barrier means (e.g., particulate titanium diboride or a graphite material such as a flexible graphite foil product sold by Union Carbide under the trade name Grafoil~) is disposed on a defined surface boundary of a filler material and matrix alloy infiltrates up to the boundary defined by the barrier means. The barrier means is used to inhibit, prevent, or terminate infiltration of the molten alloy, thereby providing net, or near net, shapes in the resultant metal matrix composite. Accordingly, the formed metal matrix composite bodies have an outer shape which substantially corresponds to the inner shape of the barrier means.
The method of U.S. Patent No. 4,828,008 was improved upon by Commonly Owned and Copending U.S. Patent Application Serial No.
07/517,541, filed April 24, 1990, which is a continuation of U.S. Patent Applicatinn ~ial Nn, 07/I68,284~, filed March 15, 1988, in thP nam.Ps of Michael K. Aghajanian and Marc S; Newkirk and entitled "Metal Matrix Composites and Techniques for Making the Same", and which published in the EPO on September 20, 1989, as Publication No. 0333629. In accordance with the methods disclosed in this U.S. Patent Application, a matrix metal alloy is present as a first source of metal and as a reservoir of matrix metal alloy which communicates with the first source of molten metal due to, for example, gravity flow. Particularly, under the conditions described in this patent application, the first source of molten matrix alloy begins to infiltrate the mass of filler material under normal atmospheric pressures and thus begins the formation of a metal matrix composite. The first source of molten matrix metal alloy is consumed during its infiltration into the mass of filler material and, if desired, can be replenished, preferably by a continuous means, from the reservoir of molten matrix metal as the spontaneous infiltration continues. When a desired amount of permeable filler has been spontaneously infiltrated by the molten matrix alloy, the temperature is lowered to solidify the alloy, thereby forming a solid metal matrix structure that embeds the reinforcing filler material. It should be understood that the use of a reservoir of metal is simply one embodiment of the invention described in this patent application and it is not necessary to combine the reservoir embodiment with each of the alternate embodiments of the invention disclosed therein, some of which could also be beneficial to use in combination with the present invention.
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g - WO 91/17275 PCI`/US91/031~0 The reservoir of metal can be present in an amount such that it provides for a sufficient amount of metal to infiltrate the permeable mass of fillen material to a predetermined extent. Alternatively, an optional barrier means can contact the permeable mass of filler on at least one side thereof to define a surface boundary.
Moreover, while the supply of molten matrix alloy delivered should be at least sufficient to permit spontaneous infiltration to proceed essentially tD the boundaries (e.g., barriers) of the permeable mass of filler material, the amount of alloy present in the reservoir could exceed such sufficient amount so that not only will there be a sufficient amount of alloy for complete infiltration, but excess molten metal alloy could remain and be attached to the metal matrix composite body. Thus, when excess molten alloy is present, the resulting body will be a complex compnsite body (e.g.; a m2rroromposite), whDrein an infiltrated ceramic body having a metal matrix therein will be directly bonded to excess metal remaining in the reservoir.
Further improvements in metal matrix technology can be found in commonly owned and copending U.S. Patent Application Serial No.
07/521,043, filed May 9, 1990, which is a continuation-in-part app11cation of U.S. Patent Application Serial No. 07/484,753, filed February 23, 1990, which is a continuation-in-part application of U.S.
Patent Application Serial No. 07/432,661, filed November 7, 1989 (now abandoned), which is a continuation-in-part application of U.S. Patent Application Serial No. 07/416,327, filed October 6, 1989 (now abandoned), which is a continuation-in-part application of U.S. Patent Application Serial No. 07/349,590, filed May 9, 1989 (now abandoned), which in turn is a continuation-in-part application of U.S. Patent Application Serial No. 07/269,311, filed November 10, 1988 (now abandoned), all of which were filed in the names of Michael K.
Aghajanian et al. and all of which are entitled RA Method of Forming Metal Matrix Composite Bodies By A Spontaneous Infiltration Process, and Products Produced TherefromN (an EPO application corresponding to U.S.
Patent Application Serial No. 07/416,327 was published in the EPO on June 27, 1990, as Publication No. 0375588). According to these Aghajanian et al. applications, spontaneous infiltration of a matrix metal into a permeable mass of filler material or preform is achieved by use of an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere which are in communication with the filler material or preform, at least at some point during the -. ~

208~55 - lO-Wo 91/17275 PCr/US91/0316 process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. Aghajanian et al. disclose a number of matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems which exhibit spontaneous infiltration. Specifically, Aghajanian et al. disclose that spontaneous infiltration behavior has been observed in the aluminum/magnesium/nitrogen system; the aluminum/strontium/nitrogen system; the aluminum/zinc/oxygen system; and the aluminum/calcium/nitrogen system. However, it is clear from the disclosure set forth in the Aghajanian et al. applications that the spontaneous infiltration behavior should occur in other matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems.
Each of the above-discussed Commonly Owned Metal Matrix Patents and Patent Applications describes methods for the production of metal matrix comnnsite bodies and novel metal matrix composite bodies which are produced therefrom. The entire disclosures of all of the foregoing Commonly Owned Metal Matrix Patents and Patent Applications are expressly incorporated herein by reference.

SummarY of the Invention A porous metal matrix composite body is produced by spontaneously infiltrating a permeable mass of filler material or a preform with a molten matrix metal. Specifically, an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material or preform, at least at some ; 25 point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. However, the amount of matrix metal which infiltrates the filler material or preform is insufficient to embed substantially completely the filler material or ` preform.
In a first preferred embodiment, a precursor to an infiltration enhancer may be supplied to at least one of a filler material or preform and/or a matrix metal and/or an infiltrating atmosphere. The supplied infiltration enhancer precursor may thereafter react with at least one of the filler material or preform and/or the matrix metal and/or the infiltrating atmosphere to produce infiltration enhancer in at least a portion of, or on, the filler material or preform. Ultimately, at least during the spontaneous infiltration, infiltration enhancer should be in contact with at least a portion of the filler material or preform.
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w O ~I/1727~ - ll - PCT/US91tO3160 In another preferred embodiment of the invention, rather than supplying an infiltration enhancer precursor, an infiltration enhancer may be supplied directly to at least one of the preform and/or matrix metal and/or infiltrating atmosphere. Ultimately, at least during the spontaneous infiltration, the infiltration enhancer should be in contact with at least a portion of the filler material or preform.
This application discusses various examples of matrix metals, which at some point during the formation of a metal matrix composite, are contacted with an infiltration enhancer precursor, in the presence IO of an infiltrating atmosphere. Thus, various references will be made to particular matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems which exhibit spontaneous infiltration. However, it is conceivable that many other matrix metal/infiltration enhancer Drecursor/inf;ltrat~ing atmosphPre systems other than those disrussed in this application may behave in a manner similar to the systems discussed above herein. Specifically, spontaneous infiltration behavior has been observed in the aluminum/magnesium/nitrogen system; the aluminum/strontium/nitrogen system; the aluminum/zinc/oxygen system; and the aluminu~ calcium/nitrogen system. Accordingly, even though this application ~iscusses only those systems referred to above herein (with part~cùlar emphasis being placed upon the aluminum/magnesium/nitrogen system), it should be understood that other matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems may behave in a similar manner.
In a preferred embodiment for forming porous metal matrix composite bodies by spontaneous infiltration, a desired amount of molten matrix metal is contacted with the preform or filler material. The preform or filler material may have admixed therewith, and/or at some point during the process, be exposed to, an infiltration enhancer -~ 30 precursor. Moreover, in a preferred embodiment, the molten matrix metal and/or preform or filler material communicate with an infiltrating atmosphere for at least a portion of the process. In another preferred embodiment, the matrix metal and/or preform or filler material communicate with an infiltrating atmosphere for substantially all of the process. The preform or filler material will be spontaneously infiltrated by molten matrix metal, and the extent or rate of spontaneous infiltration and formation of metal matrix composite will vary with a given set of processing conditions including, for example, ~ the concentration of infiltration enhancer precursor provided to the :., ~ . :
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.; . , 2 ~) 8~5W5 91/17275 - 12 - PCr/US91/0~16 system (e.g., in the molten matrix alloy and/or in the filler material or preform and/or in the infiltrating atmosphere), the size and/or composition of the filler material, the size and/or composition of particles in the preform, the available porosity for infiltration into the preform or filler material, the time permitted for infiltration to occur1 and/or the temperature at which infiltration occurs.
Moreover, by varying the composition of the matrix metal and/or the amount of matrix metal provided and/or the processing conditions, the physical and mechanical properties of the formed porous metal matrix composite bodies may be engineered to any particular application or need. For example, by providing a predetermined amount of filler material and by selecting the amount of matrix metal provided for infiltration, the amount of porosity within a formed metal matrix ç~mposite body can be controlled~ MoreoYer, by vary~ng the amount and/or composit;on of matrix metal provided to, e.g., one portion of a filler material or preform relative to another portion of the filler material or preform, the porosity in the metal matrix composite body may be tailored to suit a spec;fic application. Further, by subjecting a formed metal matrix composite body to a post treatment process (e.g., heat treatment, etc.) the mechanical and/or physical properties may be further engineered to meet any particular application or need. Still further, by controlling the processing conditions during the formation of a metal matrix composite the, e.g., nitrogen content, etc., of the formed metal matrix composite may be tailored to meet a wide range of industrial applications.
Moreover, by controlling the composition and/or size (e.g., ~ particle diameter) and/or geometry of the filler material or the- material comprising the preform, in combination with controlling the amount of matrix metal provided for infiltration, the physical and/or mechanical properties of the formed porous metal matrix composite can be controlled or engineered to meet any number of industrial needs. For example, the mechanical and/or physical properties (e.g., density, elastic and/or specific modulus, strength and/or specific strength, etc.) of a formed porous metal matrix composite body may be tailored depending on the loading of the filler material in the loose mass or in the preform and the amount of matrix metal provided for infiltration.
Accordingly, a porous metal matrix composite body can be achieved by providing, for example, a 100se mass or preform comprising a mixture oi filler particles of varying sizes and/or shaDes to achieve a relatively : .
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~--.w o 91/17275 P ~ /US91/0~160 high loading, due to enhanced packing of the filler material, in combination with providing an amount of matrix metal which is insufficient to embed substantially completely the filler material or preform. Moreover, the density of a porous metal matrix composite body can be further reduced by providing a porous filler material or porous preform (e.g., a loosely packed filler material or preform and/or a hollow filler material) in combination with an amount of matrix metal which is sufficient only to coat the filler material. The precise combination of filler material and amount of matrix metal provided depends upon the desired end use for the porous metal matrix composite body. Accordingly, by practicing any of the above teachings, alone or in combination, a porous metal matrix composite can be engineered to contain a desired combination of properties.
MnrenvPr; in another preferred embQd~ment for form;ng porous metal matrix composite bodies, a metal matrix composite body may be formed by partially, or substantially completely, infiltrating a permeable mass of filler material or preform, and subsequently, leaching out at least a portion of the matrix metal from the composite body by, e.g., thermal etching, chemical etching, etc., to produce a porous metal matrix composite body.
Porous metal matrix composite bodies formed according to the method of the present invention may be tailored to suit a wide number of industrial applications. By varying, for example, the composition of the matrix metal and/or filler material, the size and/or shape of the metal matrix composite body, the composition of the filler material, the porosity within the metal matrix body, etc., porous metal matrix composite bodies may be tailored for use in such applications as thermal insulation materials, filters, strainers, etc. Moreover, a porous metal matrix composite body may be used as a preform for forming a metal matrix composite body by a spontaneous infiltration technique, or by an alternate metal matrix formation technique. For example a filler material or preform which normally might not be compatible with a particular matrix metal due to, for example, poor wettability by the matrix metal, can be infiltrated with a molten matrix to form a porous metal matrix composite body which exhibits favorable wettability by the matrix metal. Accordingly, porous metal matrix composite bodies formed by the method of the present invention may be tailored to serve a wide variety of uses.

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WO ~1/17275 PCr/US91/~316,~
Definitions ~ Aluminum", as used herein, means and includes essentially pure metal (e.g., a relatively pure, commercially available unalloyed aluminum) or other grades of metal and metal alloys such as the commercially available metals having impurities and/or alloying constituents such as iron, silicnn, copper, magnesium, manganese, chromium, zinc, etc., therein. An aluminum alloy for purposes of this def;nition is an alloy or intermetallic compound in which aluminum is the major constituent.
~Balance Non-Oxidizinq Gas", as used herein, means that any gas present in addition to the primary gas comprising the infiltrating atmosphere, is either an inert gas or a reducing gas which is substantially non-react?ve with the matrix metal under the process conditions. Any oxi~izing gas which may be present as an impurity in the gas(es) used should be insufficient to oxidize the matrix metal to any substantial extent under the process conditions.
"Barrier" or "barrier means", as used herein, means any suitable means which interferes, inhibits, prevents or terminates the migration, movement, or the like, of molten matrix metal beyond a surface boundary of a permeable mass of filler material or preform, where such surface boundary is defined by sa;d barr;er means. Suitable barrier means may be any s~ch material, compound, element, composition, or the like, which, under the process conditions, maintains some integrity and is not substantially volatile (i.e., the barrier mater;al does not volat;lize to such an extent that it is rendered non-functional as a barrier).
Further, suitable abarrier means" includes materials which are substantially non-wettable by the migrating molten matrix metal under the process conditions employed. A barrier of this type appears to exhibit substantially little or no affinity for the molten matrix metal, . 30 and movement beyond the defined surface boundary of the mass of filler material or preform is prevented or inhibited by the barrier means. The barrier reduces any final machining or grinding that may be required and defines at least a portion of the surface of the resulting metal matrix compos;te product. The barrier may in certain cases be permeable or porous, or rendered permeable by, for example, drilling holes or puncturing the barrier, to permit gas to contact the molten matrix metal, etc.
"Carcass" or "Carcass of Matrix Metal", as used herein, refers to any of the original body of matrix metal remaining which has not been :
..
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. .
. . .. . .
, : . -. .
, , - WO 91/17275 PCr/US91/03160 high loading, due to enhanced packing of the filler material, in combination with providing an amount of matrix metal which is insufficient to embed substantially completely the filler material or preform. Moreover, the density of a porous metal matrix composite body can be further reduced by providing a porous filler material or porous preform (e.g., a loosely packed filler material or preform and/or a hollow filler material~ in combination with an amount of matrix metal which is sufficient only to coat the filler material. The precise combination of filler material and amount of matrix metal provided depends upon the desired end use for the porous metal matrix composite body. Accordingly, by practicing any of the above teachings, alone or in combination, a porous metal matrix composite can be engineered to contain a desired combination of properties.
Mnrenver; in another prefPrred embod~ment fcr forming porous metal matrix composite bodies, a metal matrix composite body may be formed by partially, or substantially completely, infiltrating a permeable mass of filler material or preform, and subsequently, leaching out at least a portion of the matrix metal from the composite body by, e.g., thermal etching, chemical etching, etc., to produce a porous metal matrix composite body.
Porous metal matrix composite bodies formed according to the method of the present invention may be tailored to suit a wide number of industrial applications. By varying, for example, the composition of the matrix metal and/or filler material, the size and/or shape of the metal matrix composite body, the composition of the filler material, the porosity within the metal matrix body, etc., porous metal matrix composite bodies may be tailored for use in such applications as thermal insulation materials, filters, strainers, etc. Moreover, a porous metal matrix composite body may be used as a preform for forming a metal matrix composite body by a spontaneous infiltration technique, or by an alternate metal matrix formation technique. For example a filler material or preform which normally might not be compatible with a particular matrix metal due to, for example, poor wettability by the matrix metal, can be infiltrated with a molten matrix to form a porous metal matrix composite body which exhibits favorable wettability by the matrix metal. Accordingly, porous metal matrix composite bodies formed by the method of the present invention may be tailored to serve a wide variety of uses.

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208~5~
w o 91~17275 - 14 - PCT/uSsl/0~16 Definitions "Aluminum", as used herein, means and includes essentially pure metal (e.g., a relatively pure, commercially available unalloyed aluminum) or other grades of metal and metal alloys such as the commercially available metals having impurities and/or alloying constituents such as iron, silicon, copper, magnesium, manganese, chromium, zinc, etc., therein. An aluminum alloy for purposes of this definition is an alloy or intermetallic compound in which aluminum is the major constituent.
~Balance Non-Oxidizinq Gas", as used herein, means that any gas present in addition to the primary gas comprising the infiltrating atmosphere, is either an inert gas or a reducing gas which is substantially non-react~Ye with the matrix metal under the process conditions. Any ~xi~izing 935 which may be present as an impurity in the gas(es) used should be insufficient to oxidize the matrix metal to any substantial extent under the process conditions.
"Barrier" or "barrier means", as used herein, means any suitable means which interferes, inhibits, prevents or terminates the migration, movement, or the like, of molten matrix metal beyond a surface boundary of a permeable mass of filler material or preform, where such surface boundary is defined by said barrier means Suitable barrier means may be any such material, compound, element, composition, or the like, which, under the process conditions, maintains some integrity and is not substantially volatile ~i.e., the barrier material does not volatilize to such an extent that it is rendered non-functional as a barrier).
Further, suitable /'barrier means" includes materials which are substantially non-wettable by the migrating molten matrix metal under the process conditions employed. A barrier of this type appears to exhibit substantially little or no affinity for the molten matrix metal, and movement beyond the defined surface boundary of the mass of filler - material or preform is prevented or inhibited by the barrier means. The barrier reduces any final machining or grinding that may be required and defines at least a portion of the surface of the resulting metal matrix composite product. The barrier may in certain cases be permeable or porous, or rendered permeable by, for example, drilling holes or puncturing the barrier, to permit gas to contact the molten matrix metal, etc.
"Carcass" or aCarcass of Matrix Metal", as used herein, refers to any of the original body of matrix metal remaining which has not been ' .
.:: . - -, -208155~

,~p WO 91/17275 PCI`/US91/0~160 and/or alloying constituents therein, an intermetallic compound or an alloy in which that metal is the major or predominant constituent.
"Matrix Metal/lnfiltration Enhancer Precursor/lnfiltratina Atmosphere Svstem" or "SDontaneous SYstem", as used herein, refers to that combination of materials which exhibit spontaneous infiltration into a preform or filler material. It should be understood that whenever a "/" appears between an exemplary matrix metal, infiltration enhancer precursor and infiltrating atmosphere that the ~/a is used to designate a system or combination of materials which, when combined in a particular manner, exhibits spontaneous infiltra~tion into a preform or filler material.
"Metal Matrix Composite" or "MMC", as used herein, means a material comprising a two- or three-dimensionally interconnected alloy or matrix mPt.~l whish hac embPdded 2 preform or fl.ller m3terial. The matrix metal may include various alloying elements to provide specifically desired mechanical and physical properties in the resulting composite.
A Metal "Different" from the Matrix Metal means a metal which does not contain, as a primary constituent, the same metal as the matrix metal (e.g., if the primary constituent of the matrix metal is aluminum, the "different" metal could have a primary constituent of, for example, nickel).
"Nonreactive Vessel for Housinq Matrix Metal" means any vessel which can house or contain a filler material (or preform) and/or molten-matrix metal under the process conditions and not react with the matrix and/or the infiltrating atmosphere and/or infiltration enhancer precursor and/or a filler material or preform in a manner which would be significantly detrimental to the spontaneous infiltration mechanism.
- The nonreactive vessel may be disposable and removable after the -~ 30 spontaneous infiltration of the molten matrix metal has been completed.
"Preform" or "Permeable Preform", as used herein, means a porous mass of filler or filler material which is manufactured with at least one surface boundary which essentially defines a boundary for infiltrating matrix metal, such mass retaining sufficient shape integrity and green strength to provide dimensional f;delity prior to being infiltrated by the matrix metal. The mass should be sufficiently porous to accommodate spontaneous infiltration of the matrix metal thereinto. A preform typically comprises a bonded array or arrangement of filler, either homogeneous or heterogeneous, and may be comprised of -.
.

208155~

w o 91/17275 pcT/ussl/
any suitable material (e.g., ceramic and/or metal particulates, powders, fibers, whiskers, etc., and any combination thereof). A preform may exist either singularly or as an assemblage.
/'Reservoir", as used herein, means a separate body of matrix metal positioned relative to a mass of filler or a preform so that, when the metal is molten, ;t may flow to replen;sh, or in some cases to in;tially prov;de and subsequently replen;sh, that portion, segment or source of matr;x metal which is in contact with the filler or preform.
"Spontaneous Infiltration", as used herein, means the infiltration of matrix metal into the permeable mass of filler or preform occurs without requ;rement for the appl;cat;on of pressure or vacuum (whether externally applied or in~ernally created).

Rriçf DescriQtion of the Fi~ures The follow;ng F;gures are provided to assist in understanding the invent;on, but are not intended to limit the scope of the invention.
S;milar reference numerals have been used wherever possible in each of the Figures to denote like components, wherein:
F;gure 1 shows a schemat;c cross sect;onal of the setup used to form the metal matr;x composite of Example l; and F;gure 2 is a photom;crograph at 400X magnification of the porous metal matrix composite body formed in Example 1.

Peta;led Descr;~tion of the Invention and Preferred Embodiments The present invention relates to forming porous metal matrix composite bod;es by spontaneously inf;ltrating a permeable mass of f;ller material or a preform with molten matrix metal. Particularly, an infiltrat;on enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere are in communication with the filler material or preform, at least at some point during the process, which permits molten matrix metal to spontaneously infiltrate the filler material or preform. However, the amount of matrix metal which ;nf;ltrates the f;ller mater;al or preform is insufficient to embed substantially completely the filler material or preform.
In a first preferred embodiment, a precursor to an ;nf;ltrat;on enhancer may be supplied to at least one of a f;ller mater;al or preform and/or a matrix metal and/or an infiltrating atmosphere. The supplied infiltration enhancer precursor may thereafter react with at least one of the filler material or preform and/or the matrix metal and/or the . .
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.. ~ r ~ WO 91/17275 PCI/US91/0?~160 infiltrating atmosphere to produce infiltration enhancer in at least a portion of, or on, the filler material or preform. Ultimately, at least during the spontaneous infiltration, infiltration enhancer should be in contact with at least a portion of the filler material or preform.
In another preferred embodiment of the invention, rather than supplying an infiltration enhancer precursor, an infiltration enhancer may be supplied directly to at least one of the preform and/or matrix metal and/or infiltrating atmosphere. Ultimately, at least during the spontaneous infiltration, the infiltration enhancer should be in contact with at least a portion of the filler material or preform.
This application discusses various examples of matrix metals, which at some point during the formation of a metal matrix composite, are contacted with an infiltration enhancer precursor, in the presence of an infiltrating atmn~ph~rP Thus; Yarinuc references will be made to particular matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems which exhibit spontaneous infiltration. However, it is conceivable that many other matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems other than those discussed in ; this application may behave in a manner similar to the systems discussed above herein. Specifically, spontaneous infiltration behavior has been observed in the aluminum/magnesium/nitrogen system; the aluminum/strontium/nitrogen system; the aluminum/zinc~oxygen system; and the aluminum/calcium/nitrogen system. Accordingly, even though this application discusses only those systems referred to above herein (with particular emphasis being placed upon the aluminum/magnesium/nitrogen system), it should be understood that other matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems may behave in a similar manner.
In a preferred embodiment for forming porous metal matrix composite bodies by spontaneous infiltration, a desired amount of molten matrix metal is contacted with the preform or filler material. The preform or filler material may have admixed therewith, and/or at some point during the process, be exposed to, an infiltration enhancer precursor. Moreover, in a preferred embodiment, the molten matrix metal and/or preform or filler material communicate with an infiltrating atmosphere for at least a portion of the process. In another preferred embodiment, the matrix metal and/or preform or filler material communicate with an infiltrating atmosphere for substantially all of the process. The preform or filler material will be spontaneously .
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w o 9l/17275 PCT/US91/0~16 infiltrated by molten matrix metal, and the extent or rate of spontaneous infiltration and formation of metal matrix composite will vary with a given set of processing conditions including, for example, the concentration of infiltration enhancer precursor provided to the system (e.g., in the molten matrix alloy and/or in the filler material or preform and/or in the infiltrating atmosphere), the size and/or composition of the filler material, the size and/or composition of particles in the preform, the available porosity for infiltration into the preform or filler material, the time permitted for infiltration to ; 10 occur, and/or the temperature at which infiltration occurs.
Moreover, by varying the composition of the matrix metal and/or the amount of matrix metal provided and/or the processing conditions, the physical and mechanical properties of the formed porous metal matrix composite bodie~ m~y hP ~nginePrPd to any particular applicatlon or need. For example, byproviding a predetermined amount of filler material and by selecting the amount of matrix metal provided for infiltration, the amount of porosity within a formed metal matrix composite body can be controlled. Moreover, by varying the amount and/or composition of matrix metal provided to, e.g., one portion of a filler material or preform relative to another portion of the filler material or preform, the porosity in the metal matrix composite body may be tailored to suit a specific application. Further, by subjecting a formed metal matrix composite body to a post treatment process (e.g., ; heat treatment, etc.) the mechanical and/or physical properties may be further engineered to meet any particular application or need. Still further, by controlling the processing conditions during the formation of a metal matrix composite the, e.g., nitrogen content, etc., of the formed metal matrix composite may be tailored to meet a wide range of industrial applications.
Moreover, by controlling the composition and/or size (e.g., particle diameter) and/or geometry of the filler material or the material comprising the preform, in combination with controlling the amount of matrix metal provided for infiltration, the physical and/or mechanical properties of the formed porous metal matrix composite can be controlled or engineered to meet any number of industrial needs. For example, the mechanical and/or physical properties (e.g., density, elastic and/or specific modulus, strength and/or specific strength, etc.) of a formed porous metal matrix composite body may be tailored depending on the loading of the filler material in the loose mass or in : . ~
, 20815~5 ~; w o 91/l7275 - 21 - PCT/~S91/0~160 the preform and the amount of matrix metal provided for infiltration.
Accordingly, a porous metal matrix composite body can be achieved by providing, for example, a loose mass or preform comprising a mixture of filler particles of varying sizes and/or shapes to achieve a relatively high loading, due to enhanced packing of the filler material, in combination with providing an amount of matrix metal which is insufficient to embed substantially completely the filler material or preform. Moreover, the density of a porous metal matrix composite body can be further reduced by providing a porous filler material or porous preform (e.g., a loosely packed filler material or preform and/or a hollow filler material) in combination with an amount of matrix metal which is sufficient only to coat the filler material. The precise combination of filler material and amount of matrix metal provided depends upon th~ desired end Use for the porous metal matriY cQmposite body. Accordingly, by practicing any of the above teachings, alone or in combination, a porous metal matrix composite can be engineered to contain a desired combination of properties.
Moreover, in another preferred embodiment for forming porous metal matrix composite bodies, a metal matrix composite body may be formed by partially, or substantially completely, infiltrating a permeable mass of f~ller material or preform, and subsequently, leaching out at least a portion of the matrix metal from the composite body by, e.g., thermal etching, chemical etching, etc., to produce a porous metal matrix composite body.
Porous metal matrix composite bodies formed according to the method of the present invention may be tailored to suit a wide number of industrial applicztions. 8y varying, for example, the composition of the matrix metal and/or filler material, the size and/or shape of the metal matrix composite body, the composition of the filler material, the porosity within the metal matrix body, etc., porous metal matrix composite bodies may be tailored for use in such applications as thermal insulation materials, filters, strainers, etc. Moreover, a porous metal matrix composite body may be used as a preform for forming a metal matrix composite body by a spontaneous infiltration technique, or by an alternate metal matrix formation technique. For example a filler material or preform which normally might not be compatible with a particular matrix metal due to, for example, poor wettability by the matrix metal, can be infiltrated with a molten matrix to form a porous metal matrix composite body which exhibits favorable wettability by the , , .

W O 91tl727~ PCT/US91/0~16 matrix metal. Accordingly, porous metal matrix composite bodies formed by the method of the present invention may be tailored to serve a wide variety of uses.
~ith reference to Figure 1, a simple lay-up 16 for forming a spontaneously infiltrated porous metal matrix composite in accordance with the present invention is illustrated. Specifically, a filler or preform 12, which may be of any suitable material, as discussed in detail below, is placed in a non-reactive vessel 1~ for housing matrix metal and/or filler material. A matrix metal 14 is placed on or adjacent to the filler or preform 12. The lay-up is thereafter placed in a fùrnace to initiate spontaneous infiltration.
Without wishing to be bound by any particular theory or explanation, when an infiltration enhancer precursor is utilized in comhination with at least onP of the matrix metal, and~or filler lS material or preform and/or infiltrating atmosphere, the infiltration enhancer precursor may react to form an infiltration enhancer which induces or assists molten matrix metal to spontaneously infiltrate a filler material or preform. Moreover, it appears as though it may be necessary for the precursor to the infiltration enhancer to be capable of being pos1tioned, located or transportable to a location which permits the infiltration enhancer precursor to interact with at least one of the infiltrating atmosphere, and/or the preform or filler material, and/or molten matrix metal. For example, in some matrix metal/infiltration enhancer precursor/infiltrating atmosphere systems, it is desirable for the infiltration enhancer precursor to volat;lize at, near, or in some cases, even somewhat above the temperature at which the matrix metal becomes molten. Such volatilization may lead to: (1) ; a reaction of the infiltration enhancer precursor with the infiltrating atmosphere to form a gaseous species which enhances wetting of the filler material or preform by the matrix metal; and/or (2) a reaction of the infiltration enhancer precursor with the infiltrating atmosphere to form a solid, liquid or gaseous infiltration enhancer in at least a portion of the filler material or preform which enhances wetting; and/or (3) a reaction of the infiltration enhancer precursor within the filler material or preform which forms a solid, liquid or gaseous infiltration - enhancer in at least a portion of the filler material or preform which enhances wetting.
Thus, for example, if an infiltration enhancer precursor was included or combined with, at least at some point during the process, ' WO 91/17275 PCr/US91/03160 molten matrix metal, it is possible that the infiltration enhancer could volatilize ;~om the molten matrix metal and react with at least one of the filler material or preform and/or the ;nfiltrating atmosphere. Such reaction could result in the formation of a solid species, if such solid species was stable at the infiltration temperature, said solid species being capable of being deposited on at least a portion of the filler material or preform as, for example, a coating. Moreover, it is conceivable that such solid species could be present as a discernable solid within at least a portion of the preform or filler material. If I0 such a solid species was formed, molten matrix metal may have a tendency to react (e.g., the molten matrix metal may reduce the formed solid species) such that infiltration enhancer precursor may become associated with (e.g., dissolved in or alloyed with) the molten matrix metal.
Accordinglv, additional infiltration enhanrer precursor may then be available to volatilize and react with another species (e.g., the filler material or preform and/or infiltrating atmosphere) and again form a similar solid species. It is conceivable that a continuous process of conversion of infiltration enhancer precursor to infiltration enhancer followed by a reduction reaction of the infiltration enhancer with molten matrix metal to again form additional inf11tration enhancer, and so on, could occur, until the result achieved is a spontaneously inflltrated metal matrix composite.
In order to effect spontaneous infiltration of the matrix metal into the filler material or preform, an infiltration enhancer should be provided to the spontaneous system. An infiltration enhancer could be formed from an infiltration enhancer precursor which could be provided ~; (I) in the matrix metal; and/or (2) in the filler material or preform;
and/or (3) from the infiltrating atmosphere; and/or (4) from an external source into the spontaneous system. Moreover, rather than supplying an infiltration enhancer precursor, an infiltration enhancer may be supplied directly to at least one of the filler material or preform, and/or matrix metal, and/or infiltrating atmosphere. Ultimately, at least during the spontaneous infiltration, the infiltration enhancer should be located in at least a portion of the filler material or preform.
In a preferred embodiment of the invention, it is possible that the infiltration enhancer precursor can be at least partially reacted ; with the infiltrating atmosphere such that the infiltration enhancer can be formed in at least a portion of the filler material or preform prior "' -; `' . ' ~ - ~
.
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2 0 w o ~l/t72~5 - 24 - PCT/US9t/0~

to or substantially contiguous with contacting the filler material or preform with the matrix metal (e.g., if magnesium was the infiltration enhancer precursor and nitrogen was the infiltrating atmosphere, the infiltration enhancer could be magnesium nitride which would be located in at least a portion of the preform or filler material).
An example of a matrix metal/infiltration enhancer precursor/inf;ltrating atmosphere system is the aluminum/magnesium/nitrogen system. Specifically, an aluminum matrix metal can be contained within a suitable refractory vessel which, under the process conditions, does not adversely react with the aluminum matrix metal and/or the filler material when the aluminum is made molten. A filler material or preform can thereafter be contacted with molten aluminum matrix.metal and spontaneously infiltrated.
MoreoYer~ rather than supplyins an infiltratinn enh2nr r precursor, an infiltration enhancer may be supplied directly to at `least one of the preform or filler mater;al, and/or matrix metal, and/or infiltrating atmosphere. Ultimately, at least during the spontaneous infiltration, the infiltratlon enhancer should be located in at least a portion of the filler material or preform.
Under the conditions employed in the method of the present invention, in the case of an aluminum/magnesium/nitrogen spontaneous infiltration system, the preform or filler material should be sufficiently permeable to permit the nitrogen-containing gas to penetrate or permeate the filler material or preform at some point during the process and/or contact the molten matrix metal. Moreover, the permeable filler material or preform can accommodate infiltration of the molten matrix metal, thereby causing the nitrogen-permeated preform to be infiltrated spontaneously with molten matrix metal to form a metal matrix composite body and/or cause the nitrogen to react with an infiltration enhancer precursor to form infiltration enhancer in the filler material or preform and thereby result in spontaneous infiltration. The extent of spontaneous infiltration and formation of the metal matrix composite will vary with a given set of process conditions, ;nclud;ng magnesium content of the aluminum alloy, magnes;um content of the preform or filler material, amount of magnesium nitride in the preform or filler material, the presence of additional alloying elements (e.g., silicon, iron, copper, manganese, chromium, zinc, and the like), average size of the filler material (e.g., particle diameter) comprising the preform or the filler material, surface condition and .

t~:: w O 91/17275 P ~ /US91/0~160 type of filler material or preform, nitrogen concentration of the infiltrating atmosphere, time permitted for infiltration and temperature at which infiltration occurs. For example, for infiltration of the molten aluminum matrix metal to occur spontaneously, the aluminum can be alloyed with at least about 1 percent by weight, and preferably at least about 3 percent by weight, magnesium (which functions as the infiltration enhancer precursor), based on alloy weight. Auxiliary alloying elements, as discussed above, may also be included in the matrix metal to tailor specific properties thereof. Additionally, the auxiliary alloying elements may affect the minimum amount of magnesium required in the matrix aluminum metal to result in spontaneous infiltration of the filler material or preform. Loss of magnesium from the spontaneous system due to, for example, volatilization should not occur to such an axt~nt. that nn m29npsillm was presPnt to form infiltration enhancer. Thus, it is desirable to utilize a sufficient amount of initial alloying elements to assure that spontaneous infiltration will not be adversely affected by volatilization. Still further, the presence of magnesium in both of the preform (or filler material) and matrix metal or the preform (or filler material) alone may ~0 result in a reduction in required amount of magnesium to achieve spontaneous infiltration (discussed in greater detail later herein).
- The volume percent of nitrogen in the infiltrating atmosphere also affects formation rates of the metal matrix composite body.
Specifically, if less than about 10 volume percent of nitrogen is present in the atmosphere, very slow or little spontaneous infiltration will occur. It has been discovered that it is preferable for at least about 50 volume percent of nitrogen to be present in the atmosphere, thereby resulting in, for example, shorter infiltration times due to a much more rapid rate of infiltration. The infiltrating atmosphere ~; 30 (e.g., a nitrogen-containing gas) can be supplied directly to the filler material or preform and/or matrix metal, or it may be produced or result from a decomposition of a material The minimum magnesium content required for the molten matrix metal to infiltrate a filler material or preform depends on one or more variables such as the processing temperature, time, the presence of auxiliary alloying elements such as silicon or zinc, the nature of the filler material, the location of the magnesium in one or more components of the spontaneous system, the nitrogen content of the atmosphere, and the rate at which the nitrogen atmosphere flows. Lower temperatures or , '. .' . ': : .':' . .. . ~ . .
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2 0 8 wo ~1/17275 - 26 - PCT/US91/0~16 shorter heating times can be used to obtain infiltration as the magnesium content of the alloy and/or preform is increased. Also, for a given magnesium content, the addition of certain auxiliary alloying elements such as zinc permits the use of lower temperatures. For example, a magnesium content of the matrix metal at the lower end of the operable range, e.g., from about I to 3 weight percent, may be used in conjunction with at least one of the following: an above-minimum processing temperaturet a high nitrogen concentration, or one or more auxiliary alloying elements. When no magnesium is added to the preform, alloys containing from about 3 to 5 weight percent magnesium are preferred on the basis of their general utility over a wide variety of process conditions, with at least about 5 percent being preferred when lower temperatures and shorter times are employed. Magnesium contents in excess of ~ho~lt 10 perçent by weight of the aluminum alloy may be employed to moderate the temperature conditions required for infiltration. The magnesium content may be reduced when used in conjunction with an auxiliary alloying element, but these elements serve an auxiliary function only and are used together with at least the above-specified minimum amount of magnesium. For example, there was ; 20 substantially no infiltration of nominally pure aluminum alloyed only with 10 percent silicon at 1000C into a bedding of 500 mesh, 39 Crystolon (99 percent pure silicon carbide from Norton Co.). However, in the presence of magnesium, silicon has been found to promote the infiltration process. As a further example, the amount of magnesium varies if it is supplied exclusively to the preform or filler material.
It has been discovered that spontaneous infiltration will occur with a lesser weight percent of magnesium supplied to the spontaneous system when at least some of the total amount of magnesium supplied is placed in the preform or filler material. It may be desirable for a lesser amount of magnesium to be provided in order to prevent the formation of undesirable intermetallics in the metal matrix composite body. In the case of a silicon carbide preform, it has been discovered that when the preform is contacted with an aluminum matrix metal, the preform containing at least about 1% by weight magnesium and being in the presence of a substantially pure nitrogen atmosphere, the matrix metal spontaneously infiltrates the preform. In the case of an alumina preform, the amount of magnesium required to achieve acceptable spontaneous infiltration is slightly higher. Specifically, it has been found that when an alumina preform, when contacted with a similar .

- 27 - 2 ~81 5 5 ~
.,~ ' WO 91/17t75 PCr/US91/03160 aluminum matrix metal, at about the same temperature as the aluminum that infiltrated into the silicon carbide preform, and in the presence of the same nitrogen atmosphere, at least about 3% by weight magnesium may be required to achieve similar spontaneous infiltration to that achieved in the silicon carbide preform discussed immediately above.
It is also noted that it is possible to supply to the spontaneous system infiltration enhancer precursor and/or inf;ltration enhancer on a surface of the alloy and/or on a surface of the preform or filler material and/or within the preform or filler material prior to infiltrating the matrix metal into the filler material or preform (i.e., it may not be necessary for the supplied infiltration enhancer or infiltration enhancer precursor to be alloyed with the matrix metal, but rather, simply supplied to the spontaneous system). For example, in the alum;num~mangesjum/nitrogen system, if the magnesil~m ~as applied to 2 surface of the matrix metal it may be preferred that the surface should be the surface which is closest to, or preferably in contact with, the permeable mass of filler material or vice versa; or such magnesium could be mixed into at least a portion of the preform or filler material.
Still further, it is possible that some combination of surface applicat~on, alloying and placement of magnesium into at least a portion of the preform could be used. Such combination of applying lnfiltration ; enhancer(s) and/or infiltration enhancer precursor(s) could result in a ; decrease in the total weight percent of magnesium needed to promote infiltration of the matrix aluminum metal into the preform, as well as achieving lower temperatures at which infiltration can occur. Moreover, the a~ount of undesirable intermetallics formed due to the presence of magnesium could also be minimized.
The use of one or more auxiliary alloying elements and the concentration of nitrogen in the surrounding gas also affects the extent of nitriding of the matrix metal at a given temperature. For example, auxiliary alloying elements such as zinc or iron included in the alloy, or placed on a surface of the alloy, may be used to reduce the infiltration temperature and thereby decrease the amount of nitride formation, whereas increasing the concentration of nitrogen in the gas may be used to promote nitride formation.
The concentration of magnesium in the alloy, and/or placed onto a surface of the alloy, and/or combined in the filler or preform material, also tends to affect the extent of infiltration at a given temperature.
Consequently, in some cases where little or no magnesium is contacted .
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directly with the preform or filler material, it may be preferred that at least about three weight percent magnesium be included in the alloy.
Alloy contents of less than this amount, such as one weight percent magnesium, may require higher process temperatures or an auxiliary alloying element for infiltration. The temperature required to effect the spontaneous infiltration process of this invention may be lower: (1) when the magnesium content of the alloy alone is increased, e.g., to at least about 5 weight percent; and/or (2) when alloying constituents are mixed with the permeable mass of filler material or preform; and/or (3) when another element such as zinc or iron is present in the aluminum alloy. The temperature also may vary with different filler materials.
In general, in the aluminum/magnesium/nitrogen system spontaneous and progressive infiltration will occur at a process temperature of at least about 675 C, and preferably a nrn~cs temnerature nf at leact abQIlt 750-C-800-C. Temperatures generally in excess of 1200-C do not appear to benefit the process, and a particularly useful temperature range has been found to be from about 675 C to about 1000-C. However, as a general rule, the spontaneous infiltration temperature is a temperature which is above the melting point of the matrix metal but below the volatil;zation temperature of the matrix metal. Moreover, the spontaneous infiltration temperature should be below the melting point of the filler material. Still further, as temperature is increased, the tendency to form a reaction product between the matrix metal and infiltrating atmosphere increases (e.g., in the case of aluminum matrix metal and a nitrogen infiltrating atmosphere, aluminum nitride may be formed). Such reaction product may be desirable or undesirable based upon the intended application of the metal matrix composite body.
Additionally, electric resistance heating is typically used to achieve the infiltrating temperatures. However, any heating means which can cause the matrix metal to become molten and does not adversely affect spontaneous infiltration, is acceptable for use with the invention.
In the present method, for example, a permeable filler material or preform comes into contact with molten aluminum in the presence of, at least sometime during the process, a nitrogen-containing gas. The nitrogen-containing gas may be supplied by maintaining a continuous flow of sas into contact with at least one of the filler material or preform and/or molten aluminum matrix metal. Although the flow rate of the nitrogen-containing gas is not critical, it is preferred that the flow rate be sufficient to compensate for any nitrogen lost from the .

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. w ~ gl/17275 P ~ /US91/0~160 atmosphere due to any nitride formation, and also to prevent or inhibit the incursion of air which can have an oxidizing effect on the molten metal.
The method of forming a metal matrix composite is applicable to a wide variety of filler materials, and the choice of filler materials will depend on such factors as the matrix alloy, the process conditions, the reactivity of the molten matrix alloy with the filler material, and the properties sought for the final composite product. For example, when aluminum is the matrix metal, suitable filler materials include (a) oxides, e.g. alumina, magnesia, zirconia; (b) carbides, e.g. silicon carb;de; (c) borides, e.g. aluminum dodecaboride, titanium diboride, and (d) nitrides, e.g. aluminum nitride, and (e) mixtures thereof. If there is a tendency for the filler material to react with the molten aluminum matrix metal t.hi~ might he ~ccommQdated by minimizing the infiltration time and temperature or by providing a non-reactive coating on the filler. The filler material may comprise a substrate, such as carbon or other non-ceramic material, bearing a ceramic coating to protect the substrate from attack or degradation. Suitable ceramic coatings include oxides, carbides, borides and nitrides. Ceramics which are preferred for use in the present method include alumina and silicon carbide in the form of particles, platelets, whiskers and fibers. The fibers can be discontinuous (in chopped form) or in the form of continuous filament, such as multifilament tows. Further, the filler material or preform may be homogeneous or heterogeneous.
It also has been discovered that certain filler materials exhibit enhanced infiltration relative to filler materials having a similar chemical composition. For example, crushed alumina bodies made by the ; method disclosed in U.S. Patent No. 4,713,360, entitled t'Novel Ceramic - Materials and Methods of Making Same", which issued on December 15, ; 30 1987, in the names of Marc S. Newkirk et al., exhibit desirable infiltration properties relative to commercially available alumina products. Moreover, crushed alumina bodies made by the method disclosed in Copending and Commonly Owned Application Serial No. 819,397, entitled "Composite Ceramic Articles and Methods of Making Same", in the names of Marc S. Newkirk et al., also exhibit desirable infiltration properties relative to commercially available alumina products. The subject matter of each of the issued Patent and Copending Patent Application is herein expressly incorporated by reference. Thus, it has been discovered that infiltration of a permeable mass of ceramic material can occur at lower - , .
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2o8~s W O 91/17275 PCT/US91/0~1 ~
infiltration temperatures and/or lower infiltration times by utilizing a crushed or comminuted body produced by the method of the aforementioned U.S. Patent and Patent Application.
The si~e, shape, chemistry and volume percent of the filler material (or preform) can be any that may be required to achieve the properties desired in the composite. Thus, the filler material may be in the form of particles, whiskers, platelets or fibers since infiltration is not restricted by the shape of the filler material.
Other shapes such as spheres, tubules, pellets, refractory fiber cloth, I0 and the like may be employed. In addition, the size of the filler material does not limit infiltration, although a higher temperature or longer time period may-be needed for infiltration of a mass of smaller particles than for larger particles or vice-versa depending on the particular reaction conditions. Average particle di2mPters aS small ~S
a micron or less to about 1100 microns or more can be successfully utilized in the present invention, with a range of about 2 microns through about IO00 microns being preferred for a vast majority of commercial applications. Further, the mass of filler material (or preform) to be infiltrated should be permeable (i.e., contain at least some interconnected porosity to render it permeable to molten matrix metal and/or to the infiltrating atmosphere). Moreover, by controlling the s;ze (e.g., part;cle diameter) and/or geometry and/or compos;t;on of the filler mater;al or the mater;al compr;s;ng the preform, the physical and mechan;cal propert;es of the formed metal matrix compos;te can be controlled or eng;neered to meet any number of ;ndustr;al needs. For example, wear res;stance of the metal matrix composite can be increased by increasing the s;ze of the f;ller material (e.g., increasing the average diameter of the filler mater;al part;cles) g;ven that the f;ller material has a higher wear resistance than the matrix metal. However, strength and/or toughness may tend to increase with decreasing f;ller s;ze. Further, the thermal expansion coefficient of the metal matrix composite may decrease with increasing filler loading, given that the coeff;c;ent of thermal expansion of the f;ller ;s lower than the coefficient of thermal expansion of the matrix metal. Still further, the mechanical and/or physical properties (e.g., density, coeffic;ent of thermal expans;on, elastic and/or spec;f;c modulus, strength and/or specific strength, etc.) of a formed metal matrix composite body may be tailored depending on the loading of the filler material in the loose mass or in the preform. For example, by providing a loose mass or ., .

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2~81~55 WO 91/17275 PCI'/US9t/0?~160 preform comprising a mixture of filler particles of varying sizes and/or shapes, wherein the density of the filler is greater than that of the matrix metal, a higher filler loading, due to enhanced packing of the filler materials, may be achieved, thereby resulting in a metal matrix composite body with an increased density. By utilizing the teachings of the present invention, the volume percent of filler material or preform which can be infiltrated can vary over a wide range. ~he lower volume percent of filler that can be infiltrated is limited primarily by the ability to form a porous filler material or preform, (e.g., about 10 volume percent); whereas the higher volume percent of filler or preform that can be infiltrated is limited primarily by the ability to form a dense filler material or preform with at least some interconnected porosity (e.g., about 95 volume percent). Accordingly, by practicing any of the above teachings, alone or in enmbination, a metal matrix composite can be engineered to contain a desired combination of properties.
The method of forming metal matrix composites according to the present invention, not being dependent on the use of pressure to force or squeeze molten matrix metal into a preform or a mass of filler material, permits the production of substantially uniform metal matrix composites having a high volume fraction of filler material and tailorable porosity. Higher volume fractions of filler material may be achieved by using a lower porosity initial mass of filler material.
Higher volume fractions also may be achieved if the mass of filler is compacted or otherwise densified provided that the mass is not converted into either a compact with closed cell porosity or into a fully dense structure that would prevent infiltration by the molten alloy.
Specifically, volume fractions on the order of about 60 to 80 volume percent can be achieved by methods such as vibrational packing, controlling particle size distribution, etc. However, alternative techniques can be utilized to achieve even higher volume fractions of filler. Volume fractions of filler on the order of 40 to 50 percent are preferred for thermo-forming in accordance with the present invention.
At such volume fractions, the infiltrated composite maintains or substantially maintains its shape, thereby facilitating secondary processing. Higher or lower particle loadings or volume fractions could be used, however, depending on the desired final composite loading after thermo-forming. Moreover, methods for reducing particle loadings can be " ~
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w o 91/17275 PCT/US9t/0~1 employed in connection with the thermo-forming processes of the present invention to achieve lower particle loadings.
It has been observed that for aluminum infiltration and matrix formation around a ceramic filler, wetting of the ceramic filler by the aluminum matrix metal may be an important part of the infiltration rnechanism. Further, the wetting of the filler by molten matrix metal May permit a uniform dispersion of the filler throughout the formed metal matrix composite and improve the bonding of the filler to the matrix metal. Moreover, at low processing temperatures, a negligible or minimal amount of metal nitriding occurs resulting in a minimal discont;nuous phase of aluminum nitride dispersed in the metal matrix.
However, as the upper end of the temperature range is approached, nitridation of the metal is more likely to occur. Thus, the amount of the nitride ph~ in ~he metal matrix can be controlled by varying the processing temperature at which infiltration occurs. The specific process temperature at which nitride formation becomes more pronounced also varies with such factors as the matrix aluminum alloy used and its quantity relative to the volume of filler or preform, the filler material to be infiltrated, and the nitrogen concentration of the infiltrating atmosphere. For example, the extent of aluminum nitride formation at a given process temperature is believed to increase as the ability of the alloy to wet the filler decreases and as the nitrogen concentration of the atmosphere increases.
It is therefore possible to tailor the constituency of the metal matrix during formation of the composite to impart certain characteristics to the resulting product. For a given system, the process conditions can be selected to control the nitride formation. A
composite product containing an aluminum nitride phase will exhibit certain properties which can be favorable to, or improve the performance of, the product. Further, the temperature range for spontaneous infiltration with an aluminum alloy may vary with the ceramic material used. In the case of alumina as the filler material, the temperature for infiltration should preferably not exceed about 1000C if it is desired that the ductility of the matrix not be reduced by the significant formation of nitride. However, temperatures exceeding 1000C may be employed if it is desired to produce a composite with a less ductile and stiffer matrix. To infiltrate silicon carbide, higher temperatures of about 1200C may be employed since the aluminum alloy .
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2~81555 ,.~..~.WO 91/17275 PCr/US91/03160 .. ..
nitrides to a lesser extent, relative to the use of a~umina as filler, when silicon carbide is employed as a filler material.
Further, the constituency of the metal matrix may be modif;ed after formation of the metal matrix composite. For example, exposure of the formed metal matrix composite to a heat treatment may improve the tensile strength of the metal matrix composite. (The standard test for tensile strength is ASTM-D3552-77 (reapproved 1982).) Specifically, a desirable heat treatment for a metal matrix composite containing a 520.0 aluminum alloy as the matrix metal may comprise heating the metal matrix composite to an elevated temperature, for example, to about 430-C, which is maintained for an extended period (e.g., 18-20 hours). The metal matrix may then be quenched in boiling water at about lOO-C for about 20 seconds (i.e., a T-4 heat treatment) which can temper or improve the ability of the composite to withstand t~ensile stresses. Morenver it may be desirable to subject a formed metal matrix composite body to, e.g., a carburizing or boronizing environment to improve, for example, the corrosion resistance, etc., of the metal matrix composite body.
Moreover, it is possible to use a reservoir of matrix metal to infiltrate the filler material and/or to supply a second metal which has 2~ a different composition from the first source of matrix metal.
Specifically, in some cases it may be desirable to utilize a matrix metal in the reservoir which differs in composition from the first source of matrix metal. For example, if an aluminum alloy is used as the first source of matrix metal, then virtually any other metal or metal alloy which was molten at the processing temperature could be used as the reservoir metal. Molten metals frequently are very miscible with each other which would result in the reservoir metal mixing with the i first source of matrix metal so long as an adequate amount of time is -I- given for the mixing to occur. Thus, by using a reservoir metal which is different in composition from the first source of matrix metal, it is possible to tailor the properties of the metal matrix to meet various - operating requirements and thus tailor the properties of the metal matrix composite.
A barrier means may also be utilized in combination with the present invention. Specifically, the barrier means for use with this invention may be any suitable means which interferes, inhibits, prevents or terminates the migration, movement, or the like, of molten matrix alloy (e.g., an aluminum alloy) beyond the defined surface boundary of the filler material. Suitable barrier means may be any material, . .
. ~ , . , ' : . .', ~ ' , , , . , . - . . , - , ;, 208~55~
w o 91/17275 PCT/US91/031 compound, element, composition, or the like, which, under the process conditions of this invention, maintains some integrity, is not volatile and preferably is permeable to the gas used with the process, as well as being capable of locally inhibiting, stopp;ng, interfering with, preventing, or the like, continued infiltration or any other kind of movement beyond the defined surface boundary of the ceramic filler.
Barrier means may be used during spontaneous infiltration or in any molds or other fixtures utilized in connection with thermo-forming of the spontaneously infiltrated metal matrix composite, as discussed in greater detail below.
Suitable barrier means includes materials which are substantially non-wettable by the migrating molten matrix alloy under the process conditions employed. A barrier of this type appears to exhibit little or no affinity for the molten matrix alloy; and movement beyond the defined surface boundary of the filler material or preform is prevented or inhibited by the barrier means. ~he barrier reduces any final machining or grinding that may be required of the metal matrix composite product. As stated above, the barrier preferably should be permeable or porous, or rendered permeable by puncturing, to permit the gas to contact the molten matrix alloy.
Suitable barriers particularly useful for aluminum matrix alloys are those containing carbon, especially the crystalline allotropic form of carbon known as graphite. Graphite is essentially non-wettable by the molten aluminum alloy under the described process conditions. A
particular preferred graphite is a graphite foil product that is sold under the trademark Grafoil~, registered to Union Carbide. This graphite foil exhibits sealing characteristics that prevent the migration of molten aluminum alloy beyond the defined surface boundary of the filler material. This graphite foil is also resistant to heat and is chemically inert. Grafoil~ graphite foil is flexible, compatible, conformable and resilient. It can be made into a variety of shapes to fit any barrier application. However, graphite barrier means may be employed as a slurry or paste or even as a paint film around and on the boundary of the filler material or preform. Grafoil~ is particularly preferred because it is in the form of a flexible graphite sheet. In use, this paper-like graphite is simply formed around the filler material or preform.
Other preferred barrier(s) for aluminum metal matrix alloys in nitrogen are the transition metal borides (e g., titanium diboride .
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208155~ `

!~?~ w O 91J17275 PCT/US91/03160 (TiB2)) which are generally non-wettable by the molten aluminum metal alloy under certain of the process conditions employed using this material. With a barrier of this type, the process temperature should not exceed about 875 C, for otherwise the barrier material becomes less efficacious and, in fact, with increased temperature infiltration into the barrier will occur. Moreover, the particle size af the barrier material may affect the ability of the material to inhibit spontaneous infiltration. The transition metal borides are typically in a particulate form (1-30 microns). The barrier materials may be applied as a slurry or paste to the boundaries of the permeable mass of ceramic filler material which preferably is preshaped as a preform.
Other useful barriers for aluminum metal matrix alloys in nitrogen include low-volatile organic compounds applied as a film or layer onto the external surface of the filler material or preform. Upon firing in nitrogen, especially at the process conditions of this invention, the organic compound decomposes leaving a carbon soot film. The organic compound may be applied by conventional means such as painting, spraying, dipping, etc.
Moreover, finely ground particulate materials can function as a barrter so long as infiltration of the particulate material would occur at a rate whlch is slower than the rate of infiltration of the filler material.
Thus, the barrier means may be applied by any suitable means, such as by covering the defined surface boundary with a layer of the barrier s means. Such a layer of barrier means may be applied by painting, dipping, silk screening, evaporating, or otherwise applying the barrier means in liquid, slurry, or paste form, or by sputtering a vaporizable barrier means, or by simply depositing a layer of a solid particulate barrier means, or by applying a solid thin sheet or film of barrier means onto the defined surface boundary. With the barrier means in place, spontaneous infiltration substantially terminates when the infiltrating matrix metal reaches the defined surface boundary and contacts the barrier means.
Various demonstrations of the present invention are included in the Examples immediately following. However, these Examples should be - considered as being illustrative and should not be construed as limiting the scope of the invention as defined in the appended claim.

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208~3 WO 91/17275 - 36 - PCI/US91/0~1 Example 1 The following Example demons~rates a method for making a porous body by a spontaneous infiltration technique.
Figure 1 is a cross-sectional schematic of the setup 16 used to form a porous metal matrix composite body. Specifically, a Grade ATJ
graphite boat (Union Carbide Corporation, Carbon Product D;vision, Cleveland, OH) measuring about 3 inches (76 mm) long by about 3 inches (76 mm) wide by about 2.5 inches (64 mm) high, and having a wall thickness of about 0.5 inch (13 mm), was lined with a graphite foil box 11. The graphite foil box 11 had been formed from a piece of PERMAFOIL~
graphite foil (TT America, Portland, OR) measuring about 6 inches (152 mm) long by about 6 inches (152 mm) wide by about 0.010 inch (0.25 mm) thick, which was cut and folded to fit within the inner dimensions of the graphite boat.
i5 A filler material mixture 12 was prepared by ball milling a mixture comprising, by weight, about 95% 38 ALUNDUM~ 500 grit alumina (Norton Co., Worcester, MA) and about 5% -325 mesh magnesium powder.
Specifically, the filler material mixture was placed into a plastic jar and ball milled for about an hour, then the filler material mixture was dried at a temperature of about 150-C for about 1 hour.
About 200 grams of the filler material mixture 12 were placed into the graphite foil box 11 within the graphite boat 10 and leveled.
About 0.75 gram of -50 mesh magnesium powder 13 were placed onto the surface of the filler material mixture 13.
About 20 grams of a matrix metal 14 designate aluminum alloy 520, and nominally comprising by weight about < 0.25% Si, < 0.30% Fe, <
0.25% Cu, < 0.15 Mn, 7.5-10.5% Mg, < 0.15% Zn, < 0.25% Ti and the balance Al, were placed onto the -50 mesh magnesium powder 13 covering the filler material mixture 12. A piece of graphite foil 15 was then placed over the top of the graphite boat 10 to complete the setup.
The setup was placed into a retort heated by a resistance furnace, and the retort door was closed. At about roo~ temperature, the - retort was evacuated to a vacuum of about 30 inches (762 mm) of mercury, ~-~ then the vacuum pump was shut off and a nitrogen atmosphere flowing at about 15 liters per minute was introduced into the retort chamber. The furnace and its contents were then heated to a temperature of about 500C at a rate of about 400C, held at about 500C for about an hour, then heated to about 750C at a rate of about 400C per hour. After about 3 hours at about 750C, the flowing nitrogen atmosphere and the 2~81555 f - ~/0 91/17275 PCI-/US91/0?~160 power to the furnace were shut off, and the setup was cooled to room temperature.
At about room temperature, the setup was disassembled to reveal that a porous metal matrix composite body had been formed. A sample of the porous metal matrix composite body was placed in an electron microscope and a photomicrograph was of the sample, taken in the secondary electron mode. Figure 2 is a photomicrograph of the sample, taken at about 400X magnification, showing the interconnected nature of the filler material particles, as well as the porosity between the alumina filler material.

.. . . . . ..
. .... . ... .

:

Claims

WO 91/17275 PCT/US91/031

1. A method for forming a porous metal matrix composite body comprising:
infiltrating a permeable mass of filler with a quantity of molten matrix metal which is insufficient to completely embed said filler.

2. The method of claim 1, wherein said permeable mass of filler is shaped into a preform.

3. The method of any one of claims 1 or 2, wherein said permeable mass of filler is substantially nonreactive with said molten matrix metal.

4. The method of any one of claims 1-3, wherein said molten matrix metal is provided in a quantity which is sufficient only to coat the filler.

5. The method of any one of claims 1-4, wherein said filler comprises a material containing at least some internal porosity, and wherein said internal porosity is noninfiltratable by said molten matrix metal.

6. The method of any one of claims 2-5, wherein said preform contains filler of different density and/or different composition and/or different packing density and/or different morphology in different portions thereof.

7. The method of any one of claim 1-6, wherein said porous metal matrix composite body which is produced is used as a preform for a subsequent metal matrix composite formation technique.

8. The method of claim 7, wherein said subsequent metal matrix composite formation technique comprises a pressure infiltration technique.

9. The method of any one of claims 1-7, wherein said infiltrating comprises spontaneous infiltration.

10. The method of claim 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.

11. The method of claim 10, wherein the infiltrating atmosphere comprises an atmosphere selected from the group consisting of oxygen and nitrogen.

12. The method of claim 10, wherein an infiltration enhancer is formed in said filler.

13. The method of claim 12, wherein said infiltration enhancer is formed by reacting an infiltration enhancer precursor with the infiltrating atmosphere.

14. The method of claim 13, wherein said matrix metal comprises aluminum, said infiltration enhancer precursor comprises magnesium, said infiltrating atmosphere comprises nitrogen and said infiltration enhancer comprises a nitride of magnesium.

15. The method of any of claims 1-14, wherein said 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.

16. A method for making a porous metal matrix composite body comprising:
providing a mass of substantially nonreactive filler;
providing a matrix metal in an amount which is insufficient to embed completely said filler;
providing a material comprising at least one of an infiltration enhancer precursor and an infiltration enhancer to at least one of said filler and said matrix metal;
causing said matrix metal to become molten; and spontaneously infiltrating said filler such that said filler is only coated by said matrix metal, thereby resulting in a porous metal matrix composite body.

17. A body made according to the process of any of the preceding claims.

18. A porous metal matrix composite body comprising:
a ceramic filler; and a matrix metal coating said ceramic filler, said matrix metal being three dimensionally interconnected.

19. The porous metal matrix composite body of claim 18, wherein said ceramic filler comprises at least one material selected from the group consisting of oxides, carbides, borides, nitrides and mixtures thereof and said matrix metal comprises aluminum.

20. The porous metal matrix composite body of any of claims 18 or 19, wherein said metal matrix composite body is formed into at least one body selected from the group consisting of a thermally insulating structure, a filler and a strainer.