JP2005536355A - Metal composite material and manufacturing method thereof - Google Patents

Abstract

A ceramic oxide fiber comprising a first metal and an insert for reinforcing the first metal, wherein the first metal is selected from the group consisting of aluminum, alloys thereof, and combinations thereof; and the insert is substantially continuous. A second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the second metal fixes substantially continuous ceramic oxide fibers in place, the second metal Extending along at least a portion of the length of the substantially continuous ceramic oxide fiber, wherein there is an interface layer between the first metal and the insert, and the interface layer between the first metal and the insert A metal matrix composite article having a peak bond strength value of at least 100 MPa. Metals including inserts for reinforcing metal matrix composite articles and methods for making the same. In another aspect, the present invention provides a metal matrix composite article reinforced with an insert and a method for making the same. Useful metal matrix composite articles include aerospace structural materials.

Description

  The present invention relates to a metal comprising an insert for reinforcing a metal matrix composite article, and a metal matrix composite article reinforced with an insert.

  Reinforcing metal composites with ceramics is well known in the art (eg, US Pat. Nos. 4,705,093 (Ogino), 4,852,630 (Hamajima et al.)). al.)), 4,932,099 (Corwin et al.), 5,199,481 (Corwin et al.), 5 , 234,080 (Pantale) and 5,394,930 (Kennerknecht), UK patents issued on May 28, 1987 and September 14, 1988, respectively. No. 2,182,970A and B, PCT application published on April 4, 2002, WO 02 26658 pamphlet, see WO 02/27048 pamphlet and WO 02/27049 pamphlet). Examples of the ceramic material used for reinforcement include particles, discontinuous fibers (including whiskers), continuous fibers, and ceramic preforms.

  In general, ceramic materials are incorporated into metals to provide a metal composite (MMC) that has improved mechanical properties compared to metal articles without ceramic materials. For example, conventional brake calipers for automobiles (eg, passenger cars and trucks) are typically made of cast iron. In order to reduce the overall weight of an automobile, especially an unsprung weight such as a brake caliper, it is required to use lighter parts and / or materials. One technique for minimizing the amount of ceramic oxide material required for a particular application that helps in the design of MMC, including the placement of ceramic oxide material, is finite element analysis.

  A brake caliper made of cast aluminum is about 50% lighter than the same caliper made of cast iron (ie, the same size and structure). The mechanical properties of cast aluminum and cast iron are not the same (i.e., cast iron has a Young's modulus of about 100-170 GPa, cast aluminum is about 70-75 GPa, cast iron has a yield strength of 300-700 MPa, and cast aluminum is 200-300 MPa. ). Thus, for certain sizes and shapes, cast aluminum brake calipers have significantly lower mechanical properties such as bending stiffness and yield strength than cast iron calipers. In general, the mechanical properties of such aluminum brake calipers are unacceptably low compared to cast iron brake calipers. A brake caliper made of an aluminum metal composite (e.g., aluminum reinforced with ceramic fibers) is desired that has the same structure as cast iron brake properties and at least (or better) mechanical properties such as bending stiffness and yield strength.

  One problem with some MMC articles is post-forming machining (adding holes or threads or cutting the material to the desired shape) or other processing (welding the two MMC articles together) To create parts with complicated shapes. Many conventional MMCs generally contain sufficient ceramic reinforcement material, making them difficult or even difficult to machine and weld. However, it is desirable to produce “net-shaped” articles that require little or no post-forming machining or processing. Techniques for making “net-shaped” articles are known in the art (eg, US Pat. Nos. 5,234,045 (Cisko) and 5,887,684 (Doell et al.). et al.)) In addition to, or instead of, feasible range, reduce ceramic reinforcement or place in areas that would interfere with other processes such as machining or welding. Good.

  Another issue in the design and manufacture of MMC is the cost of ceramic reinforcement materials. The mechanical properties of the continuous polycrystalline alpha alumina fiber marketed under the trade name “NEXTEL 610” from the 3M Company in St. Paul, Minn. (3M Company, St. Paul, MN) has a low density like aluminum. Higher than metal. Furthermore, the cost of ceramic oxide materials such as polycrystalline alpha alumina fibers is substantially higher than metals such as aluminum. Therefore, in order to maximize the properties imparted by the ceramic oxide material, it is desirable to minimize the amount of ceramic oxide material used and optimize the placement of the ceramic oxide material.

  Furthermore, it would be desirable to provide a ceramic reinforcement material in a form that can be used relatively easily to produce a package or metal composite.

  PCT applications published on Apr. 4, 2002, WO 02/26658, WO 02/27048 and WO 02/27049, PCT applications include packages or metal matrix composite articles. There is a description of an embodiment that addresses the need for a ceramic reinforcement material in a form that can be used relatively easily to manufacture, but preferably a metal matrix composite having properties superior to conventional metal composites There is a need for additional solutions that provide articles and / or other novel ways of providing alternatives.

  In one aspect, the invention includes a first metal and one insert that reinforces the first metal (in some embodiments, at least two, three or more inserts), wherein the first metal is aluminum, A ceramic oxide fiber selected from the group consisting of the alloy and combinations thereof, the insert comprising a substantially continuous ceramic oxide fiber, and a second metal selected from the group consisting of aluminum, the alloy and combinations thereof; Two metals substantially fix a continuous ceramic oxide fiber in place, and a second metal extends along at least a portion of the length of the substantially continuous ceramic oxide fiber. An interface layer between the first metal and the insert, and the interface layer peak bond strength value between the first metal and the insert is at least 100 MPa (an embodiment Oite at least 125 MPa, 150 MPa, 175 MPa, further provides a metal matrix composite article is at least 200 MPa). In certain embodiments, the interface layer preferably does not include oxygen.

In another aspect, the present invention, in one embodiment,
Placing an insert in a mold comprising a substantially continuous ceramic oxide fiber and a first metal selected from the group consisting of aluminum, alloys thereof and combinations thereof, wherein the first metal is substantially A continuous ceramic oxide fiber in place, the first metal extending along at least a portion of the length of the continuous ceramic oxide fiber, and the first metal And having a second metal (eg, Cu, Au, Ni, Ag, Zn, and combinations thereof) on the outer surface of the first metal and having a thickness of the second metal of at least 5 micrometers. (In some embodiments, preferably at least 10 micrometers, at least 15 micrometers, even at least 20 micrometers, more preferably 5-2. A step of micrometers),
Providing a mold with a molten third metal selected from the group consisting of aluminum, alloys thereof and combinations thereof;
Cooling the molten third metal to provide an article;
Providing a metal matrix composite article according to the present invention by hot isostatic pressing (HIP) of the article to provide a metal matrix composite article according to the present invention. In some embodiments, the casting can be performed in air, but in an argon atmosphere (eg, at least 90% by volume (at least 95%, 99% or even 100% by volume based on the total volume of the atmosphere). It is preferable to carry out 10% by volume, 5% by volume, 1% by volume or less, and further 0% by volume of O ₂ ) based on the total volume of Ar) and the atmosphere).

In another aspect, the present invention provides
Placing an insert in a mold comprising a substantially continuous ceramic oxide fiber and a first metal selected from the group consisting of aluminum, alloys thereof and combinations thereof, wherein the first metal is substantially Fixing the continuous ceramic oxide fibers in place, wherein the first metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers;
Providing a mold with a molten third metal selected from the group consisting of aluminum, alloys thereof and combinations thereof, at least 90% by volume (at least 95% by volume, 99% by volume, or even 100% by volume) To a third metal mold melted by applying an atmosphere containing 10% by volume or less, 5% by volume or less, 1% by volume or less, and further 0% by volume of O ₂ based on the total volume of the atmosphere. A process of performing the provision in an atmosphere;
Cooling the molten third metal to provide a metal matrix composite article. In some embodiments, the first metal has an outer surface, and the second metal (eg, Cu, Au, Ni, Ag, Zn, and combinations thereof) is on the outer surface of the first metal, and the second The metal has a thickness of at least 5 micrometers (in some embodiments, preferably at least 10 micrometers, at least 15 micrometers, even at least 20 micrometers, more preferably 5-20 micrometers). In certain embodiments, the method includes hot isostatic pressing (HIP) after at least partially cooling the molten third metal, thereby providing a metal matrix composite article.

In this specification,
The “peak bond strength value” refers to a peak bond strength value obtained by at least one of the following Comparative Example A or Example 4.
“Oxygen-free” means that there is no continuous oxide layer visually identifiable at the interface when viewed at 250 × with an optical microscope, as described in “Oxygen layer test” below.
“Substantially continuous ceramic oxide fiber” refers to a ceramic oxide fiber having a length of at least 5 cm.

  Examples of the metal composite material according to the present invention include structural parts for aerospace applications, brake calipers, high-speed rotating rings, and industrial machinery high-speed machine arms.

  The present invention provides a metal matrix composite article comprising at least one metal and a substantially continuous ceramic oxide fiber. In general, metal matrix composite articles according to the present invention are designed for specific applications to achieve the best or at least acceptable balance of desired properties, low cost and ease of manufacture.

  In general, metal matrix composite articles according to the present invention, such as inserts, are designed for specific applications and / or to have specific properties and / or characteristics. For example, an existing article made of one metal (eg, steel) may be redesigned to be manufactured from another metal (eg, aluminum) reinforced with a material that includes a substantially continuous ceramic oxide fiber. The latter (ie, the metal composite version of the article) is selected for certain desired properties (eg, Young's modulus, yield strength) that are at least equal to those required to use the original article made from the first metal. And ductility). Optionally, the article may be redesigned to have the same physical dimensions as the original article.

  The composition of the desired metal matrix composite article, the desired properties, the metals that can be used and the ceramic oxide materials that are preferred for manufacturing, and the relevant properties of these materials, can be used together to obtain a possible suitable structure. In one embodiment, a preferred method for creating a possible structure is a finite element analysis (using FEA software) that is performed using a conventional computer system (using a central processing unit (CPU) and input / output devices). FEA). Suitable FEA software is commercially available, including those commercially available under the trade name “ANSYS” from Ansys, Inc., Canonsburg, Pa. FEA helps to model the article mathematically and identify regions that provide the desired level of properties through the placement of continuous ceramic oxide fibers, metals, and other possible materials. It is generally necessary to run several FEA's repeatedly to obtain a more favorable design.

  Referring to FIG. 1, an illustrative (metal composite) insert 10 for producing a metal matrix composite article according to the present invention is a substantially continuous (longitudinally aligned as shown) ceramic oxide. Fiber 12 and aluminum or its alloy 14 are included. In some embodiments, the outer surface 15 of aluminum or its alloy 14 comprises a first metal 16 (eg, Cu, Au, Ni, Ag, Zn, and combinations thereof). Further, in some embodiments, the outer surface 17 of the second optional metal 18 has a second optional metal (eg, Ni) 18. The second optional metal is commonly used when the first optional metal is Cu and / or Ag. Using Ni tends to help adhere to the insert surface of metals such as Cu and / or Ag.

  Referring to FIG. 2, another example (metal composite) insert 10 for producing a metal matrix composite article according to the present invention is a substantially continuous (longitudinally aligned as shown) ceramic. The oxide fiber 22 and aluminum or its alloy 24 are included. In some embodiments, the outer surface 25 of aluminum or its alloy 24 has a first metal (eg, Cu, Au, Ni, Ag, Zn, and combinations thereof) 26. Further, in some embodiments, the outer surface 27 of the second optional metal 28 has a second optional metal (eg, Ni) 28.

  In certain exemplary embodiments of the invention, the continuous ceramic oxide fibers are substantially longitudinally aligned and substantially parallel to each other. Ceramic oxide fibers may be incorporated into the insert as individual fibers, but more commonly are incorporated into the insert as a group of fibers in the form of a bundle or tow. The fibers in the bundle or tow are maintained in a longitudinally aligned (ie, substantially parallel) relationship with each other. Even when using multiple bundles or tows, the fiber bundles or tows are maintained in a longitudinally aligned (ie, substantially parallel) relationship with one another. In certain embodiments, all continuous ceramic oxide fibers are preferably maintained in a substantially longitudinal configuration, and the alignment of the individual fibers is within ± 10 ° of their average long axis, and more Preferably it is ± 5 °, and most preferably ± 3 °.

  For certain metal matrix composite articles according to the present invention, it is preferred or necessary to bend the ceramic oxide fibers from a straight line (not extending in a planar manner). Thus, for example, ceramic oxide fibers may be planar over the entire fiber length or non-planar (ie, bent) over the entire fiber length, with some portions being planar and other portions being It may not be planar (bent). In certain embodiments, the substantially continuous ceramic oxide fibers are in a curvilinear configuration (ie, aligned longitudinally) that does not substantially intersect throughout the curved portion of the metal matrix composite article. In certain embodiments, the substantially continuous ceramic oxide fibers are maintained in a substantially equidistant relationship with one another throughout the curved portion of the metal matrix composite article.

  For example, referring to FIG. 3, an illustrative insert 50 for producing a metal matrix composite article according to the present invention comprises substantially continuous (as shown, longitudinally aligned) ceramic oxide fibers 52. The substantially continuous ceramic oxide fiber 52 is bent in the length direction. In some embodiments, the outer surface 55 of aluminum or its alloy 54 comprises a first metal 56 (eg, Cu, Au, Ni, Ag, Zn, and combinations thereof). Further, in some embodiments, the outer surface 57 of the second optional metal 58 has a second optional metal (eg, Ni) 58. An example of a metal composite material that can be manufactured from the latter type of insert is a metal composite ring as shown in FIG. The ring 60 includes aluminum or its alloy 54 and ceramic oxide fibers 52 (see FIG. 3). Such a ring is useful, for example, for a high-speed rotating machine with a large centrifugal force.

  In other embodiments of certain metal matrix composite articles according to the present invention, 2, 3, 4 or more plies of substantially continuous ceramic oxide fibers (ie, one ply is substantially continuous ceramic oxide fibers). At least one layer (in some embodiments, at least one layer of tow comprising substantially continuous ceramic oxide fibers). The plies may be oriented in various ways with respect to each other. Examples of ply relationships are shown in FIGS. Referring to FIG. 5, insert 70 comprises first and second plies of substantially continuous ceramic oxide fibers 71 and 72 (aligned longitudinally as shown) and aluminum or an alloy 74 thereof. Contains. In some embodiments, the outer surface 75 of aluminum or its alloy 74 has a first metal (eg, Cu, Au, Ni, Ag, Zn, and combinations thereof) 76. Further, in certain embodiments, the outer surface 77 of the second optional metal 78 has a second optional metal (eg, Ni) 78. The first ply of substantially continuous ceramic fibers 71 is disposed at 45 ° with respect to the second ply of substantially continuous ceramic oxide fibers 72. However, depending on the specific application, the difference in ply placement relative to other plies may be greater than zero degrees to 90 degrees. Such a ply configuration is useful when a biaxial or triaxial load is applied to a metal composite article. Optionally, the metal matrix composite article according to the present invention can have more than one ply.

  As shown in FIG. 6, the grouping of fibers covered with substantially continuous ceramic oxide fibers is also advantageous. The insert 80 is substantially continuous (in the longitudinal direction, as shown) spirally wrapped around the ceramic oxide fiber 81 and aluminum or its alloy 84, which are substantially continuous (aligned in the longitudinal direction as shown). Ceramic oxide fibers 82 (consistently). In some embodiments, the outer surface 75 of aluminum or its alloy 74 has a first metal (eg, Cu, Au, Ni, Ag, Zn, and combinations thereof) 76. Further, in certain embodiments, the outer surface 77 of the second optional metal 78 has a second optional metal (eg, Ni) 78. An example of a metal matrix composite article that benefits from properties substantially obtained by a ply of ceramic oxide fibers includes an article that undergoes bending forces around two vertical axes during use.

  Generally, the length of the substantially continuous ceramic oxide fiber is at least 10 cm (many are at least 15 cm, 20 cm, 25 cm or more). In certain embodiments of the present invention, the substantially continuous ceramic oxide fiber is in the form of a tow (ie, the tow comprises a substantially continuous ceramic oxide fiber). Generally, the length of the substantially continuous ceramic oxide fiber containing tow is at least 10 cm (many are at least 15 cm, 20 cm, 25 cm or more).

  The ceramic oxide fibers comprise or consist essentially of substantially continuous, longitudinally aligned ceramic oxide fibers. “Aligned in the longitudinal direction” refers to an array of fibers substantially parallel to the length of the fibers.

  In certain embodiments, it is preferred that the average diameter of the substantially continuous reinforced ceramic oxide fibers used to make the metal matrix composite article according to the present invention is at least about 10 micrometers. In certain embodiments, the average fiber diameter is about 200 micrometers or less, more preferably about 100 micrometers or less. For fiber tows, in certain embodiments, the average fiber diameter is preferably about 50 micrometers or less, more preferably about 25 micrometers or less.

  In certain embodiments, the average tensile strength of the substantially continuous continuous oxide fiber is at least about 1.4 GPa, more preferably at least about 1.7 GPa, more preferably at least about 2.1 GPa, and most preferably at least about 2 .8 GPa. However, lower tensile strength fibers are also useful for certain applications.

  Continuous ceramic oxide fibers are commercially available as single filaments or groupings (eg, yarns and tows). The yarn or tow may comprise, for example, at least 420 individual fibers per tow, at least 760 individual fibers per tow, at least 2600 individual fibers per tow or more. Tow is well known in the textile industry and refers to a plurality of (individual) fibers (generally at least 100 fibers, more generally at least 400 fibers) assembled in an untwisted form. A yarn refers to a twisted or rope-like structure. Ceramic oxide fibers, including ceramic oxide fiber tows, are available in various lengths. The cross-sectional shape of the fiber may be circular or elliptical.

  Useful ceramic oxide fibers include alpha alumina fibers, aluminosilicate fibers and aluminoborosilicate fibers. Other useful ceramic oxide fibers will be apparent to those skilled in the art upon reviewing the present disclosure.

Methods for producing alumina fibers are known in the industry and include those disclosed in US Pat. No. 4,954,462 (Wood et al.). In certain embodiments, the alumina fibers are preferably polycrystalline alpha alumina based fibers, greater than about 99 wt.% Al ₂ O ₃ and about 0.2-0 based on the theoretical oxide based on the total mass of the alumina fibers. 5% by mass of SiO ₂ is contained. In other aspects, in certain embodiments, preferred polycrystalline alpha alumina based fibers comprise alpha alumina with an average grain size of less than 1 micrometer (more preferably less than 0.5 micrometers). In other aspects, in certain embodiments, preferred polycrystalline alpha alumina based fibers have an average tensile strength of at least 1.6 GPa (preferably at least 2.1 GPa, more preferably at least 2.8 GPa). Alpha alumino fibers are commercially available, for example, under the trade name “NEXTEL 610” from 3M Company, St. Paul, Minn. Other alpha-Falmina fibers containing about 89 weight percent Al ₂ O ₃ , 10 weight percent ZrO ₂ and about 1 weight percent Y ₂ O _{3 based} on the total weight of the fiber are 3M Company More commercially available under the trade name “NEXTEL 650”.

Methods for producing aluminosilicate fibers are known in the art and include those disclosed in US Pat. No. 4,047,965 (Karst et al.). In some embodiments, the aluminosilicate fibers preferably theoretical oxide basis based on the total weight of the aluminosilicate fibers, Al ₂ O ₃ and SiO ₂ of about 33 to about 15 weight percent to about 67 to about 85 weight percent Including. In certain embodiments, preferred aluminosilicate fibers comprise from about 67 to about 77 weight percent Al ₂ O ₃ and from about 33 to about 23 weight percent SiO _{2 based} on the theoretical oxide, based on the total weight of the aluminosilicate fiber. . In certain embodiments, preferred aluminosilicate fibers comprise about 85 weight percent Al ₂ O ₃ and about 15 weight percent SiO _{2 based} on the theoretical oxide based on the total weight of the aluminosilicate fiber. In certain embodiments, preferred aluminosilicate fibers comprise about 73 weight percent Al ₂ O ₃ and about 27 weight percent SiO _{2 based} on the theoretical oxide based on the total weight of the aluminosilicate fiber. Aluminosilicate fibers are commercially available from 3M Company under the trade names “NEXTEL 440”, “NEXTEL 720”, and “NEXTEL 550”, for example.

Methods for producing aluminosilicate fibers are known in the industry and include those disclosed in US Pat. No. 3,795,524 (Sowman). In certain embodiments, preferably the aluminoborosilicate fiber is from about 35 weight percent to about 75 weight percent (e.g., from about 55 weight percent to about 55 weight percent, based on the total weight of the aluminoborosilicate fiber, based on the theoretical oxide). 75 weight percent Al ₂ O ₃ , greater than 0 weight percent (eg, at least about 15 weight percent) and less than about 50 weight percent (eg, less than about 45 weight percent, or even less than about 44 weight percent) SiO ₂ , and greater than about 5 weight percent (or, for example, less than about 25 weight percent, less than about 1 weight percent to about 5 weight percent, or even less than about 2 weight percent to about 20 weight percent) B ₂ O Including ₃ . Aluminoborosilicate fiber is commercially available, for example, under the trade name “NEXTEL 312” from 3M Company.

  Commercially available substantially continuous ceramic oxide fibers often contain organic sizing materials added to the fibers to provide lubricity during manufacture and to protect the fiber strands during handling. Sizing is believed to tend to reduce fiber breakage, reduce static electricity and, for example, reduce the amount of dust during conversion to fiber. Sizing can be removed, for example, by dissolution or combustion.

  It is also within the scope of the present invention to provide a coating on ceramic oxide fibers. The coating is used, for example, to improve the wettability of the fiber and reduce or prevent the reaction between the fiber and the molten metal matrix material. Such coatings and techniques for providing such coatings are well known in the fiber and metal composite industry.

  The metal casting around the insert may be the same as or different from the metal fixing the continuous ceramic oxide fibers. The aluminum and aluminum alloys used to manufacture the inserts and metal matrix composite articles according to the invention may contain impurities, but in some embodiments, in some embodiments, relatively pure metals (e.g., 0 .1 weight percent, and metals containing less than 0.05 weight percent impurities (eg, Fe, Si and / or Mg less than 0.25 weight percent, less than 0.1 weight percent, and even less than 0.05 weight percent each) ) Is preferably used. High purity metals tend to be preferred for making high tensile strength materials, but low purity forms of metals are also useful.

  Suitable aluminum and aluminum alloys are commercially available. For example, aluminum is available from Alcoa of Pittsburgh, PA under the trade name “SUPER PURE ALUMINUM, 99.99% Al”. Aluminum alloys (Al-2 wt% Cu (0.03 wt% impurities)) are available from Belmont Metals, New York, NY. In certain embodiments, preferred aluminum alloys include alloys containing at least 98 weight percent Al, aluminum alloys containing at least 1.5 weight percent Cu (e.g., 1.5-2. 5, preferably an aluminum alloy containing Cu in the range of 1.8 to 2.2 weight percent. Useful families of aluminum alloys include 200 (e.g., 201 aluminum alloy, A201.1 aluminum alloy, 201.2 aluminum alloy, 203 aluminum alloy, 206 aluminum alloy, A206.0 aluminum alloy, 224 aluminum alloy, and 224.2). Aluminum alloy), 300 (for example, A319.1 aluminum alloy, 354.1 aluminum alloy, 355.2 aluminum alloy, A356 aluminum alloy, D356 aluminum alloy, A356.1 aluminum alloy, A357 aluminum alloy, and D357 aluminum alloy), 400 (Eg 413 aluminum alloy, 443 aluminum alloy, 443.2 aluminum alloy and 444.2 aluminum alloy), 700 (eg 713 Al Nium alloy and 771 aluminum alloy), 2000 (eg 2036 aluminum alloy and 2618 aluminum alloy), 6000 (eg 6061 aluminum alloy, 6063 aluminum alloy, 6101 aluminum alloy, 6151 aluminum alloy and 6201 aluminum alloy) and / or 7000 ( For example, a 7072 aluminum alloy) type aluminum alloy can be mentioned.

  In certain embodiments, preferred aluminum alloys for the insert include alloys containing at least 98 weight percent Al, aluminum alloys containing at least 1.5 weight percent Cu (e.g., from 1.5 to 1.5, based on the total weight of the alloy). 2.5, preferably an aluminum alloy containing Cu in the range of 1.8 to 2.2 weight percent). In certain embodiments, preferred aluminum alloys for the insert include 2000 (eg, 2036 aluminum alloy and 2618 aluminum alloy), 6000 (eg, 6061 aluminum alloy, 6063 aluminum alloy, 6101 aluminum alloy, 6151 aluminum alloy and 6201 aluminum alloy). And / or 7000 (for example, 7072 aluminum alloy) based aluminum alloys.

  In certain embodiments, preferred aluminum alloy castings around the insert include 200 (eg, 201 aluminum alloy, 203 aluminum alloy, 206 aluminum alloy and 224 aluminum alloy), 300 (eg, A356 aluminum alloy, D356 aluminum alloy, A357). Aluminum alloys and D357 aluminum alloys), 400 (eg 413 aluminum alloys and 443 aluminum alloys), 700 (eg 771 aluminum alloys) and / or 6000 (eg 6061 aluminum alloys) based aluminum alloys.

  Thicknesses outside the specified values for metals such as Cu, Au, Ni, Ag, Zn and combinations thereof are also useful, but too thin will preheat the insert and protect the interface from oxidation, Without helping to reduce oxidation, the coating tends to diffuse, and too thick tends to prevent obtaining the desired bond strength between the metal of the insert and the metal of the metal matrix composite article. Techniques for depositing metals such as Cu, Au, Ni, Ag, Zn and combinations thereof are known in the industry and include electroplating and vapor deposition techniques.

  In general, the thickness of any Ni is greater than about 1 micrometer, more typically greater than 2 micrometers. In other embodiments, the thickness of such metals is generally less than about 10 micrometers, more typically less than about 5 micrometers. Thicknesses outside these values are also useful, but if the thickness is too thin, there is no tendency to be useful in assisting adhesion of metals such as Cu, Au, Ag, Zn and combinations thereof to the insert. If it is too thick, it tends to hinder obtaining a desired bond strength between the metal of the insert and the metal of the metal composite material. In some embodiments, Ni is deposited by electroless plating deposition.

  The insert may be, for example, a mandrel having a desired size and shape for a metal insert design intended to be a plurality of ceramic oxide fibers (in some embodiments, preferably grouped (such as yarns and tows)). It can be created by wrapping. In certain embodiments, the wrapping fibers are preferably sized. Sizing includes water (in certain embodiments, preferably deionized water), wax (eg, paraffin), and polyvinyl alcohol (PVA). If the sizing is water, the fiber is typically wrapped around a mandrel. After winding, the mandrel was removed from the winder and placed in a refrigerated cooler until the wound fiber was frozen. The frozen and wrapped fiber can be cut appropriately. For example, if the fiber is wrapped around a mandrel made of four tangential plates, the rectangular plate can be removed to provide a frozen fiber preform. The preform can be cut into pieces to give a small preform. Generally, the sizing is removed prior to use to form the insert. Sizing can be removed, for example, by heating the die in a die (in certain embodiments, preferably graphite or sand), for example. The insert is formed using a die.

  To form the insert, remove the sizing, if any, and place the die in a can, preferably a stainless steel can open only at one end. The interior of the can is in some embodiments preferably coated with boron nitride or similar material to prevent reaction between the aluminum / aluminum alloy and the can during subsequent casting and / or a metal matrix. Facilitates release of composite article from mold. The can containing the die was placed inside the pressure vessel of the pressure casting machine. Subsequently, aluminum and / or an aluminum alloy (eg, a piece of aluminum and / or aluminum alloy cut from an ingot) is placed on top of the can. The pressure vessel is degassed and heated at a temperature above the melting point of the aluminum / aluminum alloy (typically about 50 ° C. to about 120 ° C. above the liquidus temperature). When the desired temperature is reached, the heater is turned off and the pressure vessel is pressurized to a pressure of about 8.5 to about 9.5 MPa, typically with argon (or a similar inert gas), to produce the molten aluminum / aluminum alloy. Infiltrate the preform. The pressure in the pressure vessel gradually attenuates as the temperature decreases. When the article solidifies (eg, when its temperature drops below about 500 ° C.), the chamber is vented and the cast metal matrix composite article (eg, insert) is removed from the die and further cooled in air.

  The insert can also be made by other techniques known in the industry including, for example, molten metal casting. For molten metal casting, for example, the formed ceramic oxide fiber is placed in a die (eg, a steel die), the existing sizing is burned, and the molten aluminum / aluminum alloy is placed in the die cavity until solidification of the cast article is complete. Apply pressure. After cooling, the resulting insert is removed from the die.

  The resulting insert can be further processed (eg, sandblasted and / or surface polished (eg, with a vertical diamond grinder)) to remove or reduce oxidation of the insert surface, for example. The insert may also be cut as appropriate to the desired shape (including water jet cutting). The insert can then be coated with a first metal, such as Cu, Au, Ni, Ag, Zn, and combinations thereof, if desired. Optionally, a second metal, such as Ni, is coated on the insert prior to coating the first metal. While not wishing to be bound by theory, it is believed that using Ni assists the adhesion of metals such as Cu and Ag to the insert.

  Certain substantially continuous ceramic oxide fibers, composites and inserts and / or process steps for producing a metal matrix composite article are selected to provide a metal matrix composite article with the desired properties. For example, to create the desired article, a substantially continuous ceramic oxide fiber and metal composite are selected that are well compatible with each other and the article manufacturing process. In certain embodiments, the metal comprising the inserts and / or regions of the metal composite material according to the present invention is a ceramic oxidation in which the metal composite material is substantially continuous, eg, to eliminate the need to provide a protective coating on the exterior of the fiber. It is preferable to select one that does not react significantly with the physical fibers (ie, is chemically inert to the molten metal).

  The metal matrix composite article according to the present invention can be cast with the insert using techniques generally known in the art (eg, gravity casting and melt casting). For example, finite element analysis (FEA) casting can be used to identify the best location and amount of ceramic oxide fibers that meet the desired performance specifications. Such an analysis can also be used, for example, to assist in selecting the size, number and position of the mold to be used. The insert and / or die may be preheated before casting. In certain embodiments, the insert is preferably preheated to about 500 ° C to 600 ° C. In certain embodiments, the die is preferably preheated to 200 ° C to 500 ° C.

  The FEA may be an aid in selecting a casting technique, casting conditions and / or mold design for casting inserts and / or metal matrix composite articles according to the present invention. Suitable FEA software is commercially available, including those sold under the trade name "PROCAST" from UES, Annapolis, MD.

  For metal matrix composite articles according to the present invention cast in air, the insert typically includes any Cu, Au, Ni, Ag, Zn, or combinations thereof. For example, for metal matrix composite articles according to the present invention cast in an atmosphere containing argon, it is usually more preferable to purge the casting atmosphere with argon one or more times before casting.

  For metal matrix composite articles that are higher than the desired amount of oxidation at the interface between the insert and the metal casting around the insert, the article is further processed using hot isostatic pressing (HIP) to remove the oxide. It may break and diffuse from the interface and become more fully wetted and / or densified. HIP technology is well known in the industry. HIP, temperature, pressure and time useful for embodiments of the present invention include 500 ° C. to 600 ° C., 25 MPa to 50 MPa, and 4 to 6 hours, respectively. Temperatures, pressures and times outside these ranges are also useful. If the temperature is lower than this, for example, the densification tends to decrease and / or the HIP time tends to be longer, and if the temperature is higher than this, the metal matrix composite article may be deformed. Lower pressures, for example, tend to reduce densification and / or increase HIP time, and higher pressures are not required, but may damage, for example, metal matrix composite articles There is a fear. If the time is shorter than this, for example, densification is reduced, and a longer time is not necessary.

  As noted above, metal matrix composite articles (including inserts) are generally designed for a specific purpose and, as a result, have specific characteristics, specific configurations, and specific materials. It is desirable that it is created with. In general, the mold is selected or made to give the desired shape of the metal matrix composite article to be cast to be net or substantially net. The net-shaped or generally net-shaped article can minimize or eliminate the need and cost of, for example, subsequent machining or other post-casting processes of the cast metal matrix composite article. In general, the mold is made or adapted to hold the insert in the desired position so that it is properly placed in a metal matrix composite article that results in a substantially continuous ceramic oxide fiber. Techniques and materials for making suitable cavities are known to those skilled in the art. The material from which the particular mold (graphite, steel and sand) is made will depend on, for example, the metal used to make the metal matrix composite article.

  Other techniques for making metal matrix composite articles will be apparent to those skilled in the art upon reviewing the present disclosure.

  The metal matrix composite article according to the present invention comprises two or more grouped (eg, two groups, three groups, etc.) substantially continuous ceramic oxide fibers, and is substantially continuous ceramic oxide. The groups of fibers are spaced apart from the other groups and hold the metal oxide substantially continuous ceramic oxide fibers in place therebetween. For example, referring to FIG. 7, the insert 90 includes substantially continuous (as aligned, longitudinally aligned) ceramic oxide fibers 92 of groups 93A, 93B, and 93C and aluminum or an alloy 94 thereof. It is out. In some embodiments, the outer surface 95 of aluminum or its alloy 94 has a first metal 96 (eg, Cu, Au, Ni, Ag, Zn, and combinations thereof) 96. Further, in some embodiments, the outer surface 97 of the second optional metal 98 has a second optional metal (eg, Ni) 98.

  Metal matrix composite articles according to the present invention may be in a variety of shapes including rods (including rods having a circular, rectangular or square cross section), I-beam, L-shape or tube. Metal matrix composite articles according to the present invention may be elongated and have a substantially constant cross-sectional area.

  In certain embodiments, the insert and metal matrix composite article according to the present invention is about 30 to about 70 volume percent (in certain embodiments) based on the total volume of the region in the region comprising substantially continuous ceramic oxide fibers. Preferably about 35 to about 60 volume percent, and further about 35 to about 45 volume percent metal, and about 70 to about 30 volume percent (in some embodiments, preferably about 65 to about 40 volume percent). About 65 to about 55 volume percent) of substantially continuous ceramic oxide fibers. In certain embodiments, preferably the insert and metal matrix composite article according to the present invention is substantially in a region comprising substantially continuous ceramic oxide fibers, based on the total volume of the region, at least on a 50 volume basis. Contains continuous ceramic oxide fibers.

  In certain embodiments, the insert is from about 30 to about 70 volume percent (in certain embodiments, preferably from about 35 to about 60 volume percent, or even from about 35 to about 45 volume percent), based on the total volume of the insert. And about 70 to about 30 volume percent (in some embodiments, preferably about 65 to about 40 volume percent, or even about 65 to about 55 volume percent) of substantially continuous ceramic oxide fibers . In certain embodiments, preferably, the insert comprises at least 50 volume-based substantially continuous ceramic oxide fibers based on the total volume of the insert.

  An embodiment of a metal matrix composite article according to the present invention does not contain oxygen at the interface between the insert or holder and the aluminum or aluminum alloy around the insert or holder as determined by the following “oxygen layer test” . Cutting a portion of the metal matrix composite article provides a cross-section of the insert or holder and the aluminum or aluminum alloy casting around the insert or holder. The section is then polished with a semi-automatic metal grinding / polishing machine (obtained under the trade name "ABRAMIN" from Struers, Inc, Cleveland, Ohio). The polishing speed is 150 rpm. Polishing is performed in the following six consecutive steps. The polishing force is 150N. However, stage 6 is 250N.

-Stage 1
Using a 120 grit silicon carbide paper (obtained from Pace Technologies, Northbrook, Ill.), The sample was run for 45 seconds while dripping water onto the polishing pad continuously and automatically during polishing. Grind. After polishing, rinse the sample thoroughly with water.

-Stage 2
A 220 grit silicon carbide paper (obtained from Pace Technologies) is used to polish the sample for 45 seconds while continuously and automatically dropping water onto the polishing pad during polishing. After polishing, rinse the sample thoroughly with water.

-Stage 3
A 600 grit silicon carbide paper (obtained from Pace Technologies) is used to polish the sample for 45 seconds while continuously and automatically dropping water onto the polishing pad during polishing. After polishing, rinse the sample thoroughly with water.

-Stage 4
The sample was polished for 4.5 minutes using a polishing pad (obtained under the trade name “DP-MOL” from Struers, Inc.), and a lubricant (“Pron DP-lubricant (PURON, (DP-LUBRICANT) ") is periodically dripped and lightly wetted, and then 6 micrometer diamond grit (" DP-SPRAY, P-6 μm "from Struers for 1 second) Spray under the trade name). After polishing, rinse the sample thoroughly with water.

-Stage 5
The sample is polished for 4.5 minutes using a polishing pad ("DP-MOL"), and a lubricant (obtained under the trade name "Puron DP-Lubricant" from Struers) Lightly wet by dripping periodically and spray with 3 micrometer diamond grit (obtained under the trade name “DP-SPRAY, P-3 μm” from Struers) for 1 second. After polishing, rinse the sample thoroughly with water.

-Stage 6
The sample is polished for 4.5 minutes using a porous synthetic polishing cloth (obtained under the trade name “OP-CHEM” from Struers), first with water hand poured onto the cloth and a colloidal silica suspension Wet with the liquid (obtained under the trade name "OP-S Suspension" from Struers). Wash the sample with water for the last 5 seconds of polishing. After polishing, the sample is dried.

  The resulting polished sample is observed with a 250 × optical microscope to confirm that a visually distinct continuous oxide layer exists between the insert or holder and the aluminum or aluminum alloy casting around the insert or holder. To do. For evaluation by this test for reference, in Example 3 (see FIG. 10) of co-pending US Patent Application No. 60 / 404,672, filed Aug. 20, 2002, the interface is visually identified. There was no continuous oxide layer applied, but it was in Comparative Example H (see FIG. 11) of the same application. Referring to FIG. 10, the polished cross section of Example 3 did not have a sharp boundary at the interface 162 between the insert composite material 166 and the cast alloy 163. Referring to FIG. 11, the polished cross section of Comparative Example H showed a steep boundary that could be considered an oxide layer at the interface 182 between the insert composite 186 and the cast alloy 183.

  Examples of metal matrix composite articles according to the present invention include brake calipers and aerospace applications (eg, electrical access doors, reinforcing structural members (eg, I-beams, stiffeners and panels) and landing gear).

  The present invention is further illustrated by the following examples, which are not intended to unduly limit the present invention to the specific materials and amounts, other conditions and details listed in these examples. Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and spirit of this invention. Unless otherwise indicated, all parts and percentages are on a mass basis.

Comparative Example A
Two aluminum composite articles (Comparative Examples A1 and A2) were made as follows. Continuous alpha alumina fiber (available under the name “NEXTEL 610” from 3M Company, St. Paul, Minn., 3000 denier, Young's modulus of about 370 GPa, average tensile strength of about A tow with 3 GPa and an average diameter of 11 micrometers was wrapped using deionized water sizing. The fiber tow was a fiber soaked in a water bath just before it was wound around a 20.3 cm (8-inch) square mandrel, and a fiber preform filled with 49.5% by volume of the fiber was prepared. The fiber was wrapped with tension (approximately 75 grams, measured by a tensiometer (obtained under the trade name “CERTEN” from Tensitron, Boulder, CO.) 8.25 cm (3 A rectangular preform plate measuring 25 inches) × 20.3 cm (8 inches) × 0.254 cm (0.1 inch thick) was formed. The mandrel was placed in a cooler to freeze the water and stabilize the resulting preform. At the time of freezing, the edge of the preform was scraped and the plate was cut into a 7.6 cm × 15.2 cm (3 inch × 6 inch) preform.

  The resulting 7.6 cm × 15.2 cm × 0.254 cm fiber preform was placed inside a graphite mold that had been coated with boron nitride. A graphite mold containing the preform was placed inside a stainless steel can open at one end. The can assembly was placed inside a cylindrical container of a conventional gas pressure caster. A piece of aluminum alloy (6061 aluminum alloy obtained from Alcoa of Pittsburgh, PA) cut from the ingot was placed on top of the can. The can was placed in a pressure vessel with a heating zone to ensure a uniform melting temperature. The pressure vessel was degassed and heated to a temperature higher than the liquidus point of the aluminum alloy (715 ° C.). When the desired temperature was reached, the heater was turned off and the pressure vessel was generally pressurized with argon to a pressure of about 9 MPa (1300 psi) to allow the molten aluminum alloy to penetrate the preform. The pressure vessel gradually attenuated as the temperature decreased. When the insert temperature was below about 500 C, the chamber was vented, the can removed from the pressure vessel, and the cast metal matrix composite article (insert plate) was removed from the can and allowed to cool in air.

  These insert plates were cut longitudinally and milled to form a finished insert having the dimensions of 0.975 cm (0.375 inch) by 15.2 cm (6 inch) by 0.254 cm (0.1 inch). .

  The surface of the finished insert was sandblasted to clean the surface and remove the oxide layer. The insert was immersed in a normal nickel sulfamate plating solution and a 1.5 A current was applied for 4.5 minutes to deposit a 1 micrometer Ni layer on the insert surface. The insert was immersed in a normal copper sulfate plating solution and a current of 4.4 A was applied for 3 minutes to deposit about 5 micrometers of Cu.

  Four copper coated inserts were placed in a sand mold. 8A and 8B, the mold 100 is shown by a solid line. The four inserts 101 are arranged in a sand mold and are indicated by phantom lines. The plate 102 defining the resulting metal matrix composite article was a rectangular prism with dimensions of 15.2 cm × 20.3 cm × 2.54 cm. The mold 100 had a sprue of 12.5 mm × 19 mm choke 106 feeding a tapered runner 108 with a width of 63 mm. The runner 108 supplies four risers 100 with a diameter of 25.4 mm, which have a blade ingate 112 with a width of 7.6 mm emanating from a riser with a diameter of 25.4 mm located above the runner 108. It was. The metal matrix composite article was cast in air by casting molten aluminum alloy D357 at 746 ° C. (1375 ° F.) into a mold in the sprue. The casting time was 7 seconds. The insert did not preheat. A chill was embedded in the sand mold to facilitate metal cooling. After solidification of the molten aluminum alloy, the resulting metal matrix composite article was removed from the sand mold and mold waste was separated from the article.

  As shown in FIG. 10, one of the four resulting metal matrix composite articles was bent until broken to give a cross-sectional fracture surface.

  One of the resulting metal matrix composite articles was sectioned, cut to a size of about 10 cm, mounted on epoxy, and a semi-automatic metal grinding / polishing machine (Struers, Inc, Cleveland, Ohio). (Abramin was obtained under the trade name of ABRAMIN). The polishing rate was 150 rpm. Polishing was performed in the following six consecutive steps. The polishing force was 150N. However, Stage 6 was 250N.

-Stage 1
Using a 120 grit silicon carbide paper (obtained from Pace Technologies, Northbrook, Ill.), The sample was run for 45 seconds while dripping water onto the polishing pad continuously and automatically during polishing. Polished. After polishing, the sample was rinsed thoroughly with water.

-Stage 2
The sample was polished for 45 minutes using 220 grit silicon carbide paper (obtained from Pace Technologies) while water was dripped continuously and automatically onto the polishing pad during polishing. After polishing, the sample was rinsed thoroughly with water.

-Stage 3
The sample was polished for 45 seconds using 600 grit silicon carbide paper (obtained from Pace Technologies) while water was dripped continuously and automatically onto the polishing pad during polishing. After polishing, the sample was rinsed thoroughly with water.

-Stage 4
The sample was polished for 4.5 minutes using a polishing pad (obtained under the trade name “DP-MOL” from Struers, Inc.), and a lubricant (“Puron DP-lubricant (PURON, (DP-LUBRICANT) ") is periodically dripped and lightly wetted, and then 6 micrometer diamond grit (" DP-SPRAY, P-6 μm "from Struers for 1 second) Sprayed under the trade name). After polishing, the sample was rinsed thoroughly with water.

-Stage 5
The sample is polished for 4.5 minutes using a polishing pad ("DP-MOL"), and a lubricant (obtained under the trade name "Puron DP-Lubricant" from Struers) It was periodically dripped and lightly wetted, and sprayed with a diamond grit of 3 micrometers (obtained under the trade name “DP-SPRAY, P-3 μm” from Struers) for 1 second. After polishing, the sample was rinsed thoroughly with water.

-Stage 6
The sample is polished for 4.5 minutes using a porous synthetic polishing cloth (obtained under the trade name “OP-CHEM” from Struers), first with water hand poured onto the cloth and a colloidal silica suspension Wet with the liquid (obtained under the trade name "OP-S suspension" from Struers). The sample was washed with water for the last 5 seconds of polishing. After polishing, the sample was dried.

  A gold layer of several angstroms was coated by sputtering gold on the polished cross section. The resulting sample is obtained from the Scanning Auger Electron (SAM) microscope (Physical Electronics Company, formerly Perkins Elmer, Eden Prairie, Minn.) Under the trade name SM600 ”. 11, the SAM micrograph shows the insert 111, interface 112 and cast aluminum alloy 113. In addition, an electronic microprobe copper wire scan was performed in a row beyond the insert, interface and cast aluminum alloy. The results are shown in Fig. 12. 121 is an insert, 122 is an interface, 123 is a cast aluminum alloy, and copper wire scan is 124.

  One of the four metal composites obtained was slit into four parts with a diamond saw, and one insert was cast for each to produce a test piece. As shown in FIGS. 9A, 9B, and 9C, each part was milled to obtain a final test piece 130. The reference number for the insert is 135. Dimension d1 is 5.08 cm (2 inches), Dimension d2 is 2.54 cm (1 inch), Dimension d3 is 0.25 cm (0.1 inch), d4 is 1 cm (0.4 inch), d5 is 0.9525 cm (0.375 inch) and d6 were nominally 0.254 cm (0.1 inch), but the area of the interface region (“interface area”) that actually supported the load was measured by measuring each sample (see FIG. 9A, 9B and 9C are marked with the reference letter “Z.” Test specimens were placed in a universal test (obtained from Instron Corporation in Canton, Mass., Model number 8500-133). Specifically, the test piece was fastened to the lower jaw of the testing machine by applying a hydraulic pressure of about 10 MPa (1.5 Ksi) (foot pedal connection sensor). The upper crosshead was lowered and the test piece was fastened with the upper jaw again using a pressure of about 10 MPa, and the load axis was well positioned with the test piece bonding surface. Care was taken to match the specimens, the specimens were pulled at a rate of 0.017 mm / sec, and both displacement and load (“load”) were recorded to the point where the interface was completely separated. The “load” was determined by dividing by “interface area.” The results of Examples 1a and 1b are shown in Table 1 below.

Comparative Example B
Three other metal matrix composite articles (Comparative Examples B1, B2 and B3) were applied to Example 1 except that the copper plating was performed for 8 minutes and the resulting Cu coating thickness was about 20 micrometers. Prepared as described. The bond strength of each comparative example B1, B2 and B3 is shown in Table 1 above along with the Cu thickness.

Comparative Example C
Four Comparative Example A (ie, Comparative Examples C1, C2, C3 and C4) metal matrix composite articles were as described in Comparative Example A, except that the insert was not sandblasted and provided no Ni or Cu coating. Created. The bond strength of each of the comparative examples C1, C2, C3 and C4 is shown in Table 1 above.

  One of the four resulting metal matrix composite articles was sectioned, polished and observed with SAM as described in Comparative Example A. Referring to FIG. 13, the SAM micrograph shows the insert 131, the interface 132 and the cast aluminum alloy 133. Furthermore, as shown in FIG. 14, an electronic microprobe oxygen beam scan was performed in a row beyond the insert 131, the interface 132 and the cast aluminum alloy 133. Reference numeral 145 denotes an oxygen beam scan. A sharp oxide peak (possibly aluminum oxide) about 3 micrometers wide was thought to prevent bonding between the insert and the cast aluminum alloy.

  One of the four resulting metal matrix composite articles was placed in a conventional x-ray radiograph. The article was placed on a turntable inside the machine chamber and placed in the center of the x-ray beam path. An unexposed x-ray film (medium speed film obtained from Eastman Kodak Company, Rochester, NY) inside the protective frame was placed behind the article. When the x-ray source was turned on and the article was exposed to 90 KV, 3.5 amps for about 3-5 minutes (ASTM standard E-94-88), a film density of about 3 was obtained. The exposed film was processed using conventional techniques. The print is shown in FIG. 151 is an insert, and 153 is a cast aluminum alloy. Detachment between the insert 151 and the cast aluminum alloy 153 is clearly seen.

Example 1
Eight Example 1 (Examples 1a, 1b, 1c, 1d, 1e, 1f, 1g, and 1h) metal matrix composite articles were not provided with Ni or Cu coating, and the mold was argon gas (ie, argon was mold) For about 15 minutes) and was prepared as described in Comparative Example A. The bond strengths for each Example 1a, 1b, 1c, 1d, 1e, 1f, 1g and 1h are shown in Table 1 above.

  One of the four resulting metal matrix composite articles was x-ray irradiated as described in Comparative Example C. As shown in FIG. 16, 161 is an insert, and 163 is a cast aluminum alloy. Compared to FIG. 15, there was no interfacial peeling in FIG. This indicates that the insert 161 and the cast aluminum alloy 163 are completely bonded.

  One of the four resulting metal matrix composite articles was sectioned and polished as described in Comparative Example A. The polished cross section was coated with several angstroms of gold as described in Comparative Example A. The resulting sample was observed with a scanning electron microscope (SEM) (obtained from Physical Electronics, Eden Prairie, Minn., Model 600). Referring to FIG. 17, the optical micrograph shows the insert 171 and the cast aluminum alloy 173.

  One of the four resulting metal matrix composite articles was sectioned, polished and observed with SAM as described in Comparative Example A. In addition, electronic microprobe oxygen beam scans were performed in rows across the insert, interface and cast aluminum alloy. Referring to FIG. 18, the SAM micrograph shows an insert 181, an interface 182, a cast aluminum alloy 183, and an oxygen beam scan 185.

Example 2
Two metal matrix composite articles (Examples 2a and 2b) were prepared as described in Comparative Example A, except that the article was further processed by hot isostatic pressing. The article was hot hydraulic compression molded in argon at about 1010 ° F. (543 ° C.) and a pressure of about 34.5 MPa (5.0 Ksi) for about 4 hours. The bond strength of each Example 2a and 2b is shown in Table 1 above along with the Cu thickness.

Example 3
Two metal matrix composite articles (Examples 3a and 3b) were prepared as described in Example 2 except that they were further processed by hot isostatic pressing as described in Example 3. The bond strength of each Example 3a and 3b is shown in the table above along with the Cu thickness.

  As shown in FIG. 19, one of the four resulting metal matrix composite articles was bent until broken to give a cross-sectional fracture surface.

Example 4
Eight metal matrix composite articles (Examples 4a, 4b, 4c, 4d, 4e, 4f, 4g and 4h) were prepared as described in Example 3 and test pieces machined from these articles. Tested as described in Comparative Example A, except that the thickness d4 dimension was 5 mm (0.2 inch). The bond strength of each Example 4a, 4b, 4c, 4d, 4e, 4f, 4g and 4h is shown in Table 2 below along with the Cu thickness.

  One of the four resulting metal matrix composite articles was sectioned, polished and observed with SAM as described in Comparative Example A. In addition, electronic microprobe oxygen beam scans were performed in rows across the insert, interface and cast aluminum alloy. Referring to FIG. 20, the SAM micrograph shows the insert 201, interface 202, cast aluminum alloy 203 and oxygen beam scan 205.

  Various modifications and alterations of this invention will be apparent to those skilled in the art without departing from the scope and purpose of this invention, and this invention is not unduly limited to the illustrative embodiments defined herein. Conceivable.

1 is a perspective view of an illustrative (metal composite) insert for making an embodiment of a metal matrix composite article according to the present invention. FIG. 1 is a perspective view of an illustrative (metal composite) insert for making an embodiment of a metal matrix composite article according to the present invention. FIG. 1 is a perspective view of an illustrative (metal composite) insert for making an embodiment of a metal matrix composite article according to the present invention. FIG. FIG. 4 is a perspective view of an illustrative metal matrix composite article made from the (metal composite) insert shown in FIG. 3. 1 is a perspective view of an illustrative (metal composite) insert for making an embodiment of a metal matrix composite article according to the present invention. FIG. 1 is a perspective view of an illustrative (metal composite) insert for making an embodiment of a metal matrix composite article according to the present invention. FIG. 1 is a perspective view of an illustrative (metal composite) insert for making an embodiment of a metal matrix composite article according to the present invention. FIG. It is a schematic side view and a plan view of a sand mold casting mold assembly used in an example. It is a schematic upper surface, a side surface, and an end view of a test piece. 4 is an optical micrograph of about 4 times the fracture surface of the metal matrix composite article of Comparative Example A. 2 is a scanning Auger electron (SAM) micrograph of a cross section of a metal matrix composite article of Comparative Example A. 2 is a scanning Auger electron (SAM) micrograph and an electronic microprobe copper wire scan of a cross section of a metal matrix composite article of Comparative Example A. 2 is a scanning Auger electron (SAM) micrograph of a cross section of a metal matrix composite article of Comparative Example C. FIG. 6 is a scanning Auger electron microprobe oxygen beam scan of a cross section of the metal matrix composite article of Comparative Example C. FIG. 2 is a micrograph of an x-ray radiograph of a metal matrix composite article of Comparative Example C. 2 is a micrograph of an x-ray radiograph of the metal matrix composite article of Example 1. FIG. 2 is an optical micrograph of 20 times the cross section of the metal matrix composite article of Example 1. FIG. 2 is a scanning Auger electron (SAM) micrograph and electronic microprobe copper wire scan of a cross section of the metal matrix composite article of Example 1. 4 is an optical micrograph of about 4 times the fracture surface of the metal matrix composite article of Example 4. FIG. 4 is a scanning Auger electron (SAM) micrograph and electronic microprobe copper wire scan of a cross section of the metal matrix composite article of Example 4.

Claims (27)

  A ceramic oxide comprising a first metal and an insert for reinforcing the first metal, wherein the first metal is selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the insert is substantially continuous. Including a fiber and a second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the second metal secures the substantially continuous ceramic oxide fiber in place; The second metal extends along at least a portion of the length of the substantially continuous ceramic oxide fiber, and there is an interface layer between the first metal and the insert; A metal matrix composite article, wherein the interfacial layer peak bond strength value between one metal and the insert is at least 100 MPa.   The metal matrix composite article of claim 1, wherein the substantially continuous ceramic oxide fibers are aligned in the longitudinal direction.   The metal matrix composite article according to claim 1, wherein the interface layer peak bond strength value between the first metal and the insert is at least 150 MPa.   The metal matrix composite article according to claim 1, wherein the interface layer peak bond strength value between the first metal and the insert determined in Comparative Example A is at least 150 MPa.   The metal matrix composite article according to claim 1, wherein the interface layer peak bond strength value between the first metal and the insert determined in Example 4 is at least 150 MPa.   The metal matrix composite article of claim 1, wherein the interface layer peak bond strength value between the first metal and the insert is at least 200 MPa.   The metal matrix composite article according to claim 1, wherein the interfacial layer peak bond strength value between the first metal and the insert determined in Comparative Example A is at least 200 MPa.   The metal matrix composite article according to claim 1, wherein the interfacial layer peak bond strength value between the first metal and the insert determined in Example 4 is at least 200 MPa.   The metal matrix composite article of claim 1, wherein the substantially continuous ceramic oxide fibers are polycrystalline alpha alumina fibers. Wherein the average tensile strength of at least 2.8GPa polycrystalline alpha alumina fibers, the polycrystalline alpha alumina fibers, on a theoretical oxide basis, greater than about 99 weight percent based on the total weight of the alumina fibers Al ₂ and O _3, and a SiO ₂ of about 0.2 to 0.5 weight percent, of claim 9 average grain size of the alpha alumina present in the polycrystalline alpha alumina fibers in less than 1 micrometer Metal matrix composite article.   The metal matrix composite article of claim 9, wherein the alpha alumina fibers are at least 50 volume percent of the total volume of the metal matrix composite article.   The metal matrix composite article of claim 1, wherein the substantially continuous ceramic oxide fiber is at least 50 volume percent of the total volume of the metal matrix composite article.   The metal matrix composite article of claim 1, wherein the first metal is an aluminum alloy comprising at least 1.5 weight percent Cu based on the total weight of the aluminum alloy.   The metal matrix composite article according to claim 1, wherein the first metal is an aluminum alloy comprising Cu in a range of 1.5 to 2.5 weight percent based on the total weight of the aluminum alloy.   The metal matrix composite article of claim 1, wherein the first metal is an aluminum alloy comprising Cu in a range of 1.8 to 2.2 weight percent based on the total weight of the aluminum alloy.   The metal matrix composite article of claim 1, wherein the first metal is a 6061 aluminum alloy.   The metal matrix composite article according to claim 16, wherein the second metal is one of 200, 300, 400, or 700 series aluminum alloy. Placing an insert in a mold comprising a substantially continuous ceramic oxide fiber and a first metal selected from the group consisting of aluminum, alloys thereof and combinations thereof, wherein the first metal is the Securing substantially continuous ceramic oxide fibers in place, wherein the first metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers; A first metal having an outer surface, Cu on the outer surface of the first metal, and a thickness of the second metal of at least 5 micrometers;
Providing the mold with a molten third metal selected from the group consisting of aluminum, alloys thereof and combinations thereof;
Cooling the molten third metal to provide an article;
A method for producing a metal matrix composite article comprising: hot isostatic pressing the article to provide a metal matrix composite article according to claim 1.   The method of claim 18, wherein the thickness of the second metal is at least 15 micrometers.   The method of claim 18, wherein the thickness of the second metal is at least 20 micrometers. Placing an insert in a mold comprising a substantially continuous ceramic oxide fiber and a first metal selected from the group consisting of aluminum, alloys thereof and combinations thereof, wherein the first metal is the Securing substantially continuous ceramic oxide fibers in place, and wherein the first metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers; ,
Providing the mold with a molten third metal selected from the group consisting of aluminum, alloys thereof and combinations thereof, comprising at least 90% by volume Ar and 10% by volume or less O ₂ in total atmosphere. Providing an atmosphere containing based on volume to provide the molten third metal to the mold under the atmosphere;
Cooling the molten third metal to provide a metal matrix composite article according to claim 1.   The method of claim 21, wherein the substantially continuous ceramic oxide fiber is polycrystalline alpha alumina fiber. Wherein the average tensile strength of at least 2.8GPa polycrystalline alpha alumina fibers, the polycrystalline alpha alumina fibers, on a theoretical oxide basis, greater than about 99 weight percent based on the total weight of the alumina fibers Al ₂ and O _3, and a SiO ₂ of about 0.2 to 0.5 weight percent, of claim 22 average crystal grain size of the alpha alumina present in the polycrystalline alpha alumina fibers in less than 1 micrometer Method.   23. The method of claim 22, wherein the alpha alumina fiber is at least 50 volume percent of the total volume of the metal matrix composite article.   The method of claim 21, wherein the third metal is an aluminum alloy comprising Cu in a range of 1.5 to 2.5 weight percent based on the total weight of the aluminum alloy.   The method of claim 21, wherein the third metal is a 6061 aluminum alloy. Placing an insert in a mold comprising a substantially continuous ceramic oxide fiber and a first metal selected from the group consisting of aluminum, alloys thereof and combinations thereof, wherein the first metal is the Securing substantially continuous ceramic oxide fibers in place, and wherein the first metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers; ,
Providing the mold with a molten third metal selected from the group consisting of aluminum, alloys thereof and combinations thereof, comprising at least 90% by volume Ar and 10% by volume or less O ₂ in total atmosphere. Providing an atmosphere containing based on volume to provide the molten third metal to the mold under the atmosphere;
Cooling the molten third metal to provide an article;
A method for producing a metal matrix composite article comprising: hot isostatic pressing the article to provide a metal matrix composite article according to claim 1.

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