RU2080964C1 - Method of making composite material with metallic matrix and composite material made according such method - Google Patents

Abstract

FIELD: composite materials. SUBSTANCE: impregnation intensifier and(or) initial component of said impregnation intensifier and(or) impregnating medium are connected with filling material or with pressing at least in some point during the process. That is why there is possibility for melt base metal to spontaneously impregnate said filling material or pressing. Such spontaneous impregnation occurs without pressure or vacuum. EFFECT: enhanced efficiency. 5 cl, 16 dwg, 11 tbl

Description

 The invention relates to a new method for forming composite bodies with a metal matrix. In particular, the impregnation enhancer and / or the starting material of the impregnation enhancer and / or the impregnation atmosphere communicate with the filler material or preformed blank, hereinafter referred to as prepress, at least in some area during the process, which makes it possible to melt the matrix metal for the purpose of spontaneous impregnation filler material or prepress. Such spontaneous impregnation occurs without the need for any pressure or vacuum.

 Composite products containing a metal matrix and a reinforcing or reinforcing phase, such as ceramic particulates, whiskers, fibers, and the like, are promising for a variety of applications since they combine something from the stiffness and wear resistance of the reinforcing phase with the strength of the metal matrix . Basically, a composite with a metal matrix will demonstrate an improvement in such properties as strength, stiffness, contact wear resistance, coefficient of thermal expansion (KTR), density, thermal conductivity, and preservation of strength at elevated temperatures with respect to the base metal in a monolithic form, but the degree to which any given property can be improved, it depends largely on the specific components, their volumetric or weight fraction, and on how they are processed during the molding of the composite. In some cases, the composite may also be lighter in weight than the base metal itself. Of interest are composites with an aluminum matrix reinforced with ceramic materials, such as silicon carbide in the form of small particles, flakes or whiskers, for example, because of their higher specific stiffness (for example, the elastic modulus with respect to density), wear resistance, thermal conductivity, low coefficient of thermal expansion (CTE) and strength at high temperatures and / or specific strength (for example, strength versus density) in relation to aluminum.

 To date, various metallurgical processes for the manufacture of aluminum matrix composites have been described, including methods based on powder metallurgy technology and liquid metal impregnation technologies that use injection molding, vacuum casting, mixing and wetting. By powder metallurgy technology, a metal in the form of a powder and a reinforcing material in the form of a powder, whiskers, sparse fibers and the like are mixed and then either cold pressed and sintered or hot pressed. It was reported that composites with an aluminum matrix reinforced with silicon carbide, which were obtained by this method, had a maximum volume fraction of ceramic material of about 25 vol. in the case of whiskers and about 40 vol. in case of small particles.

 The production of metal matrix composites by powder metallurgy using known processes imposes certain restrictions on the characteristics of the resulting product. The volume fraction of the ceramic phase in the composite is usually limited, for example, in the case of fine particles, up to 40. The pressing operation also imposes restrictions on the practically achievable size. Only relatively simple forms of the product are possible without further processing (for example, molding or machining) or without the use of complex processes. During sintering, uneven shrinkage can also occur, as well as heterogeneity of the structure caused by segregation in the compacts and grain growth.

 A known method of forming a composite with a metal matrix containing fibrous reinforcing material, for example silicon carbide or alumina in the form of whiskers having predetermined fiber orientation patterns (see US Patent N 3.970.136, CL B 22 D 19/02, 1976). The composite is obtained by laying parallel mats or felt of planar fibers in a mold with a reservoir of molten base metal, for example between at least several of the mats, and applying pressure in order to impregnate the mats with molten metal and surround them with oriented fibers. Molten metal can be drained onto the stack of mats while passing it under pressure between the mats. It was reported that in the composite, the loading or filling of reinforcing fibers reached 50 vol.

 The above-described method of impregnation in the form of its dependence on external pressure for forcing the molten base metal towards the fibrous mats is exposed to the vicissitudes caused by the pressure of technological processes, i.e., possible heterogeneity of matrix formation, porosity and the like. The heterogeneity of the properties is possible even though the molten metal can be introduced at many places in the fibrous structure. Therefore, in order to achieve adequate and uniform penetration of fiber mats into the foot, it is necessary to provide complex structures for the location of mats and the tank, as well as flow paths. The mentioned method of pressure impregnation also makes it possible to provide only a relatively low content of reinforcing material with respect to the volume fraction of the matrix, which should be achieved due to the difficulty inherent in the impregnation of larger mats. In addition, molds are needed to maintain molten metal under pressure, which increases the cost of the process. Finally, the above method, limited by impregnating the aligned particles or fibers, is not aimed at forming composites with an aluminum metal matrix reinforced with materials in the form of randomly oriented particles, whiskers or fibers.

 In the manufacture of composites with an aluminum matrix filled with alumina (aluminum oxide), aluminum does not so easily moisten alumina, thereby complicating the formation of a coherent product. Various technical solutions to this problem have been proposed. One of them is the coating of alumina with a metal, for example nickel or tungsten, which is then subjected to hot pressing together with aluminum. In another method, aluminum is alloyed with lithium, and alumina may be coated with silica. However, these composites show changes in properties, or coatings can destroy the filler, or the matrix contains lithium, which can adversely affect the properties of the matrix.

There is a method in which some difficulties in the field of technology that are encountered in the production of composites with an aluminum matrix reinforced with alumina are eliminated (see US Patent N 4,232.091, CL B 22 B 15/04). This patent describes the use of pressures in the range of 75-375 kg / cm ² to form molten aluminum (or molten aluminum alloy) into an alumina mat of fibers or whiskers, which is preheated to 700-1050 ^o C. The maximum volumetric ratio between alumina and the metal in the resulting solid casting was 0.25 1. Due to the dependence of the impregnation achievement on external pressure, this method is subject to many of the same drawbacks as the Kennel method and others.

It is known to obtain composites based on aluminum-alumina, especially useful as components of electrolytic cells, by filling voids in a preformed matrix of alumina with molten aluminum (see European patent application N 115.742). This application emphasizes the non-wettability of alumina with aluminum, therefore, different methods are used to wet alumina throughout the pre-compression. For example, alumina is coated with a wetting agent on titanium, zirconium, hafnium or niobium diboride, or a metal, for example lithium, magnesium, calcium, titanium, chromium, iron, cobalt, nickel, zirconium or hafnium. Inert atmospheres such as argon are used to facilitate wetting. This application also describes the use of pressure to induce molten aluminum to penetrate an uncoated matrix. In this regard, impregnation is achieved by vacuumizing the pores, and then applying pressure to the molten aluminum in an inert atmosphere, such as argon. Alternatively, the prepress can be impregnated by vapor deposition to wet the surface before filling the voids by impregnation with molten aluminum. To ensure guaranteed retention of aluminum in the pores of the prepress, heat treatment is necessary, for example, at a temperature of 1400 1800 ^o C either in vacuum or in argon. Otherwise, either the action of gas on the material impregnated under pressure or the removal of the impregnation pressure will cause aluminum loss from the body of the product.

 It is also known to use wetting agents for impregnating an alumina component in a molten metal electrolyzer (see European Patent Application No. 94353). This application describes the production of aluminum by electrolytic separation using an electrolytic cell containing a cathode current feeder in the form of a plate or base of an electrolytic cell. To protect this base from molten cryolite before turning on the electrolytic cell or while it is immersed in molten aluminum obtained as a result of the electrolytic process, a thin layer of a mixture of a wetting agent and a solubility suppressant is applied to the base from alumina. As wetting agents, titanium, zirconium, hafnium, silicon, magnesium, vanadium, chromium, niobium or calcium are mentioned in this application; titanium is mentioned as the preferred substance. As compounds useful for the solubility pressure of wetting agents in molten aluminum, boron, carbon and nitrogen compounds are mentioned. However, this source does not propose the preparation of metal matrix composites and does not propose the formation of such composites, for example, in a nitrogen atmosphere.

In addition to using pressure and a wetting agent, it has also been published that the applied vacuum will help penetrate molten aluminum into a porous ceramic dense mass. For example, it is known to impregnate a ceramic dense mass (e.g., boron carbide, aluminum oxide and beryllium oxide) or molten aluminum, beryllium, magnesium, titanium, vanadium, nickel or chromium under a vacuum of less than 10 ^-6 Torr (see US Patent N 3,718,441 , CL B 44 D 1/02, 1973). A vacuum of 10 ^-2 10 ^-6 Torr led to poor wetting of the ceramic material by molten metal to the extent that the metal did not freely enter the voids present in the ceramic material. However, it was indicated that wetting improves when the vacuum drops to less than 10 ^-6 Torr.

It is also known to use a vacuum to achieve impregnation (see US Patent No. 3.864.154, class C O3 C 17/00, 1975). This patent describes loading a dense mass of cold pressed AlB ₁₂ powder onto a layer of aluminum cold pressed powder. Additional aluminum is then applied over a compacted AlB ₁₂ powder. A crucible filled with a compacted AlB ₁₂ “sandwich-like” between layers of aluminum powder was placed in a vacuum oven. For degassing, a vacuum of up to about 10 ^-5 Torr was created in the furnace. The temperature was further increased to 1100 ^° C. and maintained for 3 hours. Under these conditions, molten aluminum impregnated the porous compacted mass AlB ₁₂ .

 The known concept of creating a self-generated vacuum in the body to improve the penetration of molten metal into the body (see US Patent N 3.364.976, 1968). In particular, it is described that a body, for example a graphite mold, a steel mold or a porous refractory material, is completely immersed in molten metal. In the case of the mold, the mold cavity filled with gas interacting with the metal communicates with the molten metal externally through at least one opening in the mold. When the mold is immersed in the melt, filling of the cavity occurs when a self-generated vacuum is formed between the gas in the cavity and the molten metal. In particular, vacuum is the result of the formation of a solid oxidized metal phase. Thus, this patent describes what is essential to initiate the reaction between the gas contained in the cavity and the molten metal. However, the use of the mold to create a vacuum may be undesirable due to the characteristic limitations associated with the use of the mold, since the latter must be given a special shape by machining, and then machined to obtain an acceptable casting surface in the mold, after which assembly before use, and then disassembly after use to extract the molded product from it; after that, the mold is repaired, which is most likely expressed in repeated finishing of the surfaces of the mold or rejection of the mold if it is no longer suitable for use. Machining molds of complex configuration can be very expensive and time consuming. In addition, extracting the molded part from the mold of complex configuration can also be difficult (i.e., molded parts of complex configuration may be damaged during removal from the mold). And yet, although it is indicated that the porous refractory material can be immersed directly in the molten metal without the need for a mold, the refractory material should be a monolithic piece, because there are no reports of impregnation of loose or separate porous material in the absence of using a containing mold (i.e., in general it is believed that the particulate material will typically dissociate or diffuse upon placement onto molten metal). In addition, if it is necessary to impregnate a powdery material or a loosely formed preform, care must be taken to ensure that the impregnating metal does not move at least portions of the particulate or preform, resulting in a heterogeneous microstructure.

 Accordingly, there has long been a need for a simple and reliable method for the production of formed composites with a metal matrix, which is not based on the use of pressure or vacuum (applied externally or internally), or would not destroy the wetting agents used to form a metal matrix that absorbs another material like ceramic material. In addition, there has also long been a need to reduce the number of final mechanical treatments associated with the production of a composite body with a metal matrix.

 The invention satisfies these needs by creating a spontaneous impregnation mechanism for impregnating a material, for example ceramic, which can be molded into prepress, with molten base metal, for example aluminum, in the presence of an impregnating atmosphere, for example nitrogen, at normal atmospheric pressures, provided that the initial component of the impregnation amplifier present at least at some point during the process.

 The subject matter relates to the subject matter of several other pending and jointly owned patent applications. In particular, these patent applications describe new methods for producing composite materials with a metal matrix (hereinafter sometimes referred to as "Commonly Owned Patent Applications for Metal Matrices").

A new method is known for producing a composite material with a metal matrix (see US Pat. No. 4.823.008, 1989), according to which a composite with a metal matrix is obtained by impregnating a permeable mass of filler material, for example, ceramic or coated with ceramic, with molten aluminum containing at least 1 wt. magnesium, preferably not less than 3 wt. magnesium. Impregnation proceeds spontaneously without the use of external pressure or vacuum. The supply of the molten metal alloy is brought into contact with the mass of filler material at a temperature of at least 675 ^° C. in the presence of a gas containing 10 100 and preferably at least 50 nitrogen by volume, and the remaining gas, if present, is a non-oxidizing gas, for example argon. Under these conditions, the molten aluminum alloy impregnates the ceramic mass under normal atmospheric pressure, forming a composite with an aluminum matrix or an aluminum alloy matrix. After the required amount of filler material has been impregnated with the molten aluminum alloy, the temperature is lowered to cure the alloy to form a strong metal matrix structure that contains a reinforcing filler material. Typically and preferably, a feed of molten alloy will be sufficient to saturate substantially to the bulk boundaries of the filler material. The amount of filler in the aluminum matrix composites prepared according to this patent can be very high. In this regard, volumetric ratios between the filler and the alloy above 1 1 can be achieved.

 Under the conditions of this method, aluminum nitride can form a discontinuous phase dispersed in an aluminum matrix. The amount of nitride in the aluminum matrix may vary depending on factors such as temperature, alloy composition, gas composition and filler material. Thus, by controlling one or more factors in the system, certain properties can be imparted to the composite. However, for some targeted applications it may be necessary for the composite to contain little or no aluminum nitride.

 It is noted that higher temperatures promote impregnation, but make the process more active in relation to the formation of nitride. In this known method, it is possible to choose a balance between the kinetics of impregnation and the formation of nitride.

 An example of an appropriate barrier agent for use in the formation of a composite with a metal matrix is known (see US Patent Application No. 141.642, 1988). According to this method, a barrier agent, for example, particle-like titanium diboride or graphite material, such as flexible graphite foil manufactured by Union Carbide and sold under the trademark Grafoil, is placed on a specific surface boundary of the filler and the main alloy is impregnated to the boundary defined by the barrier agent. A barrier agent is used to inhibit, prevent, or stop impregnation of the molten alloy, thereby providing pure or nearly pure forms in the resulting composite with a metal matrix. Correspondingly formed composite bodies with a metal matrix have an external shape, which essentially corresponds to the internal shape of the barrier means.

 The method (see US Patent Application No. 049.171) was improved by the US patent application of common ownership and at the same time pending N 168.284, filed March 15, 1988 and entitled "Composites with a metal matrix and methods for their preparation." In accordance with the methods described in this US patent application, a base metal alloy is present as a first metal source and as a reservoir of a base metal alloy that communicates with the first source of molten metal by virtue of, for example, gravitational flow. In particular, under the conditions described in this patent application, the first source of molten base alloy begins to impregnate the filler mass at normal atmospheric pressures and thereby begins to form a composite with a metal matrix. The first source of molten base metal alloy is consumed during its impregnation in the filler mass and, if necessary, can be replenished preferably continuously from the pool of molten base metal when spontaneous impregnation continues. When the required amount of permeable filler was spontaneously impregnated with the molten base alloy, the temperature is lowered for curing, resulting in a solid structure with a metal matrix that encloses a reinforcing filler material. It should be understood that the use of a metal reservoir is simply one embodiment of the invention described in this patent application, and it is not necessary to combine the reservoir variant with each alternative embodiment of the invention described herein, some of which may be beneficial to use in combination with this invention.

 The metal reservoir may be present in such an amount that it provides a sufficient amount of metal to impregnate the permeable mass of the filler to a predetermined degree. Alternatively, a possible barrier means may come into contact with the permeable mass of the filler on at least one side thereof to limit the surface interface.

 In addition, while the supply of molten base alloy feed must be at least sufficient to allow spontaneous impregnation and substantially reach the boundaries (e.g., barriers) of the permeable mass of the filler, the amount of alloy present in the reservoir may exceed such a sufficient amount that there will be not only a sufficient amount of alloy for complete impregnation, but an excess molten base alloy can remain and can be attached to a composite body with a metal matrix s. Thus, when excess molten alloy takes place, the resulting body will be a complex composite body (e.g., macro composite) in which the impregnated ceramic body having a metal matrix is directly bonded to the excess metal remaining in the reservoir.

 In each of the above (in common ownership) patent applications for a metal matrix, methods for producing composite bodies with a metal matrix and new composite bodies with a metal matrix obtained using them are described. All technical solutions in all the aforementioned (in common ownership) patent applications for a metal matrix are specifically included in this application as prototypes.

 A composite body with a metal matrix is obtained by spontaneous impregnation of a permeable mass of filler or prepressing with molten base metal. In particular, the impregnation amplifier and / or the initial component of the impregnation amplifier and / or the impregnating atmosphere communicate with the filler or prepress at least at some point during the process, which allows the base metal to spontaneously impregnate the filler or prepress.

 In a first preferred embodiment, the starting component of the impregnation amplifier can be introduced at least into the filler or prepress and / or base metal and / or the impregnating atmosphere. The input component of the impregnation amplifier may then react at least with either the filler and / or prepress and / or the base metal and / or the impregnating atmosphere to form an impregnation amplifier from the initial component (precursor of the amplifier) at least in part of the filler or prepress or on them. At least during spontaneous impregnation, the impregnation amplifier must be in contact with at least part of the filler or prepress.

 In another preferred embodiment of the invention, instead of supplying the initial component of the impregnation enhancer, the impregnation enhancer can be fed directly to at least one of: either prepress and / or base metal and / or the impregnating atmosphere. Finally, at least during spontaneous impregnation, the impregnation amplifier must be in contact with at least part of the filler or prepress.

 In this description, various examples of base metals are given which at some point during the formation of the composite with a metal matrix are in contact with the starting component of the impregnation amplifier in the presence of an impregnating atmosphere. Thus, reference will be made to specific base metal systems / precursor of the impregnation amplifier / impregnation atmosphere, which show spontaneous impregnation. However, it is believed that many other base metal / impregnation amplifier precursor / impregnation atmosphere systems other than those described in this invention may behave similarly to the systems described above. Specifically, the phenomenon of spontaneous impregnation can be observed in the aluminum / magnesium / nitrogen system, the aluminum / strontium / nitrogen system, the aluminum / zinc / oxygen system, the aluminum / calcium / nitrogen system. Accordingly, even if only those systems that are mentioned above are given in this description, it should be understood that other base metal systems / impregnation amplifier precursor / impregnating atmosphere can behave similarly.

 In a preferred embodiment, in order to achieve spontaneous impregnation into the permeable mass of the filler or prepress, the molten base metal is brought into contact with the prepress or filler material. The prepress or filler may be mixed there and / or at some other point during the process, where interaction with the initial component of the impregnation amplifier occurs. In addition, in a preferred embodiment, the molten base metal and / or prepress or filler is in contact with the impregnating atmosphere for at least part of the process. In another preferred embodiment, the base metal and / or prepress or filler is in contact with the impregnating atmosphere substantially throughout the process. The prepress or filler will be spontaneously impregnated with the molten base metal and the size or degree of spontaneous impregnation and the formation of the composite with a metal matrix will vary under a given set of operating conditions, including, for example, the concentration of the precursor of the impregnation amplifier intended for the system (for example, in molten base metal and / or filler or prepress and / or impregnating atmosphere), the size and / or composition of the filler material, the size and / or composition of the particles in prepress, possible porosity for impregnation in prepress or filler, time allowed for impregnation and / or temperature at which impregnation occurs. Spontaneous impregnation usually occurs to a sufficient extent to essentially completely cover the pre-compression or filler.

 In addition, by changing the composition of the base metal and / or the processing conditions, the physical and mechanical properties of the molded composite bodies with a metal matrix can be adapted to any specific application or need. Subsequently, the formed composite body with a metal matrix is subjected to further processing (for example, directional solidification, heat treatment, etc.), the mechanical and / or physical properties can be further adapted in accordance with the requirements of a particular application or due to necessity. Also, by controlling the processing conditions during the formation of the composite with a metal matrix, the nitrogen content in the formed composite with a metal matrix can be adapted in accordance with the requirements of a wide range of industrial applications.

 In addition, by controlling the composition and / or size (e.g., particle diameter) and / or geometry of the filler material or material containing the prepress, the physical and / or mechanical properties of the formed metal matrix composite can be controlled and adapted to meet any number of industrial requirements. For example, it was found that the wear resistance of a composite with a metal matrix can be increased by increasing the size of the filler material, for example, by increasing the average particle diameter of the filler material, provided that the wear resistance of the filler material is higher than that of the base metal. However, strength and / or toughness may tend to increase with decreasing filler size. The coefficient of thermal expansion of the composite with a metal matrix can decrease with increasing loading of the filler, provided that the coefficient of thermal expansion of the filler is lower than the coefficient of thermal expansion of the base metal. In addition, the mechanical and / or physical properties (for example, density, elastic modulus and / or specific elastic modulus, strength and / or specific strength, etc.) of the formed composite body with a metal matrix can adapt depending on the loading of the filler material in loose mass or prepress. For example, by creating a loose mass or prepress containing a mixture of filler particles of different sizes and shapes, in which the filler density is higher than that of the base metal, higher loading of the filler can be achieved due to the enhanced packing of the filler material, which leads to the formation of a composite body with a metal high density matrix. By using the technical solutions according to the invention, the volume percentage of the filler material or prepress that is impregnated can vary over a wide range. The lower volume percent of the filler that can be impregnated is mainly limited by the ability to form a porous filler material or preform (for example, about 10 vol.), While the upper volume percent of the filler or prepress that can be impregnated is mainly limited by the ability to form a dense filler material or prepress with at least partially interconnected porosity (for example, about 95 vol.). Accordingly, by implementing the above technical solutions, individually or in combination, it is possible to adjust the composite with a metal matrix so that it contains the desired combination of properties.

 The term “Aluminum” as used herein means and includes substantially pure metal (eg, relatively pure unalloyed aluminum commercially available from the industry) or other metal grades and metal alloys, such as commercially available metals having impurities and / or alloying additives, such like iron, silicon, copper, magnesium, manganese, chromium, zinc, etc. An aluminum alloy for the purposes of this definition is an alloy or intermetallic compound in which aluminum is the predominant component.

 A “non-oxidizing gas balance," as used herein, means that any gas present in addition to the base gas constituting the impregnating atmosphere is either an inert gas or a reducing gas that does not substantially react with the base metal under the process conditions. Any oxidizing gas that may be present as an impurity in the gas (s) used must be insufficient to oxidize the base metal to any significant extent under the process conditions.

 "Barrier" or "barrier means", as used here, means any suitable means that interferes, prevents, prevents or stops the migration, movement or the like of molten base metal beyond the surface boundary of the permeable mass of filler or prepress, where such a surface boundary is defined barrier tool. The corresponding barrier means can be any such materials, compounds, elements, compositions, and the like, which undergo the integrity of the process and essentially do not evaporate (i.e., the barrier material does not volatilize to such an extent that it becomes unable to function as a barrier) .

 Suitable "barrier agents" include materials that are not substantially wetted by the migrating molten base metal under process conditions. A barrier of this type exhibits a substantially small agent or does not manifest it at all with the molten base metal, and movement beyond a certain surface boundary of the mass of the filler or prepress is prevented or inhibited by the barrier agent. The barrier reduces any finishing or grinding that may be required and defines at least a portion of the surface of the resulting metal matrix composite. The barrier may in some cases be permeable or porous, or become permeable, for example by drilling holes or punching holes in the barrier to allow the gas to come into contact with the molten base metal, etc.

 “Frame” or “base metal frame”, as used herein, means the original base metal body remaining after a process that was not used during the formation of the composite body with a metal matrix, and usually, if given the opportunity for cooling, it remains at least in partial contact with the composite body with a metal matrix that has been formed. It should be understood that the framework may also include a second or foreign metal.

 “Filler,” as used herein, means either single components or mixtures thereof that do not substantially react with the parent metal and / or have limited solubility therein and may be single phase or multiphase. Fillers can be used in a wide variety of forms, for example, powders, flakes, tablets, microspheres, whiskers, gas bubbles and the like, and can be dense or porous. The filler may also include ceramic fillers, such as alumina or silicon carbide, in the form of fibers, chopped fibers, microparticles, whiskers, gas bubbles, spheres, fiber mats and the like, and ceramic-coated fillers such as carbon fibers coated with alumina or silicon carbide to protect carbon from exposure to, for example, molten aluminum parent metal. Fillers may also include metals.

 “Installing profitable extensions,” as used herein, means placing a substance at one end (the “upper profitable” end) of at least a partially formed composite with a metal matrix that (the substance) exothermically reacts with at least one of the following components: base metal and / or filler material and / or other material fed to the upper profitable end. This exothermic reaction should provide enough heat to maintain the base metal at the upper profitable end in a molten state, while the rest of the base metal in the composite is cooled to the curing temperature.

 "Impregnating atmosphere", as used here, means that the atmosphere that is present interacts with the base metal and / or prepress (or filler) and / or the precursor of the impregnation amplifier and / or the impregnation amplifier, and provides or enhances spontaneous impregnation of the base metal and its normal course.

 "Impregnation enhancer," as used herein, means a material that facilitates or aids the spontaneous impregnation of a base metal in a filler material or preform. The impregnation enhancer can be formed, for example, as a result of the reaction of the initial component (precursor) of the impregnation enhancer with the impregnating atmosphere, with the formation of: 1) gaseous products, and / or 2) the reaction product of the impregnation enhancer precursor and the impregnating atmosphere, and / or 3) the product reactions of the precursor of the impregnation enhancer and filler or prepress. In addition, the impregnation enhancer can be supplied directly to at least one of the following components: prepress and / or base metal and / or impregnating atmosphere, and function essentially in the same way as the impregnation enhancer that was formed during the reaction between the precursor booster impregnation and other components. Finally, at least during spontaneous impregnation, the impregnation enhancer must be at least in the portion of the filler or prepress in order to achieve spontaneous impregnation.

“Impregnation agent precursor” or “precursor of an impregnation agent” as used herein means a material which, when used in combination with a base metal, prepress and / or impregnating atmosphere, forms an impregnation enhancer that induces or promotes the base metal to spontaneously impregnate the filler or prepress . Without striving to be bound by any particular theory or explanation, it is considered necessary that the precursor of the impregnation amplifier be in a condition acceptable to accommodate, position or transport to a place where the precursor of the impregnation amplifier can interact with the impregnating atmosphere and / or prepress or filler and / or base metal. For example, in some base metal systems / impregnation enhancer precursor / impregnation atmosphere, it is desirable that the impregnation amplifier precursor evaporate at a temperature level and sometimes just above the temperature level at which the base metal becomes molten. Such evaporation can lead to:
1) the reaction of the precursor of the impregnation amplifier with an impregnating atmosphere with the formation of gas substances that enhance the wetting of the filler or prepress the base metal; and / or
2) the reaction of the precursor of the impregnation amplifier with an impregnating atmosphere with the formation of a solid, liquid or gaseous impregnation amplifier in at least part of the filler or prepress, which enhances wetting; and / or
3) the reaction of the precursor of the impregnation enhancer with a filler or prepress to form a solid, liquid or gaseous enhancer of impregnation in at least part of the filler or prepress, which enhances wetting.

 "Base metal" or "Base metal alloy", as used here, means a metal that is used to form a composite with a metal matrix (for example, before impregnation) and / or metal that is mixed with a filler to form a composite body with a metal matrix (for example after impregnation). When a given metal is indicated as a base metal, it should be understood that such a base metal includes the named metal essentially as a pure metal, a commercially available metal having impurities and / or alloying components therein, an intermetallic compound or an alloy in which this metal is the predominant or dominant component.

 "Base metal system / precursor of the impregnation amplifier / impregnating atmosphere" or "Spontaneous system", as used here, means a combination of materials that show spontaneous impregnation in a prepress or filler. It should be understood that when the “/” sign is shown between the indicative base metal, the precursor of the impregnation enhancer and the impregnating atmosphere, the “/” sign is used to indicate a system or combination of materials that are combined in this way and exhibit spontaneous impregnation into a prepress or filler.

 “Metal matrix composite” or “KMM,” as used herein, means a material containing a two- or three-dimensionally bonded alloy or base metal that fills a pre-compression or filler. The base metal may comprise various alloying elements to obtain the specially required mechanical or physical properties of the resulting composite.

 A metal "different" from the base metal means a metal that does not contain the same metal as the main component as the base metal (for example, if the main component of the base metal is aluminum, the "different" metal can have as the main component, for example nickel).

 "Non-reactive vessel for placement of the base metal" means any vessel or reservoir that can contain or contain filler (or prepress) and / or molten base metal under process conditions and does not react with the base metal and / or impregnating atmosphere and / or precursor of the impregnation enhancer and / or filler or prepress to such an extent that it could significantly destroy the spontaneous impregnation mechanism. A non-reactive vessel can be eliminated and transmitted after completion of spontaneous impregnation of the molten base metal.

 “Prepress” or “permeable prepress”, as used herein, means a porous mass of filler or filler material that is manufactured with at least one surface interface that substantially forms an impregnation border of the base metal, which mass retains its shape uniformly and strength of the raw sand to ensure dimensional accuracy before impregnation with the base metal. The mass should be sufficiently porous to accommodate the base metal during spontaneous impregnation. Prepressing, as a rule, includes the associated order or arrangement of the filler (homogeneous or heterogeneous) and may consist of any suitable material (for example, ceramic and / or metal particles, powders, fibers, whiskers, etc.), and any their combinations. The prepress can exist either separately or in the assembly.

 "Reservoir", as used here, means a separate body of the base metal, located relative to the mass of the filler or prepress so that when the metal is molten, it can flow to replenish, or in some cases, first for the initial formation and then to replenish that part, fraction or a source of base metal that is in contact with the filler or prepress.

 “Spontaneous impregnation,” as used herein, means impregnation or penetration of a base metal into a permeable mass of filler or prepress, which occurs without the need for pressure or vacuum (externally or internally).

 In FIG. 1 is a schematic cross-sectional view of a stacking to obtain a composite with a metal matrix by spontaneous impregnation; in FIG. 2 is a schematic cross-sectional view of a stacking to obtain a composite with a metal matrix by spontaneous impregnation; in FIG. 3 is a schematic cross-sectional view of a stacking to obtain a composite with a metal matrix by spontaneous impregnation; in FIG. 4 is a schematic cross-sectional view of a stacking to obtain a composite with a metal matrix by spontaneous impregnation; in FIG. 5 is a schematic cross-sectional view of layering to form a composite with a metal matrix using spontaneous impregnation according to Example 5; in FIG. 6 is a schematic cross-sectional view of layering for forming a composite with a metal matrix by spontaneous impregnation according to Example 5; in FIG. 7 is a schematic cross-sectional illustration of layers for forming a composite with a metal matrix using spontaneous impregnation according to Example 5; in FIG. 8 is a schematic cross-sectional view of layers for forming a composite with a metal matrix by spontaneous impregnation according to Example 5; in FIG. 9 is a schematic cross-sectional illustration of layers for forming a composite with a metal matrix by spontaneous impregnation according to Example 5; in FIG. 10 is a schematic cross-sectional illustration of layers for forming a composite with a metal matrix by spontaneous impregnation according to Example 5; in FIG. 11 is a schematic cross-sectional illustration of layering for forming a composite with a metal matrix by spontaneous impregnation according to Example 5; in FIG. 12 is a schematic cross-sectional illustration of layering for the formation of spontaneous impregnation of a composite with a metal matrix according to example 5; in FIG. 13 is a schematic cross-sectional view of layers for forming a composite with a metal matrix and spontaneous impregnation according to Example 6; in FIG. 14 is a schematic cross-sectional view of the layers for forming a composite with a metal matrix and spontaneous impregnation according to Example 6; in FIG. 15 is a schematic cross-sectional view of the layers for forming a composite with a metal matrix and spontaneous impregnation according to Example 6; in FIG. 16 is a schematic cross-sectional view of layers for forming a composite with a metal matrix and spontaneous impregnation according to Example 16.

 The invention relates to the production of a composite with a metal matrix by spontaneously impregnating a filler or pressing molten base metal. In particular, the impregnation enhancer and / or the initial component of the impregnation enhancer / and / or the impregnating atmosphere communicate with the filler or prepress at least at some point during the process, which allows the molten base metal to spontaneously impregnate the filler or prepress.

 In FIG. 1 shows a simple stacking 10 for forming a composite with a metal matrix using spontaneous impregnation. Specifically, a filler or prepress 1, which may be of any suitable material, as explained in detail below, is placed in a non-reactive vessel 2 to contain the base metal and / or filler. The base metal 3 is placed on or adjacent to the filler or prepress 1. After this, the styling is placed in the furnace to initiate spontaneous impregnation.

Without the desire to be bound by any theory or explanation, when the precursor of the impregnation enhancer is used in combination with at least one of the following components: the base metal, and / or filler or prepress, and / or the impregnating atmosphere, the precursor of the impregnation enhancer can react to form an impregnation enhancer that causes or promotes the molten base metal to spontaneously impregnate the filler or preform. In addition, it is believed that the precursor of the impregnation amplifier must necessarily be in a state that allows its placement, location or transportation to a place where the precursor of the impregnation amplifier can interact with the impregnating atmosphere, and / or prepress or filler, and / or molten base metal. For example, in some base metal systems / impregnation amplifier precursor / impregnating atmosphere, it is required to ensure that the impregnation amplifier precursor evaporates at a temperature level and sometimes even above the level at which the base metal melts. Such evaporation can lead to:
1) the reaction of the precursor of the impregnation amplifier with an impregnating atmosphere with the formation of gas substances that enhance the wetting of the filler or prepress the base metal; and / or
2) the reaction of the precursor of the impregnation amplifier with an impregnating atmosphere with the formation of a solid, liquid or gaseous impregnation amplifier in at least part of the filler or prepress, which enhances wetting; and / or
3) the reaction of the precursor of the impregnation enhancer with a filler or prepress to form a solid, liquid or gaseous enhancer of impregnation of at least part of the filler or prepress, which enhances wetting.

 So, for example, if the initial component of the impregnation amplifier was introduced or combined at least at some point during the process with the molten base metal, then it is possible that the impregnation amplifier could evaporate from the molten base metal and interact with at least one of components, such as filler or prepress, and / or impregnating atmosphere. Such a reaction could lead to the formation of solids, if this type of solid is stable at the temperature of impregnation, while said solid is capable of being deposited on at least part of the filler or prepress as, for example, a coating. In addition, it is believed that such a solid could be present as a tangible solid inside at least part of the prepress or filler. If such a solid was formed, the molten base metal may have a tendency to react (for example, the molten base metal can restore the formed solid), so that the precursor of the impregnation enhancer can be associated with the molten base metal (for example, be dissolved in it or fused with him). Accordingly, an additional precursor to the impregnation enhancer may then be available for evaporation and reaction with other types of substances, for example filler or prepress and / or impregnating atmosphere, and again form a solid type of substance. It is believed that the continuous process of converting the impregnation amplifier precursor into an impregnation amplifier, followed by the reduction reaction of the impregnation amplifier with the molten base metal, to again form an additional impregnation amplifier, etc., can occur until the result of the formation of the metal matrix composite by spontaneous impregnation.

 For spontaneous impregnation of the base metal in the filler or prepress, an impregnation amplifier should be provided for the spontaneous system. The impregnation amplifier can be formed from the initial component of the impregnation amplifier, which can be provided: 1) in the base metal, and / or 2) in the filler or prepress; and / or 3) from an impregnating atmosphere, and / or 4) from an external source in a spontaneous system. In addition, instead of using the precursor of the impregnation enhancer, the impregnation enhancer may be applied directly to at least one of the components, such as filler material or prepress, and / or base metal, and / or impregnation atmosphere. Finally, at least during spontaneous impregnation, the impregnation booster should be placed in at least part of the filler or prepress.

 In a preferred embodiment of the invention, it is possible that the initial component of the impregnation enhancer can at least partially interact with the impregnating atmosphere so that the impregnation enhancer can be formed at least in part of the filler or prepress before or simultaneously in contact with the filler or prepress with the base metal, for example, if magnesium was a precursor to an impregnation enhancer and nitrogen was an impregnating atmosphere, the impregnation enhancer may be magnesium nitride, which should It must be at least part of the prepress or filler.

 An example of a base metal / impregnation amplifier precursor / impregnation atmosphere system is an aluminum / magnesium / nitrogen system. Specifically, aluminum as a base metal may be contained in an appropriate refractory vessel, which under the process conditions does not react with aluminum as a base metal and / or filler when aluminum is in a molten state, with negative consequences for them. After this, the filler or prepress can come into contact with molten aluminum as the base metal and spontaneously impregnated.

 In addition, instead of supplying the precursor to the impregnation enhancer, the impregnation enhancer may be applied directly to at least one of the components, such as prepress or filler, and / or the base metal and / or impregnation atmosphere. Finally, at least during spontaneous impregnation, the impregnation amplifier should be at least in the part of the filler or prepress.

 In the conditions used in the method according to the invention, in the case of a spontaneous impregnation system of aluminum / magnesium / nitrogen, the prepress or filler must be sufficiently permeable to allow the nitrogen-containing gas to penetrate or to impregnate the filler or prepress at some point during the process and / or contact with the molten base metal. In addition, a permeable filler or preform can accommodate an impregnated molten base metal, thereby causing the nitrogen impregnated preform to be impregnated with spontaneously molten base metal to form a composite body with a metal matrix and / or to induce nitrogen to react with the precursor of the impregnation agent to form an impregnation amplifier in the filler or prepress , thereby leading to spontaneous impregnation. The degree of spontaneous impregnation and the formation of a composite with a metal matrix can intentionally change under a given set of operating conditions, including the magnesium content in the aluminum alloy, the magnesium content in the prepress or filler, the amount of magnesium nitride in the prepress or filler, the presence of additional alloying elements, for example silicon, iron, copper, manganese, chromium, zinc, and the like, the average size of the filler material, for example, the diameter of the particle containing the prepress or filler, according to surface condition and type of filler or prepress, nitrogen concentration of the impregnating atmosphere, time allowed for impregnation, and temperature at which the impregnation occurs. For example, for spontaneous leakage of the impregnation of a molten base metal of aluminum, aluminum can be 1 by weight, preferably at least 3 by weight of magnesium, which functions as a precursor to the impregnation enhancer based on the weight of the alloy. Auxiliary alloying elements, as mentioned above, can also be included in the base metal to obtain its specific properties. Additionally, auxiliary alloying elements can affect the minimum amount of magnesium required in the base metal of aluminum in order to have spontaneous impregnation of the filler or prepress.

 The loss of magnesium from a spontaneous system due to, for example, evaporation, should not occur to such an extent that magnesium will not be present to form an impregnation enhancer. Thus, it is necessary to use a sufficient amount of starting alloying elements to ensure that spontaneous impregnation is not adversely affected by evaporation. The presence of magnesium in the prepress (or filler) and in the base metal or in only one prepress (or filler) can lead to a decrease in the required amount of magnesium to achieve spontaneous impregnation (which is explained in more detail below).

 The volume percentage of nitrogen in the impregnating atmosphere also affects the rate of formation of a composite body with a metal matrix. If less than 10 vol. nitrogen, there will be a very slow or slight spontaneous impregnation. It has been found that preferably at least about 50 vol. nitrogen in the atmosphere, which leads to shorter periods of time of impregnation due to a higher speed of impregnation. An impregnating atmosphere, such as a gas containing nitrogen, may be supplied directly to the filler or prepress and / or base metal, or may form or leak as a result of decomposition of the material.

The minimum magnesium content required for impregnation of the filler or prepress by molten base metal depends on one or more variables such as operating temperature, time, availability of auxiliary alloying elements, such as silicon or zinc, nature of the filler material, location of magnesium in one or more spontaneous components systems, the nitrogen content in the atmosphere and the rate at which the nitrogen atmosphere flows. Lower temperatures or shorter heating times can be used to completely impregnate when the magnesium content in the alloy and / or prepress is increased. Also at a given magnesium content, the addition of certain auxiliary alloying elements, such as zinc, makes it possible to use lower temperatures. For example, the magnesium content in the base metal at a lower limit of the allowable range, about 1 to 3 weight. can be used in combination with one of the following parameters: ultra-minimum operating temperature, high nitrogen concentration, one or more additional alloying elements. When no magnesium is added to the prepress at all, alloys containing about 3,5 weight are preferred. due to their general utility under a wide variety of operating conditions, and when using lower temperatures and shorter periods of time, the preferred magnesium content is not less than 5 Magnesium content over 10 weight. in aluminum alloy can be used to mitigate the temperature conditions required for impregnation. The magnesium content can be reduced while using an additional alloying element, but these elements have only an auxiliary function and are used together with at least the above amount of magnesium. For example, no impregnation of nominally pure aluminum doped only with silicon in an amount of 10 at a temperature of 1000 ^° C was observed in a layer of 39 Kristolon 500 mesh (99th pure silicon carbide manufactured by Norton Co.). However, it was found that in the presence of magnesium, silicon promotes the impregnation process. As another example, you can specify that the amount of magnesium changes if it is supplied only to the prepress or filler. It was found that spontaneous impregnation will occur at a lower weight percent of the amount of magnesium introduced into the spontaneous system, when at least a portion of the total amount of magnesium introduced is placed in a prepress or filler. It may be desirable to provide less magnesium to prevent the formation of undesirable intermetallic compounds in the metal matrix composite body. In the case of the prepress in the form of silicon carbide, it has been found that when the prepress is in contact with the base metal by aluminum, the prepress contains at least 1 weight. magnesium and is in the presence of a practically pure nitrogen atmosphere, the base metal spontaneously impregnates the prepress. In the case of prepressing from alumina, the amount of magnesium required to achieve the corresponding spontaneous impregnation is somewhat higher. In particular, it was found that in the case of alumina prepress when it comes in contact with a similar base metal with aluminum, at approximately the same temperature at which aluminum impregnated the prepress from silicon carbide, and in the presence of the same atmosphere, to achieve the same spontaneous impregnation that was achieved in the prepress the silicon carbide described previously required at least about 3 weight. magnesium.

 It is also noted that it is possible to introduce into the spontaneous system the initial component of the impregnation amplifier and / or the impregnation amplifier on the surface of the alloy and / or the surface of the prepress or filler and / or inside the prepress or filler before impregnating the base metal of the filler or prepress (i.e., it is not necessary to dope the introduced an impregnation amplifier or an initial component of a base metal impregnation amplifier, or you can simply enter it into a spontaneous system). For example, in an aluminum / magnesium / nitrogen system, if magnesium was deposited on the surface of the base metal, it may be preferable that this surface is closest to the permeable mass of the filler or prepress or is in contact with it, or vice versa; or such magnesium can be mixed with at least a portion of the prepress or filler. In addition, you can use some combination of methods of surface deposition, alloying and placing magnesium in at least part of the prepress. Such a combination of the use of an impregnation enhancer (s) and / or the initial component (s) of an impregnation enhancer can lead to a decrease in the total weight of magnesium as a percentage necessary to promote the impregnation of the base metal of aluminum in the prepress, as well as to achieve lower temperatures at which impregnation may occur. In addition, it is also possible to minimize the amount of undesired intermetallic compounds formed as a result of the presence of magnesium.

 The use of one or more additional alloying elements and the concentration of nitrogen in the surrounding gas also affects the degree of nitriding of the base metal at a given temperature. For example, additional alloying elements, such as zinc, iron, introduced into the alloy or placed on the surface of the alloy, can be used to lower the impregnation temperature and thereby reduce the amount of nitride formation, while increasing the nitrogen content in the gas can be used for promotion nitride formation.

The magnesium content in the alloy and / or placed on the surface of the alloy and / or combined with the filler or prepress material also tends to affect the degree of impregnation at a given temperature. Consequently, in some cases in which a small amount of magnesium is in contact with the prepress or filler or not in contact at all, it may be preferable to introduce at least about 3 weight into the alloy. magnesium. All quantitative values less than this amount (for example, 1 weight. Magnesium) may require higher temperatures to carry out the impregnation process or to include an additional alloying element. The temperature necessary for the implementation of the spontaneous impregnation process according to the invention may be lower: 1) with an increase in the amount of magnesium only in the alloy, for example, to at least 5 weight. and / or 2) when mixing the alloying components with a permeable mass of filler or prepress, and / or 3) if there is another element in the aluminum alloy, such as zinc or iron. The temperature may also vary with various filler materials. In general, in the aluminum / magnesium / nitrogen / spontaneous and gradual impregnation system will occur at a process temperature of at least about 675 ^° C. and preferably at a process temperature in the range of 750 - 800 ^° C. Temperatures generally above 1200 ^° C. are not considered to be beneficial process and it was found that the most useful temperature range is a temperature of about 675 1200 ^o C. However, as a rule, the spontaneous infiltration temperature is a temperature which exceeds the melting point of the parent metal but below the eratury evaporation of the parent metal. In addition, the temperature of spontaneous impregnation should be below the melting point of the filler material. In addition, with increasing temperature, there is an increasing tendency to form a reaction product between the base metal and the impregnating atmosphere, for example, in the case of the base metal of aluminum and the nitrogen atmosphere of impregnation, aluminum nitride can be obtained. Such a reaction product may be desirable or undesirable depending on the intended use of the metal matrix composite body. Additionally, heating due to electrical resistance is used to achieve impregnation temperatures. However, for use in the invention, any heating means that may cause the base metal to melt and which does not adversely affect spontaneous impregnation is acceptable.

 For example, in the proposed method, a permeable filler or prepress comes in contact with molten metal aluminum in the presence of at least sometimes during the process of nitrogen-containing gas. Nitrogen-containing gas can be introduced by maintaining a continuous stream of gas in contact with at least one of the components, such as filler or prepress and / or molten base metal aluminum. Although the flow rate of nitrogen-containing gas is not important, it is preferable that the flow rate be sufficient to compensate for any loss of nitrogen from the atmosphere resulting from the formation of nitrides in the base alloy, as well as to prevent or slow the leakage of air, which can have an oxidizing effect on the molten metal.

 The method of forming a composite with a metal matrix is applicable to a wide variety of filler materials and the choice of fillers will depend on factors such as the base alloy, process conditions, the reactivity of the molten base metal with respect to the filler, and on the properties necessary for the final composite product. For example, when the base metal is aluminum, the corresponding filler materials may be the following: a) oxides, for example alumina, magnesium oxide, zirconia; b) carbides, for example silicon carbide; c) borides, for example aluminum dodecaboride, titanium diboride; g) nitrides, for example aluminum nitride; e) mixtures thereof. If there is a tendency for the filler to interact with molten base metal aluminum, this can be compensated by applying a non-reactive coating to the filler and by minimizing the time for impregnation. The filler material may contain a base, such as coal or other non-ceramic material, on which a ceramic coating is applied to protect the base from exposure or destruction. Suitable ceramic coatings include oxides, carbides, borides and nitrides. Preferred ceramic materials for use in the invention include alumina and silicon carbide in the form of particles, tablets, whiskers and fibers. The fibers may be sparse or in the form of continuous filaments, like bundled bundles of fibers. In addition, the filler or prepress may be homogeneous or heterogeneous.

 It was also found that some fillers show increased impregnation with respect to fillers of the same chemical composition. For example, crumbled alumina bodies obtained in a known manner (see US Patent N 4,713,360, 1987), which shows the required properties of the impregnation in comparison with alumina products manufactured by industry. In addition, crumbled alumina bodies obtained by the method described in simultaneously filed and jointly owned by application N 819.397, "Composite ceramic products and methods for their preparation", M. S. Newkirk and others also show the required properties of impregnation compared with alumina products manufactured by industry. Thus, it was found that the complete impregnation of the permeable mass of ceramic material can occur at lower impregnation temperatures and / or shorter periods of impregnation by using crushed or crushed bodies obtained by a known method (see US Patent N 4.713.360, 1987 and patent application N 819.397).

 The size, shape, chemical composition and volume percent of the filler material or prepress can be any that may be required to achieve the desired properties in the composite. So, for example, the filling material may be in the form of particles, whiskers, tablets or fibers, since the impregnation is not limited to the shape of the filling material. Other forms may be used, such as balls, tube-shaped tablets, refractory non-woven material and the like. Additionally, the size of the filler material does not limit the impregnation, although a higher temperature and a longer period of time may be required to complete the impregnation of the mass of smaller particles than larger ones, or vice versa, depending on the specific reaction conditions. Average particle diameters as small as 1 μm or less and up to 1100 μm or more can be successfully used in the invention, preferably in the range of 2 1000 μm, in relation to the vast majority of industrial applications. The mass of filler material (or prepress) that must be impregnated must be impregnated (i.e., contain at least partially interconnected pores so that it is permeable to the molten base metal and / or to the impregnated atmosphere). In addition, by controlling the size, such as particle diameter, and / or the geometry and / or composition of the filler material or the material containing the prepress, the physical and mechanical properties of the moldable metal matrix composite can be controlled or adapted to meet any number of industrial needs. For example, the wear resistance of a composite with a metal matrix can be improved by increasing the size of the filler material, for example, by increasing the average particle diameter of the filler material, provided that the filler material has higher wear resistance than the base metal. However, strength and / or toughness may tend to increase with decreasing filler size. The coefficient of thermal expansion of the composite with a metal matrix can decrease with increasing loading of the filler, provided that the coefficient of thermal expansion of the filler is lower than the coefficient of thermal expansion of the base metal. Mechanical and / or physical properties, such as density, coefficient of thermal expansion, elastic modulus and / or specific elasticity, strength and / or specific strength, etc. of a molded composite body with a metal matrix can be adapted (adapted) depending on the loading of the filling material in loose mass or in prepress. For example, by forming a loose mass or prepress containing a mixture of filler particles of different sizes and / or shapes in which the filler density is greater than that of the base metal, a higher filler loading can be achieved due to the increased compaction (packing) of the filler materials, which results in composite body with a metal matrix of high density. By using the technical solutions according to the invention, the volume percentage of the filler material or prepress that can be impregnated can vary over a wide range. The lower volume percentage of the filler that can be impregnated is mainly limited by the ability to form a porous filler material or preform, for example about 10 vol. whereas the upper volumetric percentage of filler or prepress that can be impregnated is mainly limited by the ability to form a dense filler material or prepress with at least partial interconnected porosity, for example about 95 vol. Accordingly, by implementing the above technical solutions, alone or in combination, the composite with a metal matrix can be adapted to contain the desired combination of properties.

 The method of forming metal matrix composites according to the invention, which is independent of the use of pressure to force or force the molten base metal to impregnate a prepress or a mass of filler material, makes it possible to produce substantially uniform metal matrix composites having a high volume fraction of filler and low porosity. Higher volume fractions of the filler can be achieved by using an initial mass of filler material with lower porosity. Higher volume fractions can also be achieved if the mass of the filler is compressed or otherwise compacted, provided that the mass is not converted either into a compact with closed porosity or into a completely dense structure, which will impede the impregnation of the molten alloy. Specifically, volume fractions of the order of 60 to 80 vol. can be achieved by methods such as vibration compaction, particle size control, distribution, etc. However, alternative means can be used to achieve higher volume fractions of the filler. Volume fractions of the filler of the order of 40 to 50 are preferred for thermoforming according to the invention. At such volume fractions, the impregnated composite retains or almost retains its shape, thereby facilitating secondary processing. Higher or lower particle loading or volume fractions may be used depending on the desired loading of the final composite after thermoforming. In addition, methods for reducing particle loads can be used in connection with the thermoforming processes of the invention to achieve lower particle loads.

 It has been established that aluminum impregnation and the formation of a matrix around a ceramic filler, wetting of the ceramic filler with a base metal with aluminum can be an important part of the impregnation mechanism. Wetting the filler with molten base metal can provide a uniform dispersion of the filler throughout the molded metal matrix composite and improve the bond of the filler with the base metal. In addition, negligible or minimal amounts of nitrided metal are formed at low processing temperatures, resulting in a minimal dispersed phase of aluminum nitride dispersed in the metal matrix. However, when the upper limit of the temperature range approaches, nitriding of the metal probably occurs more significantly. Thus, the magnitude of the nitride phase in the metal matrix can be controlled by changing the processing temperature at which the impregnation occurs. The special process temperature at which nitride formation becomes pronounced also varies depending on factors such as the primary aluminum alloy used and its amount relative to the volume of the filler or prepress, the impregnated filler and the concentration of nitrogen in the impregnating atmosphere. For example, the size of the formation of aluminum nitride at a given operating temperature is considered to increase, since the ability of the alloy to wet the filler decreases and the concentration of nitrogen in the atmosphere increases.

Therefore, it is possible to adjust or adapt the composition of the metal matrix during the formation of the composite in order to impart certain characteristics to the final product. For a given system, process conditions may be selected to control nitride formation. A composite product containing an aluminum nitride phase will exhibit some properties that may be favorable or improve product performance. The temperature range for spontaneous impregnation with an aluminum alloy can be intentionally varied using the ceramic material used. In the case of alumina as a filler material, the temperature of the impregnation should preferably not exceed about 1000 ^° C. if it is required that the ductility of the matrix does not decrease due to significant nitride formation. However, temperatures in excess of 1000 ^° C. may be used if a composite with a less plastic and stiffer matrix is desired. To impregnate silicon carbide, higher temperatures of about 1200 ^° C. can be used, since the aluminum alloy forms nitrides to a lesser extent than using alumina as a filler when silicon carbide is used as a filler.

 The composition of the base metal in the composite with a metal matrix and defects, such as porosity, can be modified by controlling the cooling rate of the composite with a metal matrix. For example, a metal matrix composite can be directionally cured by any method, including by placing a container containing the metal matrix composite on a cooling plate, and / or by selectively placing insulating material around the container. The composition of the metal matrix can be modified after the formation of the composite with the metal matrix. For example, heat treatment of the formed metal matrix composite can improve the tensile strength of the metal matrix composite (a standard tensile strength test is given in A S TM D 3552-77, revised in 1982).

For example, a suitable heat treatment of a metal matrix composite containing 520.0 aluminum alloy as the base metal may include heating the metal matrix composite to a high temperature, for example about 430 ^° C., which is maintained for a long time, for example 18 to 20 hours The metal matrix can then be cooled in boiling water at a temperature of about 100 ^o C for 20 s (ie, heat treatment T-4), which can strengthen or increase the ability of the composite to withstand tensile stresses.

 In addition, you can use the reservoir of the base metal to ensure complete impregnation of the filler and / or metal to ensure complete impregnation of the filler and / or to submit a second metal, which has a different composition, different from the first source of the base metal in the tank. Specifically, in some cases it may be necessary to use a base metal in a tank that is different in composition from the first source of the base metal. For example, if an aluminum alloy is used as the first source of the base metal, then any other metal or metal alloy that has been molten at operating temperature is possible, can be used as the reservoir metal. The molten metals often have a high ability to mix with others, which can lead to mixing of the tank metal with the first metal source, if an adequate amount of time is allotted for the flow of mixing. Thus, by using a reservoir metal that is different in composition from the first source of the base metal, it is possible to adapt the properties of the metal matrix to meet various operating requirements and thereby adapt the properties of the composite with the metal matrix.

 A barrier agent may also be used in conjunction with the invention. In particular, any suitable means that interferes with, inhibits, inhibits or stops the migration, movement or the like of a molten base alloy, such as an aluminum alloy, beyond the indicated surface boundary of the filler can be a barrier means for use in the invention. A suitable barrier means can be any material, compound, element, composition and the like, which maintains integrity under the conditions of the process according to the invention, does not evaporate and is preferably permeable to the gas used in the process, and is also able to inhibit, stop, interfere, interfere locally and the like, by continuing to impregnate or another type of melt movement beyond the designated surface boundary of the ceramic filler. The barrier means can be used during spontaneous impregnation in molds or holding devices used in connection with heat treatment to form a composite with a metal matrix with spontaneous impregnation, as described in more detail below.

 A suitable barrier means includes materials that are practically not wetted by the migrating molten base metal under the process conditions. A barrier of this type shows little or no similarity with the molten base alloy and does not show such similarity at all, and movement beyond the indicated surface boundary of the filler or prepress is prevented or slowed down by the barrier means. The barrier reduces the final machining or lapping that may be necessary for a composite product with a metal matrix. As stated above, the barrier should preferably be permeable or porous or made permeable by making holes to allow the gas to come into contact with the molten base alloy.

 Corresponding barriers most useful for basic aluminum alloys are materials containing carbon, especially carbon in a crystalline allotropic form known as graphite. Graphite is essentially a non-wettable molten aluminum alloy under the described process conditions. A particular preferred graphite is graphite foil, which is sold under the trademark GRAFOIL, registered by Union Caribid. This graphite foil shows seal characteristics that prevent the migration of molten aluminum alloy beyond the indicated surface boundary of the filler. This graphite foil is also heat resistant and chemically inert. Graphoil Graphite Foil is flexible, compatible, appropriate and resilient. It can be made in a variety of forms to suit barrier use. However, a graphite barrier agent can be used as a suspension or paste, or even as a film of paint around and at the border of the filler or prepress. Graphoil is particularly preferred for the reason that it is in the form of a flexible graphite sheet. When used, this paper-like graphite is simply applied around the filler or prepress.

Other preferred barriers to metal alloys of the aluminum aluminum matrix in nitrogen are metal transition borides (e.g. titanium diboride TiB ₂ ), which are generally non-wettable molten aluminum metal under certain process conditions used with this material. In the case of a barrier of this type, the process temperature should not exceed about 875 ^o C, since otherwise the barrier material becomes less efficient and, in fact, at an elevated temperature, impregnation into the barrier occurs. In addition, the particle size of the barrier material may affect the ability of the material to inhibit or slow down spontaneous impregnation. The resulting metal borides of a typical are in the form of particulates (1 30 μm). The barrier materials can be used as suspensions or pastes and are applied at the boundary locations on the permeable masses of ceramic fillers, which are preferably preformed as pre-presses.

 Other useful barriers for aluminum metal matrix alloys in nitrogen include low volatility organic compounds applied as a film or layer to the outer surface of the filler or preform. When fired in nitrogen, especially in the process conditions according to the invention, the organic compound decomposes, leaving a carbon finished film. The organic compound can be applied by conventional means such as dyeing, spraying, dipping, etc.

 In addition, the finely divided powdery material can function as a barrier when the impregnation of the powdery material proceeds at a rate that is slower than the rate of impregnation of the filler.

 Thus, the barrier agent can be applied by any suitable method, such as, for example, coating a designated surface boundary with a layer of the barrier agent. Such a layer of the barrier agent may be applied by dyeing, dipping, spraying, vaporizing or otherwise, applying the barrier agent in a liquid, suspension or paste form, or by spraying a volatile barrier agent, or simply by depositing a layer of a solid, particle-like barrier agent, or by applying a thin a solid sheet or film of barrier means at a designated surface boundary. With the barrier means installed in place, spontaneous impregnation essentially ceases when the impregnating base metal reaches the designated surface boundary and comes into contact with the barrier means.

 Various representative embodiments of the invention are included in the examples.

Example 1. In FIG. 1 shows a complex in cross section, which was used to form a composite with a metal matrix using spontaneous impregnation according to the invention. A foam polystyrene bowl with a height of approximately 3 and 1/4 inches (83 mm), an inner diameter at the wide end of about 2 and 3/4 inches (70 mm), and an inner diameter at the narrow end of about 1 and 9/16 inches (40 mm) immersed in a suspension (or sludge) containing substantially equal weight parts of 20 colloidal alumina from Remet Co., and powdered silicon carbide with a grit of 1000 from Norton Co., sold under the trademark 37 Kristolon. The extractable mandrel coated with the suspension was sprinkled with a dry powder of 90 grit silicon carbide (37 Kristolon), which adhered to the suspension coating. The subsequent stages of immersion - deposition were repeated three times, after which the sprayed powder was replaced by silicon carbide with a grain size of 24 (37 Kristolon). Subsequent Dive Steps
the spraying was repeated three times again. The resulting coating was dried at 65 ^° C. for 1/2 hour after each step of immersion spraying in the order of the steps.

After the last spraying immersion step, in sequence order, the deposited shell was calcined in an air oven at a temperature of about 850 ^° C. for about 1 hour to remove the foam styrene cup by evaporation. The resulting coating shell 4, which was about 3/16 inch thick, was then filled up to about half with a filler layer 2 containing a mixture of 1000 grit silicon carbide sold under the trademark Kristolon 39 and manufactured by Norton Co. and about 2 weight. 350 mesh grit powder produced by Aezar by Johnson Matthew Co. This mixture was pre-mixed thoroughly in a ball mill for 24 hours. The filler layer 2 was then slightly compacted (by hand pressure) to form a denser filler body in the coating sheath 4. After this compaction step, the base metal ingot 3, consisting of about 15 by weight silicon, 5 magnesium and aluminum balance and measuring approximately 1.5 '' (38 mm) x 1.5 '' (38 mm) x 1 '' (25 mm), was placed on top of the filler layer 2. Before placing ingot 3 of the main alloy on the surface of the filler layer the ingot was first a little sandblasted and then washed with ethanol to remove foreign debris from the surface, such as oils from the treatment, which could remain.

 The coating shell 4, containing the ingot of the base alloy 3 and the filler material 2, was placed in the layer of refractory particles 5 so that the surface of the layer of refractory particles was about half the height of the side of the coating shell 2. The refractory particles contained in the graphite boat 1, consisted of 24 gum alumina known under the trademark 38 Alundum manufactured by Norton Co.

The complex, consisting of a graphite refractory boat and its contents, was placed in a resistance vacuum furnace with a controlled atmosphere at room temperature and high vacuum (approximately 1 • 10 ^-4 Torr) and was created in a vacuum furnace. The furnace was filled with nitrogen to a pressure of 1 atm. and then a constant flow of nitrogen gas was established in the furnace at a flow rate of 1.5 l / min. Then, the furnace temperature was brought to 750 ^° C in 3 hours and maintained at 750 ^° C for 20 hours. After a 20-hour heating period, the furnace power was turned off and the complex naturally cooled in the furnace to about 40 ^° C for about 12 hours. Upon reaching 40 ^o C the complex was removed from the oven and disassembled. The metal matrix composite containing the base metal, which absorbed the filler mixture, was recovered from the complex.

 Thus, this example shows that the filler can be impregnated spontaneously in an aluminum / magnesium / nitrogen alloy system to form a composite with a metal matrix.

 Example 2. In FIG. 2 shows a complex in cross section, which was used to obtain a composite body with a metal matrix using spontaneous impregnation in accordance with the invention. Box 2 with dimensions of approximately 2 '' (51 mm) x 1 '' (25 mm) x 2 '' (51 mm) was made of OTV graphite foil with a thickness of 15/1000 inches (0.38 mm) manufactured by Union carbide "sold under the trademark Grafoil. The box was made by stapling Grafoyl sections of the appropriate size and sealing the joints with a paste prepared by mixing powdered graphite (brand KS-44 from Lonza Inc.) and colloidal silicon dioxide (Ludex HS from DuPont de Nemur). The weight ratio between graphite and colloidal silicon dioxide was about 1 3. A box of Grafoil was placed on top of a layer of about 1/2 inch (13 mm) of particle-like boron carbide (Atlantic Equipment Engineering), which was contained in boat 1 made of refractory alumina . A base metal ingot 4 of about 2 '' (51 mm) x 1 '' (25 mm) and 0.5 '' (13 mm) in size and containing about 3 weight. calcium and aluminum balance, placed at the bottom of the box from Grafoil. Alumina 5 with 220 grit, known under the trademark Alundum 38 and manufactured by Norton Co., poured into a graphoil box 2 on top of an ingot of base metal 4, until the ingot was coated with a layer about 1 inch thick with filler 5 from Alundum 38. Then an additional boron carbide 3 into an alumina boat outside the graphoil box 2, until the surface of the layer of boron carbide is just below the top of the graphoil box 2.

The complex, consisting of boat 1 of refractory alumina and its contents, was placed in an electric tube resistance furnace at room temperature. The furnace was evacuated to about 1 • 10 ^-1 Torr and then purged with nitrogen gas at room temperature to a pressure of about 1 atm. After filling the furnace with nitrogen, a continuous flow of nitrogen gas was established in the furnace at a flow rate of 800 cm ³ / min. Then, the oven temperature rose to about 900 ^° C at a speed of 250 ^° C / h, was maintained at 900 ^° C for about 5 hours, and then cooled to room temperature at a speed of 250 ^° C / h. After reaching room temperature, the complex was removed from the furnace and dismantled. A metal matrix composite containing Alundum 38 as a filler interspersed in the base metal was detected.

 Thus, this example shows that it is possible to spontaneously impregnate a mass of filler material in an aluminum / calcium / nitrogen alloy system.

 Example 3. In FIG. 3 is a cross-sectional view schematically illustrating a complex that was used to form a composite with a metal matrix using spontaneous impregnation according to the invention. For the formation of prepress approximately 94 weight. powder of aluminum nitride (powder "A" company "German Stark"), 5 wt. powdered silicon nitride (Atlantic Equipment Engineering) and about 1 weight. polyvinylpriolene 30 (polyvinylpriolene, mol. m. 30, manufactured by "GAF Corp.") was mixed with 100% ethanol to form a suspension containing about 50 vol. solids and 50 vol. ethanol. The suspension was then poured into a mold measuring 3 '' (76 mm) x 3 '' (76 mm) x 1 '' (25 mm) and formed of a square steel frame and a bottom made of gypsum panel. The steel frame was not connected to the gypsum panel and could easily be removed by lifting. The gypsum panel was used to draw moisture (liquid) from the suspension. After drying, the suspension formed a prepress of 3 '' (76 mm) x 3 '' (76 mm) x 1 '' (25 mm) in size. The prepress 5 with a size of 1.5 '' (38 mm) x 3/4 '' (76 mm) x 1/2 '' (13 mm) was cut from a larger prepress. A base metal ingot 3 of approximately 1 '' (25 mm) x 2 '' (51 mm) x 1/2 '' (13 mm) in size, containing 3 strontium, 8 silicon, 8 nickel and aluminum balance by weight, was coated on one surface layer with a thickness of about 0.25 mm of a mixture containing 50 weight. powdered iron (company "Serac Inc.") and 50 weight. powdered aluminum nitride (Exolon-ESK company). Prepress 5 was then placed on top of layer 4 of powdered aluminum / iron nitride and the base metal assembly / prepress was placed on top of a 1 '' (25 mm) layer of particle-like boron carbide 6 (Atlantic equipment engineers) contained in box 2 made of graphite tape OTV brand with a thickness of 15/1000 inches (0.38 mm) (manufactured by Union Carbide and sold under the trademark Grafoil). The box was formed by stapling the corresponding sections of the grafoy tape together and sealing the joints of the box with slurry, made by mixing graphite powder (brand KS-44 from Lonza Inc.) and colloidal silica (Ludex HS from DuPont). The weight ratio of graphite to colloidal silica was about 1 3. Box 2 was large enough to accommodate assembly of the base metal / prepress without contact with the assembly.Graphoil box 2 was installed on the bottom of boat 1 made of refractory alumina.An additional boron carbide 6 was introduced into graphoil box 2 until the base metal assembly / prepress was completely surrounded and covered with 6. bidom boron carbide boron layer thickness of about 1/2 inch (13 mm) covers the upper surface of the prepressing.

The complex, consisting of an alumina refractory boat 1 and its contents, was placed in a tubular resistance furnace at room temperature. The furnace was then evacuated to about 1 • 10 ^-1 Torr, filled at room temperature with nitrogen to about 1 atm. After filling with nitrogen in the furnace, a continuous flow of nitrogen was established with a flow rate of about 600 cm ³ / min. Then the temperature of the furnace was increased to about 1200 ^o C at a speed of 200 ^o C / h The oven temperature was maintained at 1200 ^° C. for about 10 hours and then decreased to room temperature at a rate of 250 ^° C./h. After reaching room temperature, the complex was removed from the furnace and disassembled. A metal matrix composite was obtained containing a base metal interspersed with a prepress.

 Thus, this example shows that it is possible to spontaneously impregnate a base metal into a prepress from a filler material in an aluminum / strontium / nitrogen alloy system.

 Example 4. In FIG. 4 shows in cross section a complex that was used to produce a composite with a metal matrix using spontaneous impregnation according to the invention. To obtain a prepress, approximately 85 weight. Alcoa calcined alumina A-17 was mixed with about 15 weight. water containing a small amount of Darwin-821A (firm "R. T. Vanderbilt & Co.") as a dispersing agent for the formation of sludge (suspension). The slurry was poured into a gypsum or Parisian rectangular shape measuring approximately 3 '' (76 mm) x 2 '' (51 mm) x 1/2 in. (13 mm). The sludge was dried for 8 hours in the mold before being removed from it as prepress 3. Prepress 3 was then dried for an additional 24 hours in air before use in the proposed method.

 A foot of three ingots of base metal 2 each approximately 3 '' (76 mm) x 2 '' (51 mm) x 0.5 '' (13 mm) in size, consisting of a commercially available 170.1 aluminum alloy containing approximately 3 weight . zinc, in addition to the zinc contained in the original alloy, the foot was coated on the top surface of the uppermost ingot with a layer of 0.05 '' (0.013 mm) thick refractory material known as Lycotte LX-60 WPS (Acme Rubber Corporation). Pressing 3 was then placed on the upper part of Lycot layer 5 and assembly of the base metal ingot / pressing was placed on the upper part of the layer with a thickness of about half an inch (13 mm) of particle-like wollastonite 4 of coarse-grained Iyad SP from NIKO Inc. contained in an alumina refractory boat 1. The assembly of the base metal ingot / prepress was installed adjacent to the wollastonite layer so that the lowermost ingot of the base metal was in contact with the layer. Additional wollastonite 4 was then introduced into the alumina refractory boat 1 until the wollastonite surface reached the level of the upper surface of the prepress 3.

The complex, consisting of an alumina refractory boat 1 and its contents, was placed in an electric resistance furnace with an air atmosphere at atmospheric pressure. The temperature of the furnace was raised to 1050 ^° C. for 10 hours, maintained at 1050 ^° C. for 60 hours, then cooled to 40 ^° C. for 10 hours. After reaching approximately 40 ^° C., the complex was removed from the furnace and disassembled. A metal matrix composite was obtained containing a matrix alloy embedded in the prepress.

 FIG. 4 is a micrograph of a metal matrix composite prepared in accordance with Example 4.

 Thus, this example demonstrates that it is possible to spontaneously impregnate a prepress from a filler material in an aluminum / zinc / oxygen alloy system.

 Example 5. This example shows that many different geometries of the filler material can be successfully used to form composite bodies with a metal matrix by spontaneous impregnation.

 In the table. Table 1 summarizes the experimental conditions used to form a plurality of composite bodies with a metal matrix, including various base metals, filler material geometries, operating temperatures, and processing time periods.

 Sample A (011189-AA1).

In FIG. 5 is a schematic cross-sectional view of a complex used to obtain a sample of a composite with a metal matrix, as described below. A mold 10 was specially prepared from silica, which had an internal cavity of about 5 '' (127 mm) long, 5 '' (127 mm) wide and 3.25 '' (83 mm) high and had five holes 11 with a diameter of about 0 , 75 '' (19 mm) and a depth of 0.75 '' (19 mm) at the bottom of the silica mold. The mold was first formed by mixing a slurry containing 2.5 to 3 weight. including powdered silica (RA NSO-SIL 4 firm "Rensom and Randolph", Mauni, OX), 1 weight. including colloidal silica (NYACOL 830 firm "Niacol product Inc.", Astland, MA) and 1 1.5 wt. including siliceous sand (RANCO-SILA sold by Rensom & Rendolf, Mauni, OX). The slurry mixture was poured into a mold for vulcanizing rubber products, having a negative sample of the desired internal cavity of the silica form, and was placed in the refrigerator overnight (approximately 14 hours). The silica mold 10 was then separated from the vulcanization mold, calcined at 800 ^° C. in an oven in air for about 1 hour, and cooled to room temperature.

 The lower surface of the molded silica mold 10 was coated with a piece of graphite foil 12 (PERMA-FOIL from TT America, Portland, OR) 5 '' (127 mm) long, 5 '' (127 mm) wide and about 0.010 '' thick ( 0.25 mm). Holes 13 with a diameter of about 0.75 '' (19 mm) were formed in graphite foil at locations that coincided coaxially with the positions of the holes 11 in the lower part of the silica mold 10. The holes 11 in the lower part of the silica mold 10 were filled with cylinders 14 of a base metal with a diameter 0.75 '' (19 mm) and a thickness of 0.75 '' (19 mm) and had a composition identical to the base metal, as described below. About 826 g of a mixture of 15 filler material containing about 95 weight. coarse-grained alumina 220 (38 ALUNDUM, Norton Co., Worcester, MA), and about 5 powdered magnesium 325 (sold by AEzar, Johnson Matthew, Sibrook, HX), was prepared in a four-liter plastic jar and shaken for 15 minutes. The filler material mixture 15 was then poured into the bottom of the silica mold 10 to a depth of about 0.75 '' (19 mm) and slightly drained to the surface level of the filler material mixture. About 1220 g of the base metal 16, containing approximately less than 0.25 weight. Si, less than 0.30 weight. Fe, less than 0.25 weight. Cu, less than 0.15 weight. Mn, 9.5-10.6 weight. Mg, less than 0.15 weight. Zn, less than 0.25 weight. Ti and aluminum balance were placed on top of the filler material mixture 15 in silica mold 10. Silica mold 10 and its contents were then placed in stainless steel container 17 10 '' (254 mm) long, 10 '' (254 mm) wide and 8 '' (203 mm) high. A titanium sponge material 18 weighing about 15 g (Kemalloy Inc., Bryn Mour, PA) was sprayed around silica mold 10 in a stainless steel container 17. A sheet of copper foil 19 was placed on the opening of the stainless steel container 17, forming an insulated chamber. The nitrogen purge pipe 20 passed through a sheet of copper foil 19 and a stainless steel container 17 and its contents were placed in a furnace heated by a block of resistors with an atmosphere of air.

The furnace was brought from room temperature to 600 ^o C at a rate of about 400 ^o C / h with a nitrogen flow of about 10 l / min (it should be noted that the insulated chamber is not gas-tight and allows nitrogen to leak out of it) and then was heated from 600 ^o C up to about 750 ^o C at a rate of 400 ^o C / h and a nitrogen flow rate of about 2 l / min. After keeping the system at 775 ^° C. for about 1.5 hours with a nitrogen flow of 2 l / min, the stainless steel container 17 and its contents were removed from the furnace. Silica mold 10 was removed from the stainless steel container 10 and part of the remaining base metal was filtered into silica mold 10. Room temperature copper cooling plate 5 '' (127 mm) long, 5 '' (127 mm) wide and 1 '' thick (25 mm) was placed in a silica mold 10 in such a way that it came into contact with the upper part of the remaining base metal in order to directionally solidify the molded composite with a metal matrix.

 Sample B (011889-AX).

 In FIG. 6 is a cross-sectional view schematically illustrating a complex used to produce a sample of a composite with a metal matrix, as described below. A steel box 32 was specially formed by placing a steel frame 30 having an internal free space of 5 '' (127 mm) long, 5 '' (127 mm) wide and 2.75 '' (70 mm) high and having a wall thickness of 0, 34 (7.9 mm), onto a steel plate 31, 7 '' (178 mm) long, 7 '' (178 mm) wide and 0.25 '' (6.4 mm) thick. The steel box 32 was lined inside by a graphite foil box 33 with a length of 5 '' (127 mm), a width of 5 '' (127 mm) and a height of 3 '' (76 mm). A box 33 of graphite foil was made of a piece of graphite foil (Perm-Foyle, TT America, Portland, OR), which was 11 '' (279 mm) long, 11 '' (279 mm) wide and 0.010 'thick '(0.25 mm). Four parallel cuts about 3 '' (76 mm) from the side and 3 '' (76 mm) long were made in graphite foil. The cut graphite foil was then bent and stacked to form a graphite foil box 33.

 About 782 g of a mixture of filler material 34 containing 95 weight. alumina (C-75 RO company "Alkan Chemicals", Montreal, Canada) and about 5 weight. powdered magnesium with a grain size of 325 mesh. (sold by Aezar Johnson Matter, Seabrook, NH), was obtained by combining materials in a plastic vessel and shaking with hands for 15 minutes. The mixture 34 of filler material was then poured into a graphite foil box 33 to a depth of 0.75 '' (19 mm) and then the mixture was slightly drained to the surface level. The surface of the filler material mixture 34 was coated with about 4 g of powdered magnesium 35 with a grain size of 50 mesh. (sold by Alpha Products, Morton Thiokol, Danvers, MA). About 1268 g of base metal 36, containing less than 0.25 weight. Si, less than 0.30 weight. Fe, less than 0.25 weight. Cu, less than 0.15 weight. Mn, 9.5-10.6 weight. Mg, less than 0.15 weight. Zn, less than 0.25 weight. Ti and balance aluminum were placed on a mixture of 34 filler material coated with powdered magnesium 35.

 The steel box 32 and its contents were placed in a stainless steel container 37 with a length of 10 '' (254 mm), a width of 104 (254 mm) and a height of 8 '' (202 mm). The lower part of the stainless steel container 37 was formed by coating the bottom of the box with a piece of graphite foil 38 with a length of 10 '' (254 mm), a width of 10 '' (254 mm) and a thickness of 0.010 '' (0.25 mm) and refractory brick 39 was placed on graphite foil 38 to support the steel box 32 in the stainless steel container 37. Approximately 20 g of titanium sponge material 40 (Kemalloy Company, Inc., Wryn Moe, PA) was sprayed on graphite foil 38 at the bottom of a stainless steel container 37 around a refractory brick 39 supporting a steel box 32. A sheet of copper foil 41 was covered over the opening (open portion) of the stainless steel container 37 to form an insulated chamber. The nitrogen purge pipe 42 passed through a sheet of copper foil 41. The stainless steel container 37 and its contents were placed in an electric furnace with an atmosphere of air.

The furnace was heated from room temperature to about 600 ^o C at a rate of 400 ^o C / h with a flow rate of nitrogen through the pipe 42 of about 10 l / min, then was heated from 600 ^o C to 800 ^o C at a speed of 400 ^o C / h with a flow of nitrogen 2 l / min The system was maintained at 800 ^° C. for about 2 hours with a nitrogen flow rate of 2 L / min. The stainless steel container 37 and its contents were removed from the furnace and the steel box 32 was removed from the stainless steel container 37 and placed on a water-cooled, room-temperature copper cooling plate having a length of 8 '' (203 mm), 8 '' wide (203 mm) and a thickness of 0.5 '' (13 mm) for directionally curing a composite with a metal matrix.

 Sample C (022189D AHI).

 In FIG. 7 is a schematic cross-sectional view of the complex used to form a sample of a composite with a metal matrix, as described below. A graphite boat 50 was specially formed, having an internal cavity 12 '' (305 mm) long, 8 '' (203 mm) wide and 5.25 '' (13.3 mm) high, made of ATJ graphite manufactured by Union Carbide " Three boxes 52 of graphite foil 8 '' (203 mm) long, 4 '' (102 mm) wide and 5 '' (127 mm) high were placed in the lower part of graphite boat 50. The box 52 of graphite foil was made of pieces of graphite foil (Grafoil of Union Carbide) 14 '' (356 mm) long, 12.5 '' wide (318 mm wide) and 0.015 '' thick (0.38 mm). Four parallel cuts 5 '' (127 mm) from the side and 5 '' (127 mm) long were made in graphite foil. The cut graphite foil was then folded into a box 52 of graphite foil, glued with a mixture containing 1 weight. parts of graphite powder (KS 44 from Londa Inc., Fair Lone. NJ) and 3 parts by weight of colloidal silica (LODOX SM from E.I. Dupont de Nemur, Wilmington, DE), and The bottom of the graphite foil box 52 was uniformly coated with a 50 mesh layer of magnesium powder 50 grit (sold by Flf Products, Morton Tiokol, Danvers, MA). The magnesium powder 53 was adhered to the bottom of the box 52 of graphite foil using a mixture containing 25-50 vol. of graphite cement (RIGIDLOCK company "Polycarbon", Valencia, KA) and the balance of ethyl alcohol.

 About 1000 g of a mixture of 54 filler material containing 98 plate alumina with a particle size of 60 (T-64 from Alcoa Industrial Chemical Division, Bauxite, AR) and 2 325 mesh powder of magnesium. (sold by AZEAR Johnson Matthew, Seabrook, NH), was placed in a plastic vessel and mixed in a ball mill for 2 hours. A mixture of 54 filler material was then poured into the bottom of the box 52 of graphite foil lining the graphite boat 50, manually compacted and coated with a 6 gram layer of 56 magnesium powder with a grain size of 50 mesh (Alpha Products Inc., Morton Tiokol, Danvers, MA). About 1239 g of base metal 55 containing less than 0.35 weight. Si, less than 0.40 weight. Fe, 1.6; 2.6 weight. Cu, less than 0.20 weight. Mn, 2.6 3.4 wt. Mg, 0.18 0.35 weight. Cr, 6.8 8.0 weight. Zn, less than 0.20 weight. Ti and balance aluminum, were placed on a mixture of 54 filler material in a graphite foil box 52.

Graphite boat 50 and its contents were placed in a retort with room temperature, a retort electric resistance furnace. The retort window was closed and the retort was evacuated to at least 762 mmHg. Art. After the formation of vacuum, nitrogen was introduced into the retort cavity with a flow rate of 2.5 l / min. The retort furnace was heated to approximately 700 ^° C at a rate of 120 ^° C / h and was maintained for 10 hours at 700 ^° C in a flowing nitrogen atmosphere at a flow rate of 2.5 L / min. Then the retort furnace was brought to about 700 ^° C. to about 675 ^° C. at a rate of about 150 ^° C./h. At about 675 ^° C, a graphite boat 50 and its contents were removed from the retort and directional curing was performed. Graphite boat 50 was placed on a graphite plate at room temperature and approximately 500 ml of the external material of profitable extensions (FEE D OL-9, supplied by Foseco Inc. Truk Park. OX) spilled onto the top of the molten base metal contained in a graphite box 52 foil and a ceramic fiber surface layer (CERAB LAN KET, Menville Refractories Products) about 2 '' (51 mm) thick was wrapped around graphite boat 50. At room temperature, the graphite foil box 52 was disassembled to establish the fact that the composite body with the metal matrix was molded.

 Sample D (060889 DAE3).

 In FIG. 8 is a schematic cross-sectional view of the complex used to form a sample of a composite with a metal matrix, as described below. A graphite boat 70 was made with an internal cavity 8 '' (203 mm) long, 4 '' (102 mm) wide and 2.5 '' (63 mm) high, made of AT graphite (manufactured by Union Carbide). A box 71 of graphite foil was 8 '' (203 mm) long, 1.5 '' (38 mm) wide and 3 '' (76 mm) high was placed in a 70 graphite boat. A graphite foil box 71 was made of a piece of graphite foils (Grafoil of Union Carbide) 14 '' long (356 mm), 7.5 '' (191 mm wide) and 0.015 '' (0.38 mm) thick. Four parallel cuts of 3 '' (76 mm) from the side and 3 '' (76 mm) of length were made in graphite foil. Then the graphite foil was bent into a box of 71 of graphite foil, glued together with graphite cement (Ridgiloc, Polycarbon, Valencia, CA) and sewn together with wire. After satisfactory drying, the graphite foil box 71 was placed in a graphite boat 70.

About 1000 g of a mixture of filler material 73 containing 96 weight. alumina plates with a diameter of 10 μm and a thickness of about 2 μm (developed grade F of Al ₂ O ₃ plates, supplied by Dupont de Nemour & Co. Inc. Wilmington D. E.) and 4 weight. powder of magnesium grit 325 mesh. (AEZAR Johnson Matthew, Seabrook, NH), was placed in a four-liter plastic vessel and the rest of the vessel was filled with ethanol to form a slurry mixture. The plastic vessel and its contents were then placed in a ball mill for at least 3 hours. The slurry mixture was subjected to vacuum filtration to separate ethyl alcohol and mixture 73 of filler material. After the removal of essentially ethyl alcohol, the mixture of filler material 73 was placed in an air-open oven set at a temperature of 110 ^{° C.} and dried overnight. The mixture 73 of filler material was then passed through a 40 mesh sieve. to complete her separation. This liquid dispersion method is hereinafter referred to as the “J method”.

 The bottom of the graphite foil box 71 was coated with an approximately 1.5 gram layer of magnesium powder 74 with a grain size of 50 mesh. (Alpha Products, Inc. Morton Tiokolo, Danvers MA), which was adhered to the bottom of the box 71 of graphite foil with graphite cement (Regilokk supplied by Polycarbon, Valencia CA). The mixture 73 of filler material was then poured into the bottom of the box 71 of graphite foil, manually compacted, and coated with a 1.5 gram layer of magnesium powder 75 with a grain size of 50 mesh. (Alpha Products Inc., Morton Tiokolo, Danvers, MA). Approximately 644 g of base metal 72, containing less than 0.25 weight. Si, less than 0.30 weight. Fe, less than 0.25 weight. Cu, less than 0.15 weight. Mn, 9.5-10.6 weight. Mg, less than 0.15 weight. Zn, less than 0.25 weight. Ti and aluminum balance were placed on a mixture of 73 filler material in a graphite foil box 71. Two graphite support plates 76 were 8 '' (203 mm) long, 3 '' (76 mm) wide and 0.5 '' (13 mm) thick were installed along the outer sides of the graphite foil box 71 (see FIG. 12 ) Material 77 of alumina with grit 220 (38 ALUNDUM by Norton Co., Worcester, MA) was placed in a graphite boat around graphite plates 76.

A system containing a graphite boat 70 and its contents was placed in a retort electric resistance furnace at room temperature. The retort window was closed and the retort was evacuated to at least 508 mmHg. Art. The retort furnace was then heated to about 775 ^° C. at a rate of 100 ^° C./h with a nitrogen flow rate of 4 L / min. After 10 hours at 775 ^° C. with a nitrogen flow rate of 4 l / min, the graphite boat 70 and its contents were removed from the retort furnace and directional curing was carried out. A graphite boat 70 was placed on a water-cooled alumina plate at room temperature and about 500 ml of the external material of the profitable allowance (FIDOL-9 sold by Foseco Inc., Brook Park, OX) was poured onto the upper part of the molten base metal contained in a box of 71 graphite foil, and a layer of ceramic fibers (Serablanquet, Menville Refractories Products) about 2 '' (51 mm) thick wrapped around a graphite boat 70. At room temperature, a box of 71 graphite foil folds was taken to establish the formation of a composite body with a metal matrix.

The formed metal matrix composite was then heat treated. The composite was placed in a basket of stainless steel wire, which was then placed in an electric resistance furnace with an air atmosphere. The furnace was brought to 435 ^{° C.} after 40 minutes, held for 18 hours, then the composite was removed from the furnace and cooled in a water bath at room temperature.

 Sample E (072988TAM).

 In FIG. 9 is a schematic cross-sectional view of the complex used to produce a composite sample with a metal matrix, as described below. A stainless steel box 90 with a length of 6 '' (152 mm), a width of 3 '' (76 mm) and a height of 5 '' (127 mm) was made by welding together 300 series stainless steel sheets. A 90 stainless steel box was fettered a box of 91 graphite foil with a length of 6 '' (152 mm), a width of 3 '' (76 mm) and a height of 5 '' (127 mm). Box 91 of graphite foil was made from a piece of graphite foil (Greyfol company Union carbide) 16 '' (406 mm) long, 13 '' (330 mm) wide and 0.015 '' (38 mm) thick. Four parallel cuts 5 '' (127 mm) from the side and 5 '' (127 mm) long were made in graphite foil. The graphite foil was folded and crosslinked to form a graphite foil box 91, then placed inside a stainless steel box 90.

 A mixture of 92 filler material was prepared by mixing in a four-liter plastic vessel about 600 g of a mixture containing about 73 weight. silicon carbide with a grit of 1000 (39CRYSTOLON of Nortor Co., Worcester, MA), 24 wt. whiskers of silicon carbide (the company "Nikkei tekno-rezerch. co. Ltd.", Japan) and about 3 weight. powder of magnesium grit 325 mesh. (firms "AEZAR, Johnson Matthew", Seabrook, NH), and the vessel was placed on a ball mill for about 1 hour

 A layer of approximately 0.75 '' (19 mm) of filler mixture 92 was poured into the bottom of the graphite foil box 91 contained in the stainless steel box 90. Ingots 93 of the base metal containing 10 weight. silicon, 5 weight. copper and aluminum balance and having a total weight of about 1216 g, were placed on top of the mixture 92 of filler material contained in a graphite foil box 91. A stainless steel box 90 and its contents were placed in an outer stainless steel container 94 with a length of 10 '' (254 mm), a width of 8 '' (203 mm) and a height of 8 '' (203 mm). About 15 g of titanium sponge material (Kemalloy Company Inc., Brin Moore, PA) and about 15 g of powdered magnesium with a grain size of 50 mesh. (Alpha Products, Morto Tiokol, Danvers, MA) were sprayed in an external stainless steel container 94 around a stainless steel box 90. A sheet of copper foil 97 covered the opening of the outer stainless steel container 94. The nitrogen purge pipe 98 passed through a copper foil 97.

A system containing a stainless steel container 94 and its contents was placed in an electric resistance furnace with an air atmosphere. The furnace was heated from room temperature to 800 ^o C at a rate of 550 ^o C / h with a nitrogen flow rate of about 2.5 l / min in a stainless steel container 94. After 2.5 hours at 800 ^° C with a nitrogen flow rate of 2.5 l / min, the outer stainless steel container 94 and its contents were removed from the furnace. A stainless steel box 90 lined with graphite foil was removed from an outer stainless steel container 94 and its contents were placed on a copper cooling plate at room temperature having a length of 8 '' (203 mm) and a width of 8 '' (203 mm) and a thickness of 0.5 '' (13 mm) for directionally curing the metal matrix composite. At room temperature, a graphite foil box 91 was removed to confirm the formation of a composite with a metal matrix.

 Sample F (090789DU).

 In FIG. 14 is a schematic cross-sectional view of the complex used to obtain the metal matrix composite sample described below. In this case, an alumina boat with an internal cavity of 3.75 '' (95 mm) long, 1.8 '' (45 mm) wide and 0.79 '' (20 mm) deep was used. A layer of approximately 1/8 inch of filler material 111 containing hollow alumina balls (aerospheres sold by Ceramic Filters Inc. Atlanta GA) was placed at the bottom of alumina boat 110. Ingot 112 of a base metal containing less than 0.25 weight. Si, less than 0.30 weight. F, less than 0.25 weight. Cu, less than 0.15 weight. Mn, 9.5-10.6 weight. Mg, less than 0.15 weight. Zn, less than 0.25 weight. Ti and aluminum balance were placed on a layer of filler material 111 in alumina boat 110.

Alumina boat 110 and its contents were placed in an electric resistance furnace at room temperature. The tube furnace was essentially sealed and its tube-shaped cavity was evacuated at least 762 mm RT. Art. Then nitrogen was supplied to the furnace with a flow rate of 0.5 l / min and the furnace was heated to 800 ^° C at a rate of 300 ^° C / h. The system was maintained at 800 ^° C. for 0.5 hours with a nitrogen flow rate of 0.5 L / min. The tube furnace was then cooled to room temperature at a rate of 300 ^° C./min. At room temperature, alumina boat 110 was removed from the furnace to determine the formation of a composite body with a metal matrix.

 Sample G (123187-DE).

 In FIG. 11 is a schematic cross-sectional view of the complex used to obtain a composite sample with a metal matrix, as described below. A graphite boat 130 was made with a length of 4 '' (102 mm), a width of 4 '' (102 mm) and a height of 3 '' (76 mm) from AT graphite manufactured by Union Carubid. A material of 131 alumina with 24 grit (38 Alundum of Norton Co. Worcester, MA) was placed at the bottom of a graphite boat 130. A box 132 of graphite foil 2 '' (51 mm) long, 2 '' (51 mm) wide and 3 'high '(76 mm) was placed in alumina 131 with a grit of 24, covering the bottom of a graphite boat 130, and the graphite box was surrounded by additional alumina 131 with a grit of 24. Box 132 of graphite foil was made of a piece of graphite foil (Grafoyl firm firm Union caruid), length 8 '' (203 mm), 8 '' wide (203 mm) and 0.015 '' thick (0.38 mm). Four parallel cuts with the calculation of 2 '' (51 mm) from the side and 3 '' (76 mm) in length were made in graphite foil. The cut graphite foil was then folded / bent, glued with a mixture containing 1 weight. including graphite powder (KS-44 company, "Lonza, Inc.", Fair Lone NJ) and 3 weight. parts of colloidal silicon (LUDOX SM firm "E.I. Dupont de Nemour co. Inc.", Wilmington, DE), and stitched together with wire, forming a box 132 of graphite foil.

 Prepressing 133 of alumina fibers with a length of 2 '' (51 mm), a width of 2 '' (51 mm) and a thickness of 0.8 '' (20 mm) was prepared from a mixture containing 90 weight. crushed alumina fibers with a diameter of about 20 μm (fiber FP firm DuPont de Nemour co., Inc. Wilmigton, DE), 10 weight. alumina fibers with a diameter of 3 μm (under the name STAFFIL of the company "ICC Amerikas", Wilmington, DE), was bound using colloidal alumina. Prepressing 133 of alumina fiber, which contained approximately 12 vol. ceramic fibers, placed on the bottom of a graphite foil box 132 in a graphite boat 130. Two base metal ingots 134 2 '' (51 mm) long, 2 '' wide (51 mm) and 1 '' high (25 mm), containing 10 5 weight. Mg, 4 weight. Zn, 0.5 weight. Si, 0.5 weight. Cu and aluminum balance were placed on a prepress 133 of alumina fiber in a box 132 of graphite foil. The space between the perimeter of the base metal ingots 134 and the side wall of the graphite foil box 132 was filled with a paste-like graphite mixture 135 containing 1 weight. including graphite powder (KS-44 company "Lonza Inc.", Fair Lone NJ) and 3 wt. including colloidal silica (LUDOX SM firm E.I. Dupont de Nemour co. Inc. ", Wilmington. DE).

The graphite boat 130 and its contents were placed in a controlled atmosphere furnace at room temperature. The oven door was closed and the oven was evacuated to at least 762 mmHg. Art. Then the furnace was heated to 200 ^o C for 0.75 hours. After at least 2 hours at 200 ^o c and a vacuum of at least 762 mm RT. Art. the furnace was purged with nitrogen with a flow rate of 32 l / min and heated to 675 ^{° C.} for 5 hours. After 20 hours at 675 ^° C with a nitrogen flow rate of 2 l / min, the furnace was turned off and cooled to room temperature. At room temperature, a graphite foil box 132 was removed to determine the formation of a composite body with a metal matrix.

 Sample H (042088-DN).

 In FIG. 16 is a schematic cross-sectional view of the complex used to form a fiber reinforced metal matrix composite sample, as described below. The stainless steel container 150 was 6.5 '' (165 mm) long, 6.5 '' (165 mm) wide and 3 '' (76 mm) high was made by welding together 300 series stainless steel sheets. 150 stainless steel container steel was lined with a 151 box of graphite foil 6 '' (152 mm) long, 6 '' (152 mm) wide and 3 '' (76 mm) high. A graphite foil box 151 was made of a piece of graphite foil (GRAPOIL from Union Carbide) 9 '' (229 mm) long, 9 '' (229 mm wide) and 0.015 '' (0.38 mm) thick. Four parallel cuts with the calculation of 3 '' (76 mm) from the side and 3 '' (76 mm) in length were made in graphite foil. The cut graphite foil was then folded / bent, glued with a mixture containing 1 weight. including graphite powder (KS-44 firm "Lontsa Inc.", Fair Lone. NJ) and 3 wt. h. colloidal silica (LUDOX SM firm E.I. Dupont de Nemour and co. Inc. "Wilmington, DE), and mixed with wire, forming a box 151 of graphite foil. After a sufficiently satisfactory drying of the adhesive box 151 of graphite foil was placed in the lower part of a stainless steel container 150. A layer of approximately 0.25 '' (6.4 mm) thick SiC 152 with a grain size of 90 (39 KRISTOLON from Norton Co., Worcester, MA) was located at the bottom of a graphite foil box 151.

 Pressing 153 of continuous fibers with a length of 6 '' (152 mm), a width of 6 '' (152 mm) and a thickness of 0.5 '' (13 mm) made of alumina fiber with a diameter of about 20 μm (FP fiber from E.I. Dupont de Nemour and co., Wilmington, DE) interfered with the upper part of layer 152 SiC with a grain of 90 in a box 151 of graphite foil lining a stainless steel container 150. Sheet of graphite foil 155 (Union Carbide GRAPOIL, size about 6 '' (152 mm) by 6 '' (152 mm) and 0.015 '' (0.38 mm) with a hole 156 in the center of a graphite sheet with a diameter of about 2 '' (51 mm) was placed on the press 153 continuous fiber flavors. 154 base metal ingots each 3.5 '' (89 mm) long, 3.5 '' (89 mm) wide and 0.5 '' (13 mm) thick, containing less than 0.25 weight Si, less than 0.30 wt. Fe, less than 0.25 wt. Cu, less than 0.15 wt. Mn, 9.5 10.6 wt. Mg, less than 0.15 wt. Zn, less than 0.25 wt. . Ti and balance aluminum, were placed on graphite sheet 155.

A stainless steel container 150 and its contents were placed in a resistance retort electric furnace at room temperature. The retort window was closed and the retort was evacuated to at least 762 mmHg. Art. The retort furnace was then heated to 200 ^° C. for 0.75 hours. After 2 hours at 200 ^° C. with a vacuum of 762 mm Hg. Art. the evacuated retort was purged with nitrogen at a flow rate of 2.5 l / min. The retort furnace was then heated to 725 ^° C. at a rate of 150 ^° C./h with a nitrogen flow rate of 2.5 L / min. The system was maintained at 725 ^° C. for 25 hours with a nitrogen flow rate of 2.5 L / min. The stainless steel container 150 and its contents were then removed from the retort. Then directional curing was carried out by placing a stainless steel container 150 on graphite plates and pouring 90 grit alumina (38 ALORTUM firm Norton Co., Worcester, MA)), which was pre-heated to at least 700 ^o C, on the residual molten base metal and the stainless steel container and its contents were coated with a layer of ceramic fiber (KERABLANKET, Menville Refractories Products). At room temperature, the complex was designed to determine the formation of a composite with a metal matrix reinforced with continuous fiber.

 Sample I (083187-Vg-7).

 A complex similar to that used for Sample G and shown in FIG. 15 was used to form a metal matrix composite sample, as described below. A graphite boat was used, 22.75 "(578 mm) long, 9.75" (248 mm) thick and 63 "(152 mm) high, made of Union Carbide graphite ATJ. 17" (452) box of graphite foil mm), 1 "(25 mm) wide and 1" (25 mm) high was made of a piece of graphite foil (GRAPOIL from Union Carbide) as described in Sample G.

A box of graphite foil was placed in a graphite boat and surrounded by 24 grit alumina (38 ALUNDUM by Norton Co., Worcester, MA). A layer of loose graphite fibers coated with silicon carbide deposited from the gas phase (T 300 Tunnel grade 309. T fibers from coal and oil pitch from Amoco Performance Products, Inc.) was placed in the bottom of the graphite foil box. The same mixture of graphite powder / colloidal silica used to glue the boxes of graphite foil was used to coat the ends of graphite fibers coated with silicon carbide deposited from the gas phase. A base metal ingot 12 '' (305 mm) long, 0.75 '' wide (19 mm wide) and 1 '' thick (25 mm), containing 6 weight. Mg, 5 weight. Zn, 12 weight. Si and aluminum balance were placed on loose graphite fibers coated with silicon carbide in a box of graphite foil. A graphite boat and its contents were placed in a controlled atmosphere furnace at room temperature. The oven door was closed and the chamber was evacuated to at least 762 mmHg. Art. at room temperature. Then the furnace was heated to 200 ^o C for 0.75 hours. After 2 hours at 200 ^o C with a vacuum of at least 762 mm RT. Art. the furnace was purged with nitrogen at a flow rate of 1.5 l / min. The furnace was then brought to 850 ^° C. over 5 hours. After 10 hours at 850 ^° C. with a nitrogen atmosphere supplied at a flow rate of 1.5 l / min, the furnace was cooled to room temperature in 3 hours. At room temperature, a graphite foil box was shown to determine the formation of a composite with a metal matrix (see tab. 1).

 After each of the samples A-1 described above was cooled to room temperature, each was cut across to determine the formation of the composite body with a metal matrix. All samples A-1 in this example were observed with respect to the molding of aluminum metal matrix composites.

 Example 6. This example shows a wide variety of compositions of the filler material, which can be successfully used to form composite bodies with a metal matrix by spontaneous impregnation.

 In the table. 2 contains summarized data on the experimental conditions used to obtain composite bodies with a metal matrix using different base metals, filler materials, temperature and processing time conditions.

 Samples A-D.

 Samples A-D, as described in Example 5, were formed using fused alumina, calcined alumina, plate alumina, and alumina plates as filler material, respectively. Each of examples A-D is contained in table. 2.

 Sample J (030689-D AF).

 This sample was obtained using a complex essentially similar to the complex for sample C, as shown in FIG. 7. A box of graphite foil 4 '' (102 mm) long, 4 '' (102 mm) wide and 3 '' (76 mm) high (made from GRAPOILA manufactured by Union Carbide Corporation) was placed in a graphite boat. Approximately 300 g of powdered magnesium oxide (TECO MoO, C-E-Minerals brand, Greenville, UK) was placed down the graphite foil box, lining a graphite boat. The surface of the magnesium oxide powder was substantially coated with magnesium powder of 50 mesh. (Alpha Products, Inc. Morton Thiokol, Danvers, MA). A base metal ingot containing less than 0.25 weight. Si, less than 0.30 weight. Fe, less than 0.25 weight. Cu, less than 0.15 weight. Mn, 9.5-10.6 weight. Mg, less than 0.15 weight. Zn, less than 0.25 weight. Ti and aluminum balance, 4.5 '' (114 mm) long, 1.5 '' (38 mm) wide and 1.5 '' (38 mm) high, were placed in powdered magnesium oxide and magnesium powder with a grain size of 50 mesh. in a box of graphite foil.

A graphite boat and its contents were placed in a retort resistance electric furnace. The retort window was closed and at room temperature the retort was evacuated to at least 762 mmHg. Art. After reaching the vacuum, the furnace was purged with nitrogen at a rate of 4 l / min. The retort furnace was then heated to 750 ^° C. at a rate of 200 ^° C./h at a nitrogen flow rate of 4 l / min. After 19 hours at 750 ^° C with a nitrogen flow rate of 4 l / min, the retort furnace was cooled to 650 ^° C at a rate of 200 ^° C / h. At 650 ^° C, the retort window was opened and the graphite boat with its contents was removed and placed in contact with the graphite plate for directionally curing the metal matrix composite and the residual base metal. At room temperature, a box of graphite foil was dismantled to determine the formation of a composite with a metal matrix containing magnesium oxide as a filler.

 Sample K (042089-AAI-1).

In FIG. 13 is a schematic cross-sectional view of a complex used to produce a sample of a composite with a metal matrix, as described below. Steel mold 190 with a trapezoidal cross-section, having a closed end length of 3 '' (76 mm) and a width of 3 '' (76 mm), and an open end length of 3.75 '' (95 mm), a width of 3.75 ''(95 mm) and a height of about 2.5''(64 mm) was made of carbon steel 14 caliber 1.9 mm thick. The inner surface of the steel mold was coated with a graphite mixture 191 containing 1.5 vol. including ethanol (manufactured by Pharmco Products Inc., Bayonne, NJ) and 1 vol. including colloidal graphite D AO-154 (Acheson colloid, Port Huron, MI). At least three coatings were applied with a graphite mixture using an air brush on the inside of the container. Each coating of the graphite mixture was dried before applying the next coating. The steel mold was placed in an electric resistance furnace with an air atmosphere brought to 330 ^° C in 2 hours for drying and adhesion of colloidal graphite coatings 191 to steel mold 190.

About 2.2 lbs (1 kg) of partially stabilized zirconia (HSY-3SD, Zirconia Sales Inc., Atlanta, GA) was preliminarily fired in an aluminum crucible with a height of 7 '' (177.8 mm), top diameter 6.25 '' (159 mm) and a lower diameter of 3.75 '' (95 mm) for 1 h at 1350 ^o C. A mixture of filler material 192 was prepared by mixing in a 4 liter plastic vessel approximately 600 g of a mixture containing 95 weight. pre-annealed ZrO ₂ and 5 weight. 325 mesh grit powder (Reed Manufacturing Co., Harst, NJ). The mixture was stirred in a ball mill for about 1 hour, then shaken manually for 10 minutes.

A layer of a mixture of 192 filler material was placed in the bottom of colloidal graphite-coated mold 190 to a depth of 1.75 '' (19 mm). The filler material was essentially coated with a layer of 193 magnesium powder with a grain size of 50 mesh (Alpha Products, Morton Tiokol, Danvers, MA). Base metal ingots containing 99.7 weight. aluminum and a balance of scattered elements, with a total weight of 537 g, was placed on top of a mixture of 192 filler material and a layer of magnesium powder 193 in steel form 190 coated with colloidal graphite. An additional 16.9 g of the second base metal 195 containing 15 weight. silicon and aluminum balance was added to the top of the original base metal 194. Form 190 and its contents were installed in an outer container 196 of carbon steel 12 '' (305 mm) long, 10 '' (254 mm) wide and 10 '' high ( 254 mm). A piece of graphite foil 197 (designated PF-25-H and sold under the trademark Perma-Foyle by TT America, Portland, OR), 12 '' (305 mm) long, 10 '' (254 mm) wide and 0 thick 01 '' (0.25 mm) covered the lower part of the inner cavity of the carbon steel outer container 196. 198 titanium sponge material weighing 20 g (Kemalloy Company Inc., Bryn Moore, PA) and 193 50 g grain powder (Alpha Products Inc., Morton Tiokol, Danvers, MA) 0.8 g was sprayed in an outer carbon steel container 196 around colloidal graphite coated steel mold 190 and on a graphite foil 197. A sheet of copper foil 200 was placed on the opening (open top) of the outer steel container 196. The nitrogen purge pipe 201 was mounted in the side wall of the outer container 196 carbon steel. The outer steel container 196 and its contents were placed in an electric resistance furnace. The furnace was brought from room temperature to 600 ^o C at a rate of 400 ^o C / h with a nitrogen flow rate of 10 l / min, then from 600 ^o C to 800 ^o C at a speed of 400 ^o C / h and a nitrogen flow rate of 2 l / min. The furnace was maintained at 800 ^° C. for 1 hour at a nitrogen flow rate of 2 l / min. The carbon steel outer container 196 and its contents were removed from the furnace, the colloidal graphite steel form 190 was removed from the outer steel container and brought into contact with a room temperature copper cooling plate 8 '' (203 mm) long, 8 '' (203 mm wide) ) and a height of 0.5 '' (13 mm) in order to directionally solidify the molded metal matrix composite.

 Sample L 042789-AX-1.

 Sample L was obtained by using a complex similar to that shown in FIG. 13 with respect to sample K. A mold with a trapezoidal cross section was prepared in the same way as was the case with sample K, except that the mold was burned for 2 hours to cure the colloidal graphite coating.

Approximately 2.2 pounds (1 kg) of Al ₂ O ₃ hardened ZrO ₂ (ZTA-85 from Zirconia Sales Inc., Atlanta GA) was prepared in the same way as the filler material in sample K. A layer of the filler material mixture applied at the bottom, coated with colloidal graphite in a steel mold to a depth of 0.75 '' (19 mm). The filler material was essentially coated with a 50 mesh layer of magnesium powder (Alpha Products Morton Tiokol, Denvers, MA). Base metal ingots containing 99.7 weight. aluminum and the balance of dispersed elements, weighing 368 g, were placed on the top of the filler material mixture, which was coated with magnesium powder. The second base metal containing 15 weight. silicon and aluminum balance, weighing 17.11 g was placed on top of the first base metal. The steel mold coated with colloidal graphite and its contents were placed in an outer carbon steel container 12 '' (305 mm) long, 10 '' (254 mm) wide, and 10 '' (254 mm) high. A piece of graphite tape (index PF25-H and sold under the trademark Perma-Foyle of TT America, Portland, OR) 12 '' (305 mm) long, 10 '' (254 mm) wide and 0.01 '' thick (0.25 mm) was applied to the lower part of the inner cavity of the outer carbon steel container. Titanium sponge material weighing 20 g (Kemalloy Company Inc., Wryn Maur, PA) and powdered magnesium with a grain size of 50 mesh, weighing 2 g, were sprayed around a form coated with colloidal graphite and onto a graphite tape in an outer carbon steel container. A sheet of copper foil was placed on the opening of an outer carbon steel container. The nitrogen purge pipe was mounted in the side wall of the carbon steel outer container.

A closed steel container and its contents were placed in an electric resistance furnace. The furnace was brought from room temperature to 600 ^o C at a rate of 400 ^o C / h with a nitrogen flow rate of 10 l / min, then from 600 ^o C to 800 ^o C at a speed of 400 ^o C / h with a nitrogen flow rate of 2 l / min. The furnace was maintained at 800 ^° C. for 1 h with a nitrogen flow rate of 2 l / min, then cooled to 580 ^° C. The outer carbon steel container and its contents were then removed from the furnace and the steel mold coated with colloidal graphite was removed from the outer carbon steel container and placed on a room temperature copper cooling plate with a length of 8 '' (203 mm), a width of 8 '' (203 mm) and a height of 0.5 '' (13 mm) for directionally curing the molded composite with a metal matrix.

 Sample M.

 In FIG. 14 is a schematic cross-sectional view of the complex used to produce a sample of a composite with a metal matrix, as described below. A graphite boat 210 was made, having an internal cavity measuring 12 '' x 9 '' x 5.5 '' (brand AT. Union Carbide Company). A box 217 was formed from graphite foil of approximately 8 '' (203 mm) long, 4 '' (102 mm) wide, and 3 '' (76 mm) deep (Union Carbide Grafoil) as described in Sample C. Approximately 1 g of powdered magnesium 211 with a grain size of 50 mesh (Alpha Products, Inc.) was placed in the lower part of box 217. A small spray of the coating (not shown in Fig. 14) of graphite cement (Rizhidlokk from Polycarbon) was formed on the bottom of box 217 graphite foil for adhesion of magnesium powder to the bottom of the box 217.

 A mixture of 212 filler material was prepared by mixing approximately 763 g of a mixture containing 98 weight. silicon carbide with a grain size of 1000 mesh (39 Kristolon firm "Norton Co.") and 2 weight. magnesium powder with a grain size of 325 mesh (Aezar company "Johnson Mattey") in the ethanol sludge (by the method J, described in the sample of example 5). This mixture of filler material 212 was then placed in a graphite box 217 on top of the magnesium powder 211.

 A layer of graphite foil 213 (Greyfol from Union Carbide) is approximately 8 '' (203 mm) long, 4 '' (102 mm) wide and 0.015 '' (0.38 mm) thick, having a 214 hole of 1.25 'diameter '(32 mm) in the center of the graphite foil, was placed on the surface of silicon carbide as a filler material 212 in a graphite boat 210. About 1 g of powdered magnesium 215 with a grain size of 50 mesh (Alpha Products Inc.) was placed on the open surface of the filler material 212 around holes 214 in graphite foil 213.

 A 216 base metal ingot weighing about 1237 g and containing 413.0 alloys having a nominal composition of about 11.0 13.0 Si, less than 2.0 Fe, less than 1.0 Cu, less than 0.35 Mn, less than 1.0 Mg , less than 0.50 Ni, less than 0.50 Zn, less than 0.15 Sn and aluminum balance was placed on the surface of graphite foil 213 so that alloy 216 covered the hole 214 in graphite sheet 213.

The reaction system containing the boat 210 and its contents was placed in a retort resistance electric furnace. The furnace was evacuated to at least 508 mm Hg. Art. then nitrogen was purged with a flow rate of about 4.5 l / min. The oven temperature was brought from room temperature to about 775 ^° C. at a rate of 200 ^° C./h. The system was maintained at 775 ^° C for about 20 hours, then the temperature was lowered to 760 ^° at a rate of 150 ^° C / h. At a temperature of 760 ^° C., the system was removed from the furnace and placed on a water-cooled aluminum cooling plate. Approximately 500 ml of exothermic profitable extension material (Fidal-9 of Foseco Inc.) was sprayed over the top of the complex and a layer of ceramic fiber (Kerablanquet of Menville Refractory Products) was wrapped around a graphite boat. Fidal-9 was used to form an exothermic reaction on the upper part of the complex to form a composite with a metal matrix for the purpose of curing during cooling, thereby preventing the formation of shrinkage porosity in the composite with a metal matrix.

 Sample N (060889-DAE-4).

 This sample was obtained using a complex essentially similar to that described in Example 5 for sample D, as shown in FIG. 12. Two ATJ grade graphite plates, 8 '' (203 mm) long, 3 '' (76 mm) wide, and 0.54 (13 mm) thick, were placed in a graphite boat 8 '' (203 mm) long, 4 'wide '(102 mm) and a height of 3' '(76 mm) to form a cavity in a graphite boat of approximately 8' '(203 mm) long, 2' '(50.8 mm) wide and 3' '(76 mm) high. A portion of the graphite boat outside the graphite plates was filled with 220 mesh alumina (38 Alundum of Norton Company). In the cavity between the alumina plates, a box of graphite foil (Grafoil of Union Carbide company) was placed in size of 8 '' (203 mm) x (2 '' (50.8 mm) x 3 '' (76 mm), which was formed as described in Sample C. In the inside of the graphite foil box, 50 mesh grit powder was placed (Alpha Products Inc.) adhered to the bottom of the graphite foil box using graphite cement (Rizhidlokk Polycarbon Ltd.) .

 A mixture of filler material with silicon carbide plates was prepared by the J method described in the sample of Example 5, whereby approximately 303 g of a mixture was obtained with a content of 96 weight. plates of silicon carbide with a diameter of 50 microns and a thickness of 10 microns (firm "C-exis technology, Ltd.") and 4 weight. 325 mesh grit powder (Johnson Matei Aezar). A mixture of filler material was placed on top of the magnesium layer in a graphite boat. A second layer of powdered magnesium with a grain size of 50 mesh in an amount of 1.5 g was placed on top of the mixture of silicon carbide filler material. An ingot weighing 644 g, containing 413.0 alloys, with the composition as set forth in table. 2, was placed on top of the magnesium layer in the system.

A system containing a graphite boat and its contents was placed in a resistance retort electric furnace. The furnace was evacuated to at least 508 mm Hg. Art. then nitrogen was purged with a gas flow rate of 4.0 l / min. The temperature in the oven was raised from room temperature to about 775 ^° C. at a rate of 100 ^° C./h. The system was maintained at 775 ^° C for 10 hours, then the temperature was lowered to 760 ^° C at a rate of 200 ^° C / h. The system was removed from the oven at 760 ^° C. and placed on a water-cooled aluminum cooling plate. Approximately 500 ml of exothermic profitable extension material (Fidal-9 of Foseco Inc.) was sprayed on the top of the complex, a layer of ceramic fibers wrapped around the surface of a graphite boat. Fidal-9 was used to form an exothermic reaction on the upper part of the complex for forcing a composite with a metal matrix to solidify directionally during cooling, thereby preventing the formation of shrinkage porosity in the composite with a metal matrix.

 Sample O (050289. AE-3).

 This sample was obtained in accordance with the schematic complex for sample M, as shown in FIG. 14. The graphite boat was made with the dimensions of the internal cavity 12 '' x 9 '' x 5.5 '' (ATY brand of Union Carbide company). A box of graphite foil 8 '' (203 mm) long, 4 '' (102 mm) wide and 3 '' (76 mm) deep (Union Carbide Grafoil) was formed as described in Sample C. Approximately 1 g 50 mesh magnesium powder (Alpha Products Inc.) was placed on the bottom of a graphite foil box. A small spray coating of graphite cement (Rizhidlokk company "Polycarbon") was made on the bottom of the box of graphite foil for adhesion of powdered magnesium to the bottom of the box.

 Filler material was prepared by mixing 94 weight. plates of titanium diboride with a diameter of 10 μm and a thickness of 2.5 μm (NTS-30 company "Union carbide") and 6 weight. magnesium powder with a grain size of 325 mesh (Aezar, Johnson Matei company) according to the J method as described in Example 5 for sample D. This mixture of filler material was poured onto the top of the magnesium powder in a graphite foil box.

 Graphite foil (Graphoil of Union Carbide) 8 '' (203 mm) x 4 '' (102 mm) x 0.015 '' (0.38 mm) in size with a hole in the center of the foil with a diameter of 1.25 '' (32 mm ) was placed on top of the filler material. About 1 g of powdered magnesium with a grain size of 50 mesh (Alpha Products) was placed on the open surface of the filler material through an opening in a graphite sheet. A base metal ingot of about 1498 g of alloy 520 containing less than 0.25 weight. Si, less than 0.35 weight. Fe, less than 0.25 weight. Cu, less than 0.15 weight. Mn, 9.5-10.6 weight. Mg, less than 0.15 weight. Zn, less than 0.25 weight. Ti and balance aluminum) was placed on top of a graphite foil sheet.

The graphite boat and its contents were placed in a resistance retort electric furnace at room temperature. The retort window was closed and the retort was evacuated to at least 508 mmHg. Art. The retort was then purged with nitrogen at a rate of 4.5 l / min. The retort furnace was then heated from room temperature to 775 ^° C. at a rate of 200 ^° C./h. After 20 hours at 775 ^° C, the retort furnace was cooled to 760 ^° C at a rate of 150 ^° C / h. At 760 ^° C, the retora window was opened and a graphite boat with its contents was removed from the retort onto a water-cooled aluminum cooling plate at room temperature, having a length of 12 '' (305 mm), a width of 9 '' (229 mm) and a thickness of 2 '' (51 mm). Approximately 500 ml of material exothermic profitable nozzle (Fidal-9 company "Foseco Inc.") was sprayed on the top of the complex and a layer of ceramic fiber (kerablanquet company "Manville refractory products") was wrapped around the surface of a graphite boat. A profitable packing material was used to form an exothermic reaction on the top of the residual base metal to assist the metal matrix composite to solidify directionally during cooling, thereby preventing the formation of shrinkage porosity in the metal matrix composite.

 Sample P (071489 DAF-1).

 In FIG. 15 is a schematic cross-sectional view of a complex used to make a composite body with a metal matrix, as described below. A stainless steel container of 6 '' (152 mm) long, 6 '' (152 mm) wide and 7.5 '' (191 mm) high was lined with a 231 graphite foil box measuring 6 '' (152 mm) x 6 '' (152 mm) x 7.5 '' (191 mm), made in accordance with the above examples. Approximately 2 g of 325 mesh powder of magnesium (Johnson Matthew Aezar) was adhered to the bottom of the graphite box using graphite cement (Polycarbon Rizhidlokk). Approximately 500 g of the mixture, 95 weight. powder aluminum nitride with an average particle diameter of 3 6 μm (A-200 AlN company "Advent refractory technology, Inc." Buffalo, NY) and 5 weight. 325 mesh grit powder (Johnson Matthew Aezar) was mechanically mixed in a four liter plastic vessel for 2 hours to obtain a homogeneous mixture of filling material 233. This mixture 233 of filling material was placed in a box 231 of graphite foil. Approximately 1 '' (25 mm) long, a 234 passage of graphite tubes with an internal diameter of 2 '' (51 mm) was installed on the top of the filler material 233. A loose layer of alumina 235 with a grain size of 220 (E-38 Alundu-m by Norton co. ") was poured around the outer diameter of the passage from graphite tubes 234, which was centered on the top of the filler material 233 in the graphite box 230. Enough alumina 235 with grain size 220 was added substantially around the passage 234 from the graphite tubes. About 5 g of powdered magnesium with a grain size of 50 mesh (Alpha Products) was placed in the interior of the passage from graphite tubes to cover the surface of the filler material 233. Approximately 1210 g of the base metal alloy 237 having a nominal composition of 413.0, containing 11.0 - 13.0 weight. Si, less than 2.0 weight. Fe, less than 1.0 weight. Cu, less than 0.35 weight. Mn, less than 0.10 weight. Mg, less than 0.50 weight. Zn, less than 0.15 weight. Sn and aluminum balance were placed on top of the reaction components, as shown in FIG. twenty.

A system containing a steel container 230 and its contents was placed in a resistance retort furnace and the furnace was evacuated to at least 508 mm Hg. Art. and purged with nitrogen gas at a flow rate of 4.0 l / min. The furnace was brought from room temperature to 200 ^° C. at a speed of 200 ^° C./h, maintained at 200 ^° C. for about 49 hours, then cooled to 550 ^° C. at a speed of 200 ^° C./h, maintained at 550 ^° C. for 1 hour, then brought to 775 ^o C at a rate of 150 ^o C / h The system was maintained at 775 ^° C for 10 hours, then cooled to 760 ^° C at a rate of about 150 ^° C / h. At 760 ^° C, the system was removed from the furnace and directed in the direction of cooling using a profitable nozzle. The system was placed on a water-cooled aluminum cooling plate having a length of 12 '' (305 mm), a width of 9 '' (229 mm) and a thickness of 2 '' (51 mm). Approximately 500 ml of material exothermic profitable nozzle (Fidal-9 company "Foseco Inc.") was sprayed on top of the complex. A layer of ceramic fibers (Manville Refractory Products' kerablanquette) was wrapped around a stainless steel container to isolate the system. A profitable nozzle material was used to form an exothermic reaction on the top of the residual base metal to aid the metal matrix composite to solidify directionally during cooling, thereby preventing formation shrinkage porosity in a composite with a metal matrix.

 The mechanical properties of some composite bodies with a metal matrix formed in accordance with this example are given in table. 2. A description of the methods used to determine the mechanical properties is given below.

 Measurement of tensile strength (PPR).

 The tensile strength of some metal matrix composites was determined using ASTM N B557-84 "Standard tensile test methods for forged and cast aluminum and magnesium products." Rectangular specimens were used for tensile testing with a length of 6 '' (154 mm), a width of 0.5 '' (413 mm) and a thickness of 0.1 '' (2.5 mm). The control section of the rectangular tensile test specimens was 3/8 inch (10 mm) wide and 0.75 '' (19 mm) long and the radius from the end section to the control section was 3 '' (76 mm). Four aluminum grip ears 2 '' (51 mm) long, 0.5 '' (13 mm) wide and 0.3 '' (7.6 mm) thick were attached to the end sections of each rectangular specimen for tensile testing using epoxy resin (referred to as Epoxy Patch, Dexter Corporation of High Sol Aerospace and Industrial Products, Seabrook, NH). The voltage on rectangular samples for tensile testing was measured using strain gauges (bridges 350 Ohm) with the index CEE-06-3750YY-350 firm "Micromjurments of Raleigh", NK. Rectangular tensile test specimens, including aluminum grip ears and strain gauges, were placed in wedge grips on a Syntech 5000 lbs (2269 kg) dynamometer (universal testing device, model N CITS 2000/6, manufactured by System Integration Technology Inc. , Starton, MA.). A computer data sampling system was connected to the measuring unit and strain gauges recorded test reactions. Rectangular tensile test specimens were deformed at a constant speed of 0.039 in / min (1 mm / min) to rupture. The maximum voltage, maximum force, and force before a rupture was formed were calculated from the geometry of the sample and the recorded reactions using a computer program.

 Measurement of the module by the resonance method.

 The elastic modulus of the metal matrix composites was determined by the method of sound resonance, which is essentially the same as the method of ASTM C848-88. A composite sample of 1.8 2.2 inches long, 0.24 inches wide and 1.9 inches thick (45 -55 x 6 x 4.8 mm, respectively) was placed between two sensors isolated from room vibrations using an air table supporting granite stone. One of the sensors was used to excite frequencies in a composite sample, while the other was used to control the frequency response of a composite with a metal matrix. The elastic modulus was determined by scanning in frequencies, monitoring and recording the characteristic levels for each frequency and by noting the resonant frequency.

 Measure the fracture toughness of a metal matrix material using a specimen with herringbone notches.

 The method of Munz, Shannon and Bassey was used to determine the fracture toughness of materials with a metal matrix. The fracture toughness was calculated from the maximum load of the specimen with herringbone type notches at four load points. Specifically, the geometry of the herringbone-type specimen was as follows: 1.8 2.2 inches (45 55 mm) long, 0.19 '' (4.8 mm) wide, and 0.24 '' (6 mm) high . A herringbone-type notch was made with a diamond saw to facilitate crack development in the specimen. Samples with herringbone-type notches, with the notch apex facing down, were placed in a clamping device in a universal testing apparatus. A notched specimen with herringbone notches was placed between two fingers (studs) at a distance of 1.6 '' (40 mm) from each other and approximately 0.79 '' (20 mm) from each finger. The upper side of the herringbone-shaped specimen came into contact with two fingers at a distance of 0.79 '' (20 mm) from each other and about 0.39 '' (10 mm) from the notch. The maximum load was measured using the CITS 2000/6 Syntec model of a universal test apparatus manufactured by System Integration Technology Incorporated. A lateral speed of 0.02 in / min (0.58 mm / min) was used. The dynamometer sensor of the universal test apparatus had an interface connection with a computer data sampling system. The geometry of the specimen with herringbone notches and the maximum load were used to calculate the fracture toughness of the material. Several samples were used to determine the average fracture toughness for a given material.

 Quantitative Fine Analysis (CIA).

 The volume fraction of the filler, the removable fraction of the base metal and the volume fraction of porosity were determined by the method of quantitative fine analysis. The presented composite material sample was mounted and polished. A polished sample was placed on the stage of a Nikon Microphoto FX optical microscope with a DAgE-MTI 68 series video camera manufactured by Michigan City connected to the upper port. The camcorder signal is sent to the DV 4400 model of the Scientific Optical Analytical System manufactured by Lamont University of State College, PA. With a corresponding magnification, ten video images of the microstructures were made through an optical microscope and loaded into the Lamont Scientific Optical Analytical System for storage. Video images taken at 50 to 100 times magnification, and in some cases, at 200 times magnification, were digitally processed to even out the light. For video images taken at 200-100x magnification, digital processing with respect to light leveling was not required. The video images under equal illumination, in the ranges of the gray level and special color intensities, were intended for specific microstructural faults, special filling material, base metal or porosity, etc. To check the correctness of the set color values and intensities, a comparison was made between the video image with the set values and the initially obtained video images. If a discrepancy was noted, corrections were made in relation to the set values of the video image using a manually sampling pen and a digital sampling console. Presented video images with preset values were analyzed automatically using computer programming tools contained in the Lamont Scientific Optical Analytical System to obtain the percentage of the filler area, the percentage of the base metal area, and the percentage of porosity area, which are essentially the same as the volume percent.

 After the above samples were cooled to room temperature, each was cut across to determine the formation of a composite body with a metal matrix. All samples A-C and J-P in this example were observed with respect to the formation of composites with an aluminum metal matrix.

 The mechanical properties of the samples are summarized in table. 2.

 Example 7

 This example shows that various filler mixtures of silicon carbide can be used to successfully form composite bodies with a metal matrix by spontaneous impregnation. A change in filler loading can be achieved depending on the size of the filler material and / or the processing conditions used. In the table. 3 contains a summary of the experimental conditions used to obtain composite bodies with a metal matrix in this example, including changes in base metals, filler materials, working temperature conditions and processing time.

 Samples Q-AH.

 These samples were formed essentially in the same manner as sample C in Example 5 and as shown in FIG. 7 in a schematic cross-section, with the exception that magnesium powder was not placed on the bottom of the graphite foil box before the introduction of the filler material.

 Example AI-AJ.

 These samples were obtained essentially the same as sample K in example 5 and as shown in a schematic cross section in FIG. 13.

 After the above samples were cooled to room temperature, each was cut across to determine the formation of a composite body with a metal matrix. All Q-AJ samples in this example were observed with respect to the formation of composites with an aluminum metal matrix.

 The mechanical properties of the samples were measured using standard test methods, as described previously, and the mechanical properties of the samples are summarized in table. 3.

 Example 8

 This example shows that composite bodies with a metal matrix can be formed over a wide range of processing time periods. The time period of the impregnation of the filler material with the base metal in the presence of the impregnating atmosphere and the impregnation enhancer or the initial component of the impregnation amplifier or the initial component of the impregnation amplifier may vary depending on the desired result. In the table. 4 summarizes the experimental conditions used to obtain composite bodies with a metal matrix in a wide range of processing time periods, including base metal, filler material and processing conditions.

 Sample AL-AN.

These samples were obtained in the same manner as sample C in example 5 and as shown in schematic section in FIG. 7, except that the graphite boat was coated with colloidal graphite (AO-154 from Acheson Colloid, Port Huron, MI) instead of lining with a box of graphite foil. The system was heated from room temperature to 350 ^o C at a speed of 200 ^o C / h, maintained at 350 ^o C for about 7 hours, then heated to 550 ^o C at a speed of 200 ^o C / h, maintained at 550 ^o C for 1 h, then heated to 775 ^o C at a speed of 150 ^o C / h and maintained at 775 ^o C for the time periods shown in table. 4. In addition, after removing the reaction system from the furnace, the formed composite was placed on a water-cooled aluminum cooling plate for directionally curing the composite.

 Example 9

 This example shows that the mechanical properties of composite bodies with a metal matrix can be changed using directional curing and / or subsequent heat treatment. In the table. 5 contains summary data on the applied experimental conditions for the formation of composite bodies with a metal matrix and the mechanical properties obtained for the formed composite bodies.

 Samples C, AQ A.

 These samples were obtained in a manner analogous to the method described with respect to sample C in Example 5 and shown in schematic section in FIG. 7. Samples AQ A are heat treated T-6, as described below.

 Heat treatment T6.

The composites were placed in a stainless steel wire basket, which was then placed in a resistance electric furnace with an air atmosphere heated to 500 ^° C. The composites were heated for 1 h at 500 ^° C, then they were removed from the furnace and cooled to room temperature using a water bath. To enable the deposition process to occur, the composites were either specially aged at 160 ^° C for 10 hours or naturally aged at room temperature for about one week.

 Samples of AT-AV.

These samples were obtained by a method essentially similar to that described with respect to sample C in example 5, except that: 1) magnesium was not placed in the lower part of the graphite foil box used; 2) the reaction systems were maintained at 750 ^° C. for 15 hours. AYY-AY samples were heat-treated with T4 as described in Example E of Example 5.

 After the above samples were cooled to room temperature, each was cut across to determine the formation of a composite body with a metal matrix (see table 5).

 Example 10

 This example shows that the nitrogen content in a composite body with a metal matrix formed by spontaneous impregnation can be intentionally changed. Depending on the combination of the base metal, filler material, the impregnating atmosphere and the impregnation enhancer or the initial component of the impregnation enhancer, as well as the conditions of this treatment, the nitrogen content in the molded body of the composite with a metal matrix can be adapted (adapted) in accordance with the requirement.

 In the table. 6 summarizes the experimental conditions used to form the metal matrix composite bodies in this example, including base metals, filler materials, processing temperature and time conditions, and the nitrogen content of each metal matrix composite body that is molded.

 Samples A-BB.

 These samples were obtained by a method that was essentially used to obtain sample F in Example 5, as shown in a schematic section in FIG. ten.

 Sample BC.

 This sample was obtained in the same essentially method as sample B in example 5 and as shown schematically in section in FIG. 6.

 Sample BD.

This sample was obtained in the same manner as sample K in Example 6 and as shown in FIG. 13 in cross section, except that the inside of the steel mold was coated by spraying with graphite material (Daylon grade AE, Daylon Industries Inc. . ", Berea OX) and burned at 260 ^o C for 1 h instead of lining the steel form with a box of graphite foil.

 Sample BE.

 This sample is a control sample that was used to determine the nitrogen content in an aluminum alloy that did not contain filler material. The internal cavity of the steel mold, which was essentially the same as that used for the BD specimen, was coated with graphite material (Dilen grade AE, Dilen Industries Inc.). Aluminum alloy 520.0 was placed in a steel mold and the reaction system was heated, as shown in table. 6.

After the above samples were cooled to room temperature, the nitrogen content in the composite bodies was determined. The nitrogen content in the metal matrix composites was measured using the method AS TM E 1019-87A "Determination of carbon, sulfur, nitrogen, oxygen and hydrogen in steels and alloys of iron, nickel and cobalt." This method uses the thermal conductivity of an inert gas at the melting stage to measure the nitrogen content. The sample was placed in a small graphite crucible and melted with either copper or nickel in a flowing helium atmosphere at least at 1900 ^° C. Nitrogen present in the sample was released as molecular nitrogen and separated from other molecular elements, for example, hydrogen and carbon monoxide, and the thermal conductivity of gas was measured mixtures of nitrogen-helium. This test was carried out on a TC436 industrial oxygen-nitrogen analyzer designed for automatic operations and calibrated in standard units of known nitrogen contents (see Reference material according to NIST 73C standards with a content of N ₂ 0,037 and AlN with a content of N ₂ 32,6).

 Example 11

 An example shows that the wear resistance of a molded composite body with a metal matrix can vary directionally depending on the filler material used for alumina. Various alumina fillers were used in combination with a base metal, an atmosphere-impregnating impregnation amplifier, and an initial component of an impregnation amplifier or an initial component of an impregnation amplifier to obtain composite bodies with a metal matrix in this example, a spontaneous impregnation method.

 In the table. 7 summarizes data on the base metal, filler material, processing conditions and the degree of wear of the composite bodies with a metal matrix formed in this example, as well as the degree of wear of the untreated metal (sample BL).

 Samples A, BF, Bg.

 These samples were obtained essentially in the same manner as sample A in Example 5 and as shown in FIG. 5.

 Samples BH BK, B.

 These samples were obtained essentially in the same manner as sample B in Example 5 and as shown in FIG. 6.

 Sample BL.

 This sample is a comparative control sample in which the 520.0 aluminum alloy was subjected to a wear test as described below.

 The wear test operation for the samples above was carried out using the Abrasive Motion Test, which is a modification of A S TM 075-82 “Abrasive Sludge by Miller Test Number” contained in A S TM Standards, Volume 3.02.

 This modified test determines the degree of wear of test materials exposed to standard sludge. This type of moving sludge abrasion test is common with slurry pump manufacturers and is used to evaluate the materials offered for use in slurry pumps.

 a) Test device.

The test device includes four mechanical rods with wear test blocks on each rod. Mechanical rods have the possibility of free articulated rotation of the relative movable cross member, connections to the crankshaft, which rotates at a speed of 48 rpm by means of a corresponding connecting rod and engine. This mechanism provides horizontal reciprocating movement with wear test rods with a stroke length of approximately 8 "(203 mm). Each mechanical rod receives a load of 5 pounds (2.3 kg) directly above the wear test block. A cam is provided for instant lifting of each mechanical rod and thus the unit for testing wear from rubber edges at the end of the cycle.Plastic trays with a length of 15 '' (381 mm), a width of 3 '' (76 mm) and a height of 2 '' (51 mm) are used to contain abrasive slurry and each mechanical w The ok has a separate tray. A neoprene rubber pad of approximately 0.125 '' (3.2 mm) thick is mounted on the bottom of the tray. The formed elastomer is used to hold the rubber pad in place at the bottom of the tray and form a U-shaped groove along the length of the wear test unit. A 45 ^° tilt at the end of the cam cycle generates a push or counterflow of sludge beneath the raised wear test block. Holders of the wear test block are 2 '' (51 mm) long, 2 '' (51 mm) wide and 0.5 '' (13 mm) thick were made of plastic with a slot for receiving blo a wear test and a slot for fixing the wear test block with a clamping screw through the holder. The holder of the wear test block is connected to the mechanical rod in such a way that it makes it possible to adjust the wear test block vertically and establish parallelism with the rubber pad. The test device can operate essentially automatically for infinite time.

 B) Test conditions.

The possible range changes under test conditions are as follows:
I. Type of particles: any (silica, aluminum, etc.).

 II. Particle size: 500-5000 microns (lm).

 III. Particle Concentration: 0 to 100 weight. solid matter.

 VI. Sludge volume: 0 200 ml.

V. Sludge temperature: 30 ^o C (room temperature).

 VI. sludge pH: 1–14 (with modification).

 VII. Wear Test Unit Load: 0 5 lbs (0 2.3 kg).

 Viii. Time: endlessly, typically 4 hours

 c) Test sample.

The wear test blocks were partitioned from the base material using a diamond circular saw and finely ground on a surface grinder to a final size: 1 '' (25 mm) long, 0.5 '' (13 mm) wide and 0.2 'thick '(5 mm) to 0.4 (9 mm)
d) Test procedure.

The wear test blocks were ultrasonically cleaned in methanol for 15 minutes, dried in a vacuum oven heated to 150 ^° C for at least 15 minutes, brought to room temperature in a dryer for 15 minutes, and then weighed to an accuracy of ± 0.1 mg. The wear test blocks were then mounted on the holders of the wear test blocks and checked for proper vertical and horizontal alignment.

 The corresponding amount of abrasive particles and water was weighed to an accuracy of ± 0.1 g, mixed and then lowered into place, thereby lowering the wear test blocks into the abrasive sludge, and the reciprocating movement started by turning on the electric motor.

The wear test units were driven back and forth in an abrasive slurry at a predetermined frequency for a predetermined period of time (typically 4 hours). After a predetermined period of time, the mechanical rods rose and the wear test blocks were removed. The wear test blocks were cleaned, dried and weighed again exactly the same as before the test. The weight loss and density of the wear test unit were used to calculate volume losses and ultimately the degree of wear (cm ³ / h). The temperature and pH of the slurry were measured at the beginning and at the end of the test. The results are shown in table. 7.

 Example 12

 This example shows that the wear resistance of the formed metal matrix composite body can intentionally vary depending on the silicon carbide filler material used. Various fillers of silicon carbide were used in combination with the base metal, the impregnating atmosphere and the impregnation enhancer, or the initial component of the impregnation enhancer to form composite bodies with a metal matrix in these examples by spontaneous impregnation.

 In tab. 8 contains summary data on the base metal, filler material, processing conditions and the degree of wear of composite bodies with a metal matrix formed in Example 12, as well as the degree of wear of the raw metal (BS sample).

 Samples BM, BN.

 These samples were obtained in the same essentially the same way as sample A in example 5 and as shown in FIG. 5.

 Samples BO BQ.

 These samples were obtained essentially in the same manner as sample B in Example 5 and as shown in FIG. 6.

 Sample BR.

 This sample was obtained essentially in the same manner as sample K in Example 6 and as shown in FIG. 13.

 Example 13

 This example shows that the mechanical properties of the formed metal matrix composite body can intentionally vary depending on the size of the filler material used.

 In the table. 9 contains summary data on the base metal, filler material, processing conditions, and mechanical properties of composite bodies with a metal matrix in this example, formed by spontaneous impregnation.

 Samples BT, BU, Q, BV.

 These samples were obtained essentially in the same manner as sample C in Example 5 using a system as shown in FIG. 7 in cross section, with the exception that magnesium powder was not used at the bottom of the graphite foil box before the introduction of the filler material.

 Example 14

 This example shows that the coefficient of thermal expansion of a composite body with a metal matrix formed by spontaneous impregnation and which contains silicon carbide as a filler material can intentionally vary depending on the particle size (s) of the filler material.

 In the table. 10 shows data on the base metal, filler material, processing conditions and coefficient of thermal expansion in relation to the samples obtained in this example.

 Samples BYY-CS.

 These samples were obtained essentially in the same manner as sample N in Example 6 and as shown in FIG. 7. In the table. 10 shows the reaction components and processing conditions for each sample. In the CF sample, instead of using a box of graphite foil in a graphite boat, a graphite coating (DAg 154, Acheson Colloid) was applied to the interior cavity of a graphite boat. The filler material was then placed in a graphite boat in substantially the same manner as schematically shown in FIG. fourteen.

 The mechanical properties were determined using the mechanical test method described above.

 Example 15

 This example shows that fiber reinforced composite bodies with a metal matrix can be formed by spontaneous impregnation.

 In the table. 11 shows combinations of a base metal, a filler material, and reaction conditions used to form composite bodies with a metal matrix of the above samples. In the table. 11 also shows a method of cooling each composite body and subsequent heat treatment, if applicable.

 Samples of CT-CY.

 These samples were obtained essentially in the same manner as sample G in Example 5 and as shown in FIG. eleven.

 Samples of CZ-DA.

 These samples were obtained essentially in the same manner as sample C in Example 5 and as shown in FIG. 7, except that: 1) magnesium powder was not used, 2) the container was made of stainless steel, not graphite, 3) a layer of ceramic fibers encircled the container during heating.

 Samples of DB-DD.

 These samples were obtained essentially in the same manner as sample G in Example 5 and as shown in FIG. 11, except that a steel plate was placed under a box of graphite foil and a graphite sheet with a hole in the center with a diameter of 2 '' (51 mm) was installed between the filler material and the base metal.

 Samples of DE-Dg.

 These samples were obtained essentially in the same manner as sample H in Example 5 and as shown in FIG. 12, except that a 0.5 '' (13 mm) layer of silicon carbide was placed on the bottom of the stainless steel container, instead of a box of graphite foil, an opening in the graphite foil between the base metal and the filler material constituting a gap of about a width 1/2 inch (13 mm) and 5 '' (127 mm) long with a 2 '' (51 mm) hole in the center of the gap.

 Samples of DH-DI.

 These samples were obtained in essentially the same manner as the DE-Dg samples, except that the silicon carbide layer was not used in the system.

 The mechanical properties of composite bodies with a metal matrix were determined by mechanical tests, as described above, and are given in table. 11. The mechanical properties of these composite bodies were measured by a method essentially similar to the D-3552 AS TM standard.

 Example 16

 This example shows that preforms having a high volume fraction of the filling material can spontaneously be impregnated to form composite bodies with a metal matrix.

 In FIG. 16 is a schematic cross-sectional view of the complex used to form the metal matrix composite in this example, as described below. Steel mold 250 was fabricated with an internal cavity of 6 '' (152 mm) long, 6 '' (152 mm) wide, and 6 '' (152 mm) deep. The bottom surface of the steel mold 250 was coated with a piece of graphite foil 251 (Grafoyl of Union Carbide) 3 '' (76 mm) long, 3 '' wide (76 mm) and 0.015 '' (0.38 mm) thick. A prepress 252 of silicon carbide (obtained from "I Sverd R element Inc.") having an outer diameter of 1.75 "" (45 mm) and an inner diameter of 0.75 '' (19 mm) and cut off with a length of 3 '' (76 mm), was wrapped in a piece of graphite foil 253 and placed on graphite foil 251 in a steel box 250. Alumina 254 with a grain of 90 (38 Alundum by Norton Co.) was poured into the space between the prepress 252 of silicon carbide and the steel mold 250. Internal the silicon carbide prepress cavity was substantially filled with 255 graphite powder (KS 44 from Lonza Inc.). A box 256 of graphite foil with a length of 5.75 '' (146 mm), a width of 5.75 '' (146 mm) and a height of 3 '' (76 mm) was made according to the method described in sample C of example 5. A hole 257 in diameter 1.75 '' (43 mm) and corresponding to the outer diameter of the silicon carbide preform 252 was cut out at the bottom of the graphite foil box 256 and the graphite foil box 256 was mounted around the top of the silicon carbide prepress 252 in a steel mold 250. Powder magnesium 258 with a grain size of 100 mesh (from Hart Corporation) was placed on top of the prepress ki 252 silicon carbide accommodated in a box 256 of the graphite foil. Base metal 259 containing 2 weight. silicon, 6 weight. magnesium and balance aluminum, was placed in a box 256 of graphite foil containing 250 in steel form.

 The steel mold 250 and its contents were placed in a resistance retort electric furnace. The retort window was closed and the retort was evacuated to at least 762 mmHg. Art.

After the vacuum was reached, nitrogen was introduced into the retort chamber with a flow rate of 3 l / min. The retort furnace was heated to 800 ^{° C.} at a rate of 200 ^° C./h and was maintained for 10 hours at 800 ^° C. with a nitrogen purge at a flow rate of 3 L / min. The retort furnace then lowered its temperature from 800 ^° C to 675 ^° C at a rate of 200 ^° C / h. At 675 ^° C., the steel mold and its contents were removed from the retort and placed on a graphite plate at room temperature for directionally curing the metal matrix composite and the residual base metal. At room temperature, the complex was dismantled to determine that the base metal spontaneously impregnated the prepress.

 The formed composite with a metal matrix was then cut across, installed, polished and subjected to quantitative fine analysis.

 The results of quantitative visual analysis showed that the loading of the reinforced silicon carbide of the composite was approximately 78, thereby showing that the metal matrix composites can be molded by spontaneous impregnation of the prepress with a high volume fraction of the filling material.

Claims (39)

1. A method of manufacturing a composite material with a metal matrix, comprising spontaneous impregnation of a non-reactive filler with molten metal in a gas atmosphere in the presence of an impregnation amplifier, wherein aluminum or its alloy is used as the matrix metal, and a ceramic material as the non-reactive filler, characterized in that as gas atmosphere use an atmosphere containing nitrogen or oxygen, as an amplifier for impregnation of at least one element selected from the group containing s calcium, strontium, magnesium, and zinc, as the spontaneous infiltration is carried out at 675 1200 ^o C for 1 to 60 hours.  2. The method according to p. 1, characterized in that spontaneous impregnation is carried out using a barrier means containing material that is permeable to the gas atmosphere.  3. The method according to p. 1 or 2, characterized in that the spontaneous impregnation is carried out using a barrier agent selected from the group consisting of carbon, graphite, titanium diboride and finely divided flake material not wetted by aluminum or its alloy.  4. The method according to p. 1, characterized in that as the barrier means using the base metal of the matrix.  5. The method according to p. 1, characterized in that the impregnation amplifier is introduced into the gas atmosphere.  6. The method according to p. 1, characterized in that the impregnation amplifier is brought into contact with at least part of the filler for at least part of the impregnation period.  7. The method according to p. 1, characterized in that the impregnation activator is located on the border between the filler and the matrix metal.  8. The method according to p. 1, characterized in that the impregnation amplifier is alloyed with the matrix metal.  9. The method according to p. 1, characterized in that the impregnation amplifier is located in the matrix metal and the filler.  10. The method according to p. 1, characterized in that the impregnation amplifier is located in at least two of the following environments: matrix metal, filler, gas atmosphere.  11. The method according to p. 1, characterized in that the compressed billet is used as a filler.  12. The method according to p. 1 or 11, characterized in that the pressed billet is made by any of the following methods: slip casting, dry briquetting, casting, tape casting, tape molding, isostatic pressing, extrusion, injection molding, compaction of loose particles.  13. The method according to p. 1, characterized in that at least one material selected from the group consisting of oxides, carbides, borides, nitrides is used as a filler.  14. The method according to p. 1, characterized in that the filler material is used in the form of powders, flakes, plates, microspheres, whiskers, beads, fibers, particles of fiber mats, crumbled fibers, balls, tablets, tubes and heat resistant fabrics.  15. The method according to p. 1 or 14, characterized in that as a filler using a material with a particle size of 1 100 microns.  16. The method according to p. 1, characterized in that as a filler use a material with limited solubility in the molten metal of the matrix.  17. The method according to p. 1, characterized in that at least a material selected from the group consisting of alumina, magnesite, zirconium dioxide, silicon carbide, titanium diboride, aluminum nitride and mixtures thereof is used as a filler.  18. The method according to p. 1 or 17, characterized in that at least one material selected from the group consisting of molten alumina particles, calcined alumina particles, crushed alumina fibers, continuous alumina fibers, silicon carbide particles, is used as a filler silicon carbide coated fibers, zirconia particles, titanium diboride plates, aluminum nitride particles and mixtures thereof.  19. The method according to p. 1, characterized in that aluminum is used as the matrix metal, at least one element selected from the group consisting of magnesium, strontium, calcium is used as an impregnation enhancer, and a substance containing nitrogen.  20. The method according to p. 1, characterized in that aluminum is used as a matrix metal, zinc is used as an impregnation enhancer, and an oxygen-containing substance is used as a gas atmosphere.  21. The method according to p. 1, characterized in that aluminum is used as the matrix metal, as an amplifier for impregnation of strontium and / or magnesium.  22. The method according to p. 1, characterized in that the matrix metal using an aluminum alloy with an element selected from the group consisting of silicon, iron, copper, manganese, chromium, zinc, calcium, magnesium and strontium.  23. The method according to p. 1 or 9, characterized in that aluminum is used as the matrix metal, and magnesium is used as an impregnation enhancer. 24. The method according to p. 1, characterized in that the molten metal of the matrix is heated to a temperature of at least 1100 ^o C. 25. The method according to p. 1, characterized in that the impregnation is carried out at 675 - 1000 ^o C. 26. The method according to p. 1, characterized in that the impregnation is carried out at 750 - 800 ^o C. 27. The method according to p. 1, characterized in that the impregnation is carried out for 1
30 h  28. The method according to p. 1, characterized in that the impregnated filler is subjected to heat treatment.  29. A composite material with a metal matrix based on aluminum or its alloy, comprising a non-reactive ceramic filler, containing at least one substance selected from the group consisting of oxides, carbides, nitrides, borides, characterized in that it contains components in the following ratio about Non-reactive filler 10 95
Metal matrix 5 90
30. The material according to p. 29, characterized in that as a metal matrix it contains an aluminum alloy with an element selected from the group consisting of silicon, iron, copper, manganese, chromium, zinc, calcium, magnesium and strontium.  31. The material according to p. 29, characterized in that the metal matrix further comprises aluminum nitride.  32. The material according to p. 29, characterized in that it contains a filler with a non-reactive coating.  33. The material according to p, characterized in that as a non-reactive coating it contains a ceramic coating.  34. The material according to p. 33, characterized in that the ceramic coating contains at least one substance selected from the group consisting of oxides, carbides, borides and nitrides.  35. The material according to p. 29 or 34, characterized in that as the oxide it contains at least one substance selected from the group consisting of alumina, zirconia, alumina and magnesium oxide.  36. The material according to p. 29 or 34, characterized in that it contains silicon carbide as carbide.  37. The material according to p. 29 or 34, characterized in that as boride it contains at least one substance selected from the group consisting of aluminum boride and titanium boride.  38. The material according to p. 29 or 34, characterized in that as the nitride it contains at least one substance selected from the group consisting of aluminum nitride and silicon nitride.  39. The material according to p. 31, characterized in that the non-reactive filler contains a mixture of at least two substances selected from the group consisting of oxides, carbides, borides, nitrides. 40. The material according to p. 29, characterized in that it has a coefficient of thermal expansion (6.5 17.7) • 10 ^{-6 o} C ^-1 .

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