TW201733713A - Methods of making metal matrix composites including inorganic particles and discontinuous fibers - Google Patents

Abstract

A method of making a porous metal matrix composite is provided. The method includes mixing a metal powder, a plurality of inorganic particles, and a plurality of discontinuous fibers to form a mixture. The method further includes sintering the mixture to form the porous metal matrix composite. Typically, the inorganic particles and the discontinuous fibers are dispersed in the metal. The metal matrix composite has a lower density than the metal without sacrificing all of the mechanical properties or appearance of the metal.

Description

Method of making a metal matrix composite comprising inorganic particles and discontinuous fibers

The present disclosure relates to a method of making a metal matrix composite comprising a mixture of a metal substrate and other materials such as a filler material.

Metal matrix composites have long been considered promising materials due to their combination of high strength, high rigidity and lightweight. Metal matrix composites generally comprise a metal matrix reinforced with fibers or other filler materials.

The present disclosure provides methods for making lightweight metal matrix composites. There is a continuing need to form a method of forming a metal matrix composite having a lower encapsulation density than metal while maintaining a quasi-physical property.

In one aspect, the present disclosure provides a method of making a porous metal matrix composite. The method includes mixing a metal powder, a plurality of inorganic particles, and a plurality of discrete fibers to form a mixture. The method further includes sintering the mixture to form the porous metal matrix composite. Generally, the inorganic particles and the discontinuous fibers are dispersed in the metal.

Various unexpected results and advantages are obtained in the illustrative embodiments of the disclosure. An advantage of at least one exemplary embodiment of the present disclosure is that a porous metal matrix composite is produced, the metal matrix composite containing inorganic particles and discontinuous fibers dispersed in the metal exhibits a lower encapsulation density than the metal and is acceptable Both the drop strength (eg, plastic drop in a tensile stress-strain curve). Moreover, in accordance with at least some exemplary embodiments of the present disclosure, it is not necessary to use any coating on the inorganic particles to provide a metal matrix composite having inorganic particles effectively dispersed in the metal. The inorganic particles in the metal matrix composite generally remain intact, and at least some of the exemplary embodiments of the present disclosure have a very small amount of broken particles.

The above summary of the disclosure is not intended to illustrate the disclosed embodiments or the embodiments. The following description more particularly exemplifies illustrative embodiments. Guidance is provided through a list of examples in several places throughout the text of the application, which can be used in various combinations. In each case, the list quoted is intended only as a representative group and should not be interpreted as an exclusive list.

10‧‧‧Metal

12‧‧‧Inorganic particles

14‧‧‧Discontinuous fiber

100‧‧‧Porous metal matrix composite

The present disclosure can be more completely understood by considering the embodiments of the various embodiments of the present disclosure as described in the accompanying drawings in which: FIG. 1 is a schematic cross section of a metal matrix composite fabricated according to an exemplary embodiment of the present disclosure. Figure.

2 is a graph of stress-strain curves for exemplary matrices and comparative matrices prepared in accordance with the present disclosure.

Figure 3 is a graph of stress-strain curves for additional exemplary matrices and comparative matrices.

4 is a graph of stress-strain curves for further exemplary matrices and comparative matrices.

Figure 5 is a graph of stress-strain curves for another exemplary matrix.

Figure 6 is a graph of the stress-strain curve of a further exemplary substrate.

Figure 7 is a graph of stress-strain curves for yet another exemplary matrix.

While the above-identified figures (which may not be drawn to scale) illustrate embodiments of the present disclosure, other embodiments (as referred to in the [embodiments]) are also contemplated.

For the terms used in the terms defined below, these definitions shall apply to the entire application, unless a different definition is provided elsewhere in the scope of the patent application or in the specification.

vocabulary

Certain terms are used in the specification and patent application, although most of these terms are well known, some explanation may be required. It should be understood that, as used herein, the singular forms "a", "the" and "the" There is a clear designation. As used in this specification and the appended claims, the <RTI ID=0.0>"or"</RTI> is used to mean "and/or" unless the context clearly indicates otherwise.

As used in this specification, the numerical range recited by the endpoint includes all numbers that fall within the range (for example, 1 to 5 include 1, 1.5, 2, 2.75, 3, 3.8, 4, and 5).

All numbers, attributes, and the like of all expressions or components in the specification and examples are to be understood in all instances as modified by the term "about" unless otherwise indicated. Therefore, unless otherwise indicated, the numerical parameters set forth in the foregoing description and the accompanying examples of the embodiments may be modified in accordance with the preferred characteristics of the embodiments of the invention. At the very least, the numerical parameters should be interpreted at least in view of the number of significant digits and by applying ordinary rounding techniques, but are not intended to limit the application of the scope of the claimed embodiment.

The words "comprises" and variations thereof in the specification and claims are not intended to be limiting.

The terms "preferred" and "preferably" in the embodiments of the present disclosure indicate that certain benefits may be provided in certain circumstances. However, other embodiments may be preferred in the same or other circumstances. In addition, the description of one or more preferred embodiments does not imply that other embodiments are not useful, and are not intended to exclude other embodiments from the scope of the disclosure.

The "one embodiment", "certain embodiments", "one or more embodiments", or "an embodiment" (an embodiment) And the use of the phrase "exemplary" before the term "embodiment" means that the specific feature, structure, material, or characteristic described in connection with the embodiment is included in the present invention. At least one embodiment of certain exemplary embodiments is disclosed. Thus, terms appearing throughout the specification, such as "in one or more embodiments", "in certain embodiments (in certain "in one embodiment", "in many embodiments" or "in an embodiment", does not necessarily refer to this disclosure. The same embodiments of some exemplary embodiments. Furthermore, the particular features, structures, materials, or characteristics may be combined in any suitable manner in one or more embodiments.

The term "dispersed" with respect to one or more fillers in a metal matrix means that the one or more fillers are distributed throughout the metal matrix, such as providing a substantially homogeneous metal matrix comprising the metal and the (etc.) filler. Complex. This is that the concentration of one or more fillers in the region of a metal matrix composite is at least two times higher than the region at different locations of the metal matrix composite (eg, several layers or groups in the metal matrix composite) a filler). Although it is possible to observe that the one or more fillers are not exactly homogeneously distributed in a sufficiently small volume of one of the metal matrix composites in the metal matrix, the (etc.) filler is still dispersed in the metal.

The term "sinter" refers to polymerization of a powdery material but not complete liquefaction to polymerize it into a solid or porous mass. The powdered material is also optionally extruded during sintering.

The term "envelope density" in relation to particles refers to the mass divided by the envelope volume. The "envelope volume" refers to the sum of the solids in each particle and any voids in the particle. Similarly, the term "encapsulation density" with respect to a metal matrix composite refers to the mass divided by the encapsulation volume, wherein the "encapsulation volume" refers to the solid in the metal matrix composite and any voids in the metal matrix composite. The sum of the volumes.

The term "skeleton density" with respect to porous particles refers to the mass divided by the volume of the skeleton. The "skeleton volume" refers to the sum of the volume of the solid material and any closed pores within the particle.

The term "average true density" in relation to a glass bubble refers to the average density of the glass bubbles rather than the density of a volume of glass bubbles (which depends on the compaction of the glass bubbles in the volume). ).

The term "plastic yield" refers to the stress at which a material undergoes a predetermined amount of permanent deformation.

The term "tensile plastic yield" refers to the stress at which a predetermined amount of permanent deformation occurs when a material is subjected to a tensile force.

The term "softening point" refers to the temperature or temperature range at which a material (eg, at a solid phase) begins to collapse due to its own weight. For materials having a defined melting point (eg, metal), the softening point can be considered substantially as the melting point of the metal or metal alloy. However, for materials that do not have a clear melting point, the softening point can be the temperature at which the elastic behavior of the material changes to a plastic flow. For example, the softening point of glass, glass-ceramic, or porcelain can occur at the glass-transfer temperature of the material and can be defined by a viscosity of ^10.75 poise. The softening point of the glass is generally determined, for example, by the Vicat method (for example, ASTM-D1525 or ISO 306) or by a heat distortion test (for example, ASTM-D648).

The term "uncoated" with respect to glass bubbles means that no additional material is applied to the outer surface of the glass bubbles (i.e., having a composition different from the glass).

The term "yield strength" refers to the stress at which the material is considered to have begun to plastically extend. As used herein, the fall strength is determined with an offset of 0.2%. ASTM B557M-15 reveals "7.6 Depth Strength - Determining the drop strength with an offset of 0.2% using the offset method. Acceptance or rejection of materials can be determined based on the Extension-Under-Load Method. For arbitration tests, use The offset method. 7.6.1 Offset Method - The "offset method" determines the intensity of the fall, and it is necessary to ensure that the stress-strain map can be plotted (automatic plot or numerically). Then, in the stress-strain diagram (Fig. 16), Om equal to the specified value of the offset is marked, and parallel OA draws mn , thus finding r , which is the intersection of mn and the stress-strain diagram (Note 12). When the fall strength obtained by this method is described, the specific value of "offset" is described in parentheses after the word fall strength. Thus: the drop strength (offset = 0.2%) = 360 MPa".

The term "transitional-alumina" means any alumina from aluminum hydroxide to alpha-alumina. Specific transition-type alumina particles include δ-alumina, η-alumina, θ-alumina, lanthanum-alumina, κ-alumina, ρ-alumina, and γ-alumina. The transition alumina particles are produced during the heat treatment of the aluminum hydroxide or aluminum oxyhydroxide. The most thermodynamically stable form is alpha-alumina.

Various illustrative embodiments of the present disclosure will now be described. Various modifications and changes may be made to the illustrative embodiments of the present disclosure without departing from the spirit and scope of the disclosure. Therefore, it is to be understood that the embodiments of the present disclosure are not limited by the description of the embodiments of the invention, and the scope of the claims.

In one aspect, the present disclosure provides a method of making a porous metal matrix composite. The method comprises mixing a metal powder, a plurality of inorganic particles, and a plurality of The fibers are continuous to form a mixture. The method further includes sintering the mixture to form the porous metal matrix composite.

In some embodiments, the mixing of the metal powder, inorganic particles, and discontinuous fibers is performed manually, such as by holding a container of the materials by hand. Shaking is often performed for at least 15 seconds, at least 20 seconds, at least 30 seconds, at least 45 seconds, or at least 60 seconds, and up to 2 minutes, up to 100 seconds, up to 90 seconds, or up to 70 seconds. When manually mixing the components for a metal matrix composite, a container containing the materials is optionally inverted at least once. In some embodiments, the mixing of the metal powder, inorganic particles, and discontinuous fibers is performed using an acoustic mixer, a mechanical mixer, a shaker table, or a tumbler. A device is used to similarly mix for at least 15 seconds, at least 20 seconds, at least 30 seconds, at least 45 seconds, or at least 60 seconds, and up to 2 minutes, up to 100 seconds, up to 90 seconds, or up to 70 seconds. The mixture produced by mixing the components comprises the inorganic particles dispersed in the metal powder and the discontinuous fibers. Dispersing the inorganic particles and discontinuous fibers in the metal powder provides a substantially homogeneous mixture as discussed above.

After mixing, the mixture was sintered. In most embodiments, the sintering is carried out for a period of at least 30 minutes, at least 60 minutes, at least 90 minutes, or at least 2 hours, and for up to 3 hours or at most 24 hours; such as between 30 minutes and 3 hours (inclusive) . Generally, the mixture is sintered in a mold (e.g., a mold). Typically at least 250 degrees Celsius (°C), at least 300° C., at least 400° C., at least 500° C., or at least 600° C., and at most 1,000° C., at most 900° C., at most 800° C., or in a hot press or furnace Sintering at up to 700 ° C; for example between 250 ° C and 1,000 ° C (inclusive), or Between 400 ° C and 900 ° C, or between 600 ° C and 800 ° C. In many embodiments, the temperature rises at a steady rate until the desired maximum temperature is reached.

In certain embodiments, sintering further comprises applying pressure to the mixture in the mold. For example, optionally at a pressure of at least 4 million Pascals (MPa), at least 5 MPa, at least 7 MPa, at least 10 MPa, at least 12 MPa, at least 15 MPa, or at least 20 MPa; and at most 200 MPa, at most 150 MPa, at most 100 MPa, at most 75MPa, up to 50MPa, or up to 25MPa; such as between 4MPa and 200MPa (inclusive), between 4MPa and 50MPa (inclusive), or between 15MPa and 200MPa (inclusive). In certain embodiments, the mold is flushed with an inert gas (e.g., nitrogen or argon) after the applied pressure is released.

After the sintering process, the metal matrix composite can be allowed to cool (e.g., inside or outside the hot press or furnace). In some embodiments, the metal matrix composite is allowed to be furnace cooled (i.e., by shutting down the furnace and waiting for the metal matrix composite to cool itself). In other embodiments, a coolant, such as, but not limited to, an inert gas (e.g., nitrogen, argon, etc.) is passed through the hot press or furnace to aid in faster cooling of the metal matrix composite.

Referring to Figure 1, a schematic cross-sectional view of a porous metal matrix composite 100 prepared in accordance with an illustrative embodiment of the present disclosure is provided. The porous metal matrix composite 100 includes a metal 10, a plurality of inorganic particles 12, and a plurality of discontinuous fibers 14. The inorganic particles 12 and the discontinuous fibers 14 are dispersed in the metal 10. For simplicity, the metal matrix composite is depicted as having a monolithic shape; however, the metal matrix composite can be formed in a number of different shapes depending on the desired application. Metal matrix composites can be applied to several products In the industry, such as the construction, automotive, and electronics industries, metal matrix composite components can be substituted for specific metal components therein.

In many embodiments, the metal comprises a porous matrix structure. The porous matrix structure is typically obtained from a powdered metal wherein the powder contains a metal structure into which a gas (e.g., air) is incorporated. In general, the metal is present in an amount of 50 weight percent or more, 55 weight percent or more, 60 weight percent or more, 65 weight percent or more, 70 weight percent or more, of the metal matrix composite, Or 75 weight percent or more; and the amount is 95 weight percent or less, 90 weight percent or less, 85 weight percent or less, or 80 weight percent or less. In another embodiment, the metal may be present in an amount between 50% and 95% by weight of the metal matrix composite, or between 70% and 95% by weight of the metal matrix composite. The metal comprises aluminum, magnesium, or an alloy thereof (i.e., an aluminum alloy or a magnesium alloy). Suitable metals include, for example, without limitation, pure aluminum (aluminum powder having a purity of at least 99.0%, such as AA1100, AA1050, AA1070, etc., such as pure aluminum powder available from Eckart (Louisville, KY)); or containing aluminum and by mass 0.2 to 2% of an aluminum alloy of another metal. Such alloys include: Al-Cu alloy (AA2017, etc.), Al-Mg alloy (AA5052, etc.), Al-Mg-Si alloy (AA6061, etc.), Al-Zn-Mg alloy (AA7075, etc.), and Al-Mn alloy, One or two or more mixtures alone. A variety of suitable metal powders are available from Atlantic Equipment Engineers (Upper Saddle River, NJ).

In general, when the metal is used in the form of a powder, the metal powder contains 300 nanometers (nm) or more, 400 nm or more, 500 nm or more, 750 nm or more. Large, 1 micrometer (μm) or larger, 2 μm or larger, 5 μm or larger, 7 μm or larger, 10 μm or larger, 20 μm or larger, 35 μm or larger, 50 μm or larger, or 75 μm or more. A large average particle diameter; and 100 μm or less, 75 μm or less, 50 μm or less, 35 μm or less, or 25 μm or less. Stated another way, the metal powder comprises an average particle size ranging between 300 nm and 100 μm; in the range between 1 μm and 100 μm; or in the range between 1 μm and 50 μm. For example, particle size can be analyzed using optical microscopy and laser diffraction.

Suitable inorganic particles include particles having 2.00 grams or less per cubic centimeter, 1.75 grams or less per cubic centimeter, 1.50 grams or less per cubic centimeter, 1.25 grams or less per cubic centimeter, or 1.00 grams per cubic centimeter or Less of a maximum encapsulation density. Generally, the plurality of inorganic particles comprise a substantially spherical shape or a needle-like shape, although in some embodiments the inorganic particles comprise multi-unit bubbles. These particles typically have an aspect ratio of the longest axis to the shortest axis of 2:1 or less.

In general, the plurality of inorganic particles comprise 50 nanometers (nm) or more, 250 nm or more, 500 nm or more, 750 nm or more, 1 micrometer (μm) or more, 2 μm or more, 5 μm. Or an average particle diameter of 7 μm or more, 10 μm or more, 20 μm or more, 35 μm or more, 50 μm or more, 75 μm or more, or 100 μm or more; and 5 mm (mm) Or smaller, 3 mm or less, 2 mm or less, 1 mm or less, 750 μm or less, 500 μm or less, or 250 μm or less. In another embodiment, the plurality of inorganic particles comprise an average particle size ranging between 50 nm and 5 mm inclusive; ranging between 1 μm and 1 mm inclusive; or ranging between 10 μm and 500 μm inclusive.

There is no particular limitation on the amount of inorganic particles dispersed in the metal. The plurality of inorganic particles are typically present in an amount of at least 1 weight percent of the metal matrix composite, at least 2 weight percent, at least 5 weight percent, at least 8 weight percent, at least 10 weight percent, at least 15 weight percent of the metal matrix composite Or at least 20 weight percent; and up to 50 weight percent, up to 28 weight percent, up to 26 weight percent, up to 24 weight percent, or up to 22 weight percent of the metal matrix composite. In certain embodiments, the inorganic particles are present in the metal matrix composite in an amount between 1 and 30 weight percent, or between 2 and 25 weight percent, or 2 of the metal matrix composite. Between the weight percentage and 15 weight percent (inclusive). The inclusion of less than 1 weight percent of the inorganic particles results in a very slight decrease in the encapsulation density of the metal matrix composite, however, including more than 30 weight percent of the inorganic particles may result in insufficient metal and fiber content of the metal matrix composite. This has a negative impact on the mechanical properties of the metal matrix composite.

In certain embodiments the plurality of inorganic particles comprise porous particles. As used herein, "porous particles" refers to particles having pores per se, and also refers to non-porous primary particle cohesomers comprising pores between at least some of the non-porous primary particles. Examples of useful porous particles include, for example and without limitation, porous metal oxide particles, porous metal hydroxide particles, porous metal carbonates, porous carbon particles, porous vermiculite particles, porous dehydrated aluminosilicate particles, porous dehydrated metal Hydrate particles, zeolite particles, porous glass particles, expanded perlite particles, expanded vermiculite particles, porous sodium citrate particles, engineered porous ceramic particles, non-porous primary particles, or a combination thereof. In certain embodiments, the gold of the metal oxide, metal hydroxide, or metal carbonate The genus is selected from the group consisting of aluminum, magnesium, zirconium, calcium, or a combination thereof. In selected embodiments, the porous particles comprise porous alumina particles, porous carbon particles, porous vermiculite particles, porous aluminum hydroxide particles, or a combination thereof. The porous particles have generally removed the associated water therefrom, often by heating the porous particles. The porous particles optionally comprise transitional alumina particles. Suitable porous particles include, for example, without limitation, Versal 250 diaspore powder available from UOP LLC (Des Plaines, IL), YH-D 16 diaspore powder from Zibo Yinghe Chemical Company, Ltd. (Shandong, China), And Alumax PB300 diaspore of PIDC International (Ann Arbor, MI).

In certain embodiments, the plurality of inorganic particles comprise ceramic bubbles or glass bubbles. Suitable materials for ceramic bubbles and glass bubbles include, for example, without limitation aluminum oxide, aluminosilicate, vermiculite, or combinations thereof. Commercially available glass bubbles include, for example, LightStar, EconoStar, and High Alumina microspheres available from Cenostar Corporation (Amesbury, MA). Preferably, the ceramic bubbles and glass bubbles are uncoated (e.g., in a metallic material to aid in wetting the bubbles with the metal matrix).

In embodiments where the metal has a high melting point (eg, aluminum) and the inorganic particles are glass bubbles, it is advantageous that the plurality of (eg, uncoated) glass bubbles comprise glass that is resistant to heating to 700 degrees Celsius. The temperature is at least two hours without softening. The use of high temperature resistant glass bubbles allows the glass bubbles to be incorporated into the metal matrix composite which would otherwise be prepared at elevated temperatures sufficient to damage the glass bubbles, such as softening at least some of the glass bubbles to their deformation and/or The extent of the rupture.

One suitable type of glass bubble comprises agitation with deionized water for 2 hours and dissolution of less than 100 micrograms of sodium ion per gram of glass bubble in deionized water. With such low sodium One advantage of dissolution rate glass bubbles is that they are useful in electronics applications where sodium ion dissolution is often unacceptable. In one embodiment, suitable compounds for making such low sodium glass bubbles include vermiculite, lime, boric acid, calcium phosphate, calcined aluminosilicates, and magnesium niobates. In certain embodiments, such low sodium glass bubbles exhibit a softening temperature between 717 ° C and 735 ° C (inclusive) as measured by thermal expansion measurements.

Preferably, the inorganic particles comprise uncoated inorganic particles. Advantageously, the use of uncoated inorganic particles provides material cost savings and coating time. A porous metal matrix composite is prepared according to the method of at least some embodiments of the present disclosure, wherein the inorganic particles are dispersed in the metal without any further material to improve contact between the inorganic particles and the metal.

The plurality of discontinuous fibers dispersed in the metal matrix composite are not particularly limited, and include, for example, inorganic fibers such as glass, alumina, aluminosilicate, carbon, basalt, or a combination thereof. More specifically, in certain embodiments the fibers comprise at least one metal oxide, aluminum oxide, aluminum oxide- vermiculite, or a combination thereof. The discontinuous fibers have an average length of less than 5 centimeters and are more prone to dispersion in the metal matrix than longer fibers. In many embodiments, the fibers have an average length that is shorter than the smallest dimension of the mold or mold used to form a metal matrix composite such that the orientation of the fibers is not limited to the mold or mold. A ratio of the fiber length to the minimum dimension of the mold or mold is typically < 1:1. In certain embodiments, the discontinuous fibers have an average length of less than 4 centimeters, less than 3 centimeters, or less than 2 centimeters. The discontinuous fibers can be formed from continuous fibers, such as by methods known in the art, such as cutting and grinding. Generally, the plurality of discontinuous fibers comprise an aspect ratio of 10:1 or greater.

Suitable discontinuous fibers can have a variety of compositions, such as ceramic fibers. The ceramic fibers can be produced in continuous lengths that are cut or sheared, as discussed herein, to provide the ceramic fibers of the present disclosure. These ceramic fibers can be produced from a variety of commercially available ceramic filaments. Examples of useful filaments for forming such ceramic fibers include those ceramic oxide fibers sold under the trademark NEXTEL (3M Company, St. Paul, MN). NEXTEL is a continuous filament ceramic oxide fiber that has low elongation and shrinkage at operating temperatures and provides good chemical resistance, low thermal conductivity, thermal shock resistance, and low porosity. Specific examples of NEXTEL fibers include NEXTEL 312, NEXTEL 440, NEXTEL 550, NEXTEL 610, and NEXTEL 720. NEXTEL 312 and NEXTEL 440 are refractory aluminum borosilicates comprising Al ₂ O ₃ , SiO ₂ and B ₂ O ₃ . NEXTEL 550 and NEXTEL 720 are aluminum silicates and NEXTEL 610 is alumina. During manufacture, the NEXTEL wire coating organic coating or finishing acts as an aid to the textile process. The coating may include the use of starch, oil, wax or other organic ingredients applied to the strands to protect and facilitate gripping. The coating can be removed from the ceramic filaments by heat cleaning the filaments or ceramic fibers, such as at a temperature of 700 ° C for one to four hours.

The ceramic fibers can be cut or cut to provide a relatively uniform length that can be achieved by cutting continuous filaments of ceramic material during mechanical shearing operations or laser cutting operations, as well as in other cutting operations. In view of the nature of the control of the height of such cutting operations, the size distribution of the ceramic fibers is very narrow, allowing control of the properties of the composite.

The length of the ceramic fiber, for example, can be equipped with a CCD Camera (Olympus DP72, Tokyo, Japan) and an analysis software (Olympus Stream) Optical microscopy (Olympus MX61, Tokyo, Japan), one of Essentials, Tokyo, Japan. Samples can be prepared by spreading a representative sample of the ceramic fibers onto a glass slide and measuring the length of at least 200 ceramic fibers at 10X magnification.

Suitable fibers include, for example, ceramic fibers sold under the trade name NEXTEL (available from 3M Company, St. Paul, MN), such as NEXTEL 312, 440, 610, and 720. A currently preferred ceramic fiber comprises polycrystalline α-Al ₂ O ₃ . Suitable alumina fiber systems are described, for example, in U.S. Patent No. 4,954,462 (Wood et al.) and U.S. Patent No. 5,185,299 (Wood et al.). Exemplary alpha alumina fibers are sold under the trade name NEXTEL 610 (3M Company, St. Paul, MN). In some embodiments, the alumina fibers are polycrystalline alpha alumina fibers, and based on the theoretical oxide, the alumina fibers comprise greater than 99 weight percent based on the total weight of the alumina fibers. Al ₂ O ₃ and 0.2 to 0.5% by weight of SiO ₂ . In other embodiments, some desirable polycrystalline alpha alumina fibers comprise alpha alumina having an average grain size of less than one micron (or even less than 0.5 microns in some embodiments). In some embodiments, the polycrystalline alpha alumina fibers have an average tensile strength (in some embodiments, at least 2.1 GPa, or even at least 2.8 GPa) of at least 1.6 GPa. Suitable aluminosilicate fibers are described, for example, in U.S. Patent No. 4,047,965 (Karst et al.). Exemplary aluminosilicate fibers are sold under the tradenames NEXTEL 440, and NEXTEL 720 by 3M Company (St. Paul, MN). Aluminoborosilicate fibers are described, for example, in U.S. Patent No. 3,795,524 (Sowman). Exemplary aluminoborosilicate fibers are sold under the tradename NEXTEL 312 by 3M Company. Boron nitride fibers can be made as described in, for example, U.S. Patent No. 3,429,722 (Economy) and U.S. Patent No. 5,780,154 (Okano et al.).

Ceramic fibers can also be formed from other suitable ceramic oxide wires. Examples of such ceramic oxide filaments include those ceramic oxide filaments (e.g., EFH75-01, EFH150-31) available from Central Glass Fiber Co., Ltd. Aluminoborosilicate glass fibers are also preferred which contain less than about 2% alkali or substantially no alkali (i.e., "E-glass" fibers). E-glass fibers are commercially available from a number of suppliers.

There is no particular limitation on the amount of discontinuous fibers dispersed in the metal matrix composite. The plurality of fibers are typically present in an amount of at least 1 weight percent of the metal matrix composite, at least 2 weight percent, at least 3 weight percent, at least 5 weight percent, at least 10 weight percent, at least 15 weight percent of the metal matrix composite, At least 20 weight percent, or at least 25 weight percent; and up to 50 weight percent, up to 45 weight percent, up to 40 weight percent, or up to 35 weight percent of the metal matrix composite. In certain embodiments, the fibers are present in the metal matrix composite in an amount between 1 weight percent and 50 weight percent, or between 2 weight percent and 25 weight percent, or 5 weight percent of the metal matrix composite. Between percentage and 15 weight percent (inclusive). Including less than 1 weight percent of such fibers causes a very slight increase in the strength of the metal matrix composite, however, including more than 50 weight percent of the fibers may be due to insufficient metal and inorganic particles in the metal matrix composite. The encapsulation density of the metal matrix composite causes a negative impact. In certain embodiments, the plurality of inorganic particles and the plurality of discrete fibers are present in combination between 5 weight percent and 50 weight percent of the metal matrix composite.

Advantageously, the metal matrix composite exhibits a reduced encapsulation density (as compared to pure metals) and also exhibits acceptable mechanical properties. For example, the metal matrix composite generally has an encapsulation density of between 1.35 and 2.70 grams per cubic centimeter (inclusive) or between 1.80 and 2.50 grams per cubic centimeter. For example, the metal matrix composite can have an encapsulation density of at least 1.60 grams, at least 1.75, at least 1.90, at least 2.00, at least 2.10, or at least 2.25 grams per cubic centimeter per cubic centimeter; and a package of up to 2.70 per cubic centimeter; Sealing density, up to 2.60, up to 2.50, up to 2.40, or up to 2.30 grams.

In certain embodiments, the metal comprises aluminum or an alloy thereof and the metal matrix composite has an encapsulation density of between 1.80 and 2.50 grams per cubic centimeter; between 2.00 and 2.30 grams per cubic centimeter; Or between 1.80 and 2.20 grams per cubic centimeter (inclusive).

In certain embodiments, the metal comprises magnesium or an alloy thereof and the metal matrix composite has an encapsulation density of between 1.35 and 1.60 grams per cubic centimeter; between 1.55 and 1.60 grams per cubic centimeter; Or between 1.35 and 1.50 grams per cubic centimeter (inclusive).

Advantageously, in many embodiments the metal matrix composite has an encapsulation density of at least 8% less than the density of the metal (or at least 10% less, at least 12% smaller, at least 15% smaller, or at least 17 smaller) %) and can withstand 1% strain before breaking. This combination of properties provides both weight reduction of the metal and maintaining some of the metallic properties in the metal matrix composite. In particular, the metal matrix composite preferably exhibits a relief strength prior to failure in a tensile test. In certain embodiments the metal matrix composite has 50 million Pascals or a greater, 75 megapascals or greater, 100 megapascals or greater, 150 megapascals or greater, or 200 MPa or greater.

The metal matrix composite of at least some exemplary embodiments of the present disclosure is found to exhibit a stress-strain curve exhibiting plasticity-floating behavior, and the metal matrix composite of at least some exemplary embodiments of the present disclosure exhibits a stress-strain The curve shows the tensile plasticity fluctuation behavior. That is, the stress-strain curve exhibits a plastic flow in a region. The plasticity curve and the tensile plasticity curve are contrasted with a pure brittle failure mechanism. That is, the pure brittle behavior exhibits only one elastic region within the stress-strain curve, and no (or very small) plastic flow region. Surprisingly, according to at least some embodiments of the present disclosure, a combination of inorganic particles and discontinuous fibers as fillers in a metal matrix composite provides a plasticity drop curve and/or a tensile plasticity drop behavior in the experiment. . For example, referring to Figure 3, the stress-strain curve of Example 13 containing both fibers and porous inorganic particles (described in detail below) appears to fluctuate before the brittle failure mechanism. In certain embodiments, the metal matrix composite can withstand a strain of 1%, 1.5%, or 2% prior to rupture. Furthermore, unexpectedly, the metal powder remains separated from the porous inorganic particles without being pushed into some of the pores of the porous inorganic particles during sintering (especially sintering under applied pressure). Interestingly, the porous inorganic particles do not tend to be damaged (e.g., chipped or crushed) during sintering, but rather maintain their porous framework structure.

In many embodiments, the metal matrix composite exhibits an ultimate tensile strength of 25 megapascals (MPa) or greater, such as 40 MPa or greater, 50 MPa or greater, 75 MPa or greater, 100 MPa or greater, 150 MPa or more, 200 MPa or more, 250 MPa or more, or 300 MPa or more. Metal matrix composite The tensile strength is related to the encapsulation density of the metal matrix composite. Generally, the tensile strength is sacrificed during the weight reduction of the composite, and the tensile strength of the metal matrix composite can be further useful. In some embodiments, the metal matrix composite has an encapsulation density between 1.80 and 2.50 grams per cubic centimeter, and 50 MPa or greater, 100 MPa or greater, 150 MPa or greater, 200 MPa or greater, An ultimate tensile strength of 250 MPa or more, or 300 MPa or more.

Advantageously, desirable mechanical properties are obtained in certain embodiments without the need for such inorganic particles and fillers other than the discontinuous fibers. In such an embodiment, the metal matrix composite consists essentially of a metal, a plurality of inorganic particles, and a plurality of discrete fibers. The metal matrix composite may thus further comprise an additive that does not substantially impact the mechanical properties of the metal matrix composite. In contrast, a metal matrix composite consisting essentially of a metal, a plurality of inorganic particles, and a plurality of discrete fibers cannot further include additives, such as materials used to aid in the dispersion of such fillers.

Metal matrix composites according to aspects of the present disclosure can be prepared according to various suitable methods known to those of ordinary skill in the art, including powder metallurgy processes such as hot pressing, powder extrusion, hot rolling, and heating followed by warm rolling. ), cold pressing and sintering, and hot isostatic pressing. In one embodiment, the inorganic particles and the discontinuous fibers may be dispersed in the metal powder by mixing a metal powder, a plurality of inorganic particles, and a plurality of discontinuous fibers, thereby sintering the mixture. A metal matrix composite is formed to form the metal matrix composite. For example, such a powder metallurgy process is described in detail in Example 1 below.

Illustrative embodiment

Example 1 is a method of making a porous metal matrix composite. The method includes mixing a metal powder, a plurality of inorganic particles, and a plurality of discrete fibers to form a mixture. The method further includes sintering the mixture to form the porous metal matrix composite.

Embodiment 2 is the method of Embodiment 1, wherein the mixture is sintered in a mold.

Embodiment 3 is the method of Embodiment 1 or Embodiment 2, wherein the sintering is performed at a temperature between 250 degrees Celsius and 1,000 degrees Celsius and containing 250 degrees Celsius and 1,000 degrees Celsius.

Embodiment 4 is the method of any one of embodiments 1 to 3, wherein the sintering comprises applying a pressure.

Embodiment 5 is the method of Embodiment 4 wherein the sintering is carried out at a pressure between 4 megapascals and 200 megapascals and containing 4 megapascals and 200 megapascals.

Embodiment 6 is the method of any one of embodiments 1 to 5, wherein the sintering is performed for a period of between 30 minutes and 3 hours.

Embodiment 7 is the method of any one of embodiments 1 to 6, wherein the mixing is performed using an acoustic mixer, a mechanical mixer, or a roller.

The method of any one of embodiments 1 to 7, wherein the mixture comprises the inorganic particles dispersed in the metal powder and the discontinuous fibers.

The method of any one of embodiments 1 to 8, wherein the metal matrix composite has a density that is at least 8% less than the density of the metal and can withstand a strain of 1% prior to rupture.

Embodiment 10 is the method of Embodiment 9, wherein the metal matrix composite is resistant to a strain of 2% prior to rupture.

The method of any one of embodiments 1 to 10, wherein the metal matrix composite has a relief strength of 50 megapascals or more.

Embodiment 12 is the method of any one of embodiments 1 to 11, wherein the metal matrix composite has a relief strength of 100 megapascals or greater.

Embodiment 13 is the method of any one of embodiments 1 to 12, wherein the metal matrix composite has an ultimate tensile strength of 100 megapascals or greater.

Embodiment 14 is the method of any one of embodiments 1 to 13, wherein the metal matrix composite has an ultimate tensile strength of 200 megapascals or greater.

Embodiment 15 is the method of any one of embodiments 1 to 14, wherein the metal matrix composite has an ultimate tensile strength of 300 megapascals or greater.

The method of any one of embodiments 1 to 15, wherein the plurality of inorganic particles comprise porous particles.

Embodiment 17 is the method of embodiment 16, wherein the porous particles have a maximum encapsulation density of 2 grams or less per cubic centimeter.

Embodiment 18 is the method of Embodiment 15 or Embodiment 16, wherein the porous particles comprise porous metal oxide particles, porous metal hydroxide particles, porous metal carbonate, porous carbon particles, porous vermiculite particles, porous dehydration Aluminosilicate particles, Porous dehydrated metal hydrate particles, zeolite particles, porous glass particles, expanded perlite particles, expanded vermiculite particles, porous sodium citrate particles, engineered porous ceramic particles, non-porous primary particles, or a combination thereof.

The method of any one of embodiments 16 to 18, wherein the porous particles comprise porous alumina particles, porous carbon particles, porous vermiculite particles, porous aluminum hydroxide particles, or a combination thereof.

Embodiment 20 is the metal matrix composite of embodiment 19, wherein the porous particles comprise transitional alumina particles.

The method of any one of embodiments 1 to 15, wherein the plurality of inorganic particles comprise ceramic bubbles or glass bubbles.

Embodiment 22 is the method of embodiment 21, wherein the glass bubbles comprise glass that is resistant to heating to a temperature of 700 degrees Celsius for at least two hours without softening.

Embodiment 23 is the method of embodiment 21 or embodiment 22, wherein the glass bubbles and deionized water are stirred for 2 hours and the sodium ions are dissolved in deionized water for less than 100 micrograms per gram of glass bubbles.

The method of any one of embodiments 1 to 23, wherein the plurality of inorganic particles comprise a maximum encapsulation density of 2 grams or less per cubic centimeter.

The method of any one of embodiments 21 to 23, wherein the plurality of inorganic particles comprise alumina, aluminosilicate, vermiculite, or a combination thereof.

The method of any one of embodiments 18 to 21, 24, or 25, wherein the inorganic particles comprise a plurality of unit cells.

The method of any one of embodiments 1 to 26, wherein the plurality of inorganic particles have a substantially spherical shape or a needle-like shape.

The method of any one of embodiments 1 to 27, wherein the plurality of inorganic particles have an average particle diameter ranging between 50 nanometers (nm) and 5 millimeters (mm);

The method of any one of embodiments 1 to 28, wherein the plurality of inorganic particles have an average particle size ranging between 1 micrometer (μm) and 1 mm (inclusive).

The method of any one of embodiments 1 to 29, wherein the plurality of inorganic particles have an average particle diameter ranging between 10 μm and 500 μm (inclusive);

The method of any one of embodiments 1 to 30, wherein the plurality of discontinuous fibers comprise glass, alumina, aluminosilicate, carbon, basalt, or a combination thereof.

The method of any one of embodiments 1 to 31, wherein the plurality of discontinuous fibers have an aspect ratio of 10:1 or greater.

The method of any one of embodiments 1 to 32, wherein the metal comprises a porous matrix structure.

The method of any one of embodiments 1 to 33, wherein the metal comprises aluminum or an alloy thereof.

The method of any one of embodiments 1 to 34, wherein the metal matrix composite has an encapsulation density of between 1.80 and 2.50 grams per cubic centimeter.

The method of any one of embodiments 1 to 34, wherein the metal matrix composite has an encapsulation density of between 2.00 and 2.30 grams per cubic centimeter.

The method of any one of embodiments 1 to 34, wherein the metal matrix composite has an encapsulation density of between 1.80 and 2.20 grams per cubic centimeter.

The method of any one of embodiments 1 to 33, wherein the metal comprises magnesium or an alloy thereof.

Embodiment 39 is the method of Embodiment 38, wherein the metal matrix composite has an encapsulation density of between 1.35 and 1.60 grams per cubic centimeter.

Embodiment 40 is the method of Embodiment 38 or Embodiment 39, wherein the metal matrix composite has an encapsulation density of between 1.55 and 1.60 grams per cubic centimeter.

Embodiment 41 is the method of Embodiment 38 or Embodiment 39, wherein the metal matrix composite has an encapsulation density of between 1.35 and 1.50 grams per cubic centimeter.

Embodiment 42 is the method of any one of embodiments 1 to 41, wherein the metal matrix composite exhibits a relief strength prior to failure in a tensile test.

The method of any one of embodiments 1 to 42 wherein the metal is present in an amount between 50 and 95 weight percent of the metal matrix composite.

The method of any one of embodiments 1 to 43 wherein the plurality of inorganic particles are present in an amount between 2 and 50% by weight of the metal matrix composite.

The method of any one of embodiments 1 to 44, wherein the plurality of discontinuous fibers are present in an amount between 2 and 25 weight percent (inclusive) of the metal matrix composite.

The method of any one of embodiments 1 to 45, wherein the plurality of inorganic particles and the plurality of discontinuous fibers are between 5 weight percent and 50 weight percent (inclusive) of the metal matrix composite The combination of numbers exists.

The method of any one of embodiments 1 to 46, wherein the encapsulation density of the inorganic particles is at least 40% less than the density of the metal.

The metal matrix composite of any one of embodiments 1 to 47, wherein the inorganic particles have an encapsulation density that is at least 50% less than the density of the metal.

The metal matrix composite of any one of embodiments 1 to 48, wherein the metal matrix consists essentially of the metal; the plurality of inorganic particles; and the plurality of discontinuous fibers.

Instance

These examples are for illustrative purposes only and are not intended to unduly limit the scope of the appended claims. The numerical ranges and parameters set forth in the broad scope of the disclosure are approximations, and the values presented in the particular examples are reported as accurately as possible. However, any numerical value inherently contains certain errors necessarily resulting from the standard deviations found in the respective test. At the very least, the numerical parameters should be interpreted at least in view of the number of significant digits, and by applying ordinary rounding techniques, but the intention is not to limit the application of the doctrine of the equal scope of the claimed patent.

Material overview

Parts, percentages, ratios, and the like in the examples and the remainder of the specification are by weight unless otherwise indicated. Table 1 provides a description and source of the materials used in the following examples:

Test Method 1. Three-point bending test

The stress and strain of the metal matrix composite were determined using a three-point bending test. In the three-point bending test, the same length is placed between the two cylindrical supports spaced 32 mm apart. A third loading cylinder of the load cell of the self-test device is lowered to contact the midpoint of the sample. A software controlled loading frame provided by MTS Systems Corporation (Eden Prairie, MN) is equipped with a 100 kilonewton (KN) load cell for applying a load to the center of the sample via the intermediate loading cylinder. The system measures the force applied to the sample and the displacement of the intermediate loading cylinder from its starting position for each time point. These values are each converted to stress and strain using standard force equations.

Test method 2. Acoustic dispersion method

To homogenously disperse one or more filler materials in a metal, all materials were poured into a 50 ml (mL) glass vial and then surely covered. Next, put the bottle Advance into a Resodyn LabRAM Acoustic Mixer (Resodyn Corporation, Butte, MT) and shake at 70% intensity for 3 minutes using automatic frequency adjustment, then shoot it 3 to 5 times against a hard surface to allow all material to fall on the bottle bottom.

Test Method 3. Ion Dissolution Test

A 100 g glass bead sample was stirred with 1000 g of deionized (DI) water in an ultrasonic oscillator for about 2 hours. The glass beads were then separated from the DI water by centrifugation at 10,000 rpm for 10 minutes. The ion concentration of the resulting leaching solution was measured by ion chromatography. Individual calibration curves for each ion are prepared by plotting the ion concentration in the standard in the region of each of the standard components. The concentration of each ion eluted from the samples is determined using the measurement region of each ion. The identification of each ion is achieved only by retention matching.

Test method 4. Artificial dispersion method

In order to manually disperse one or more filler materials in a metal, all materials are poured into a 50 ml (mL) glass bottle, which is then properly covered. Next, the bottle was manually shaken for 30 seconds and then pulled 3 to 5 times against a hard surface to allow all material to fall to the bottom of the bottle.

Preparation example 1

The amounts of each of the materials listed in Table 2 below were mixed and placed in a quartz glass crucible. The mixture is then in a furnace at 2320 degrees Fahrenheit (1271 degrees Celsius) Heat for 4 hours. The material is then cooled to room temperature (eg, about 23 degrees Celsius). The material was cut from the crucible and crushed into glass frit particles by a disc grinder (BICO Inc., Burbank, CA). The maximum size of the frit is less than 5 millimeters (mm). The glass frit particles were then jet milled into a powder having a mass median diameter (D50) of 20 micrometers (μm) using a jet mill (Hosokawa Alpine, Augsburg, Germany). 1000 g of this powder was then mixed with 1100 g of water, 2 weight percent of supplemental boric acid, and 0.3 weight percent of sulfur from zinc sulfate, and 1 weight percent of CMC, each based on the total weight of the glass powders. The total solids of the slurry was made to 48 weight percent. The water/glass frit slurry system was milled to a D50 of a primary particle size of 1.4 μm using a LabStar mill (NETZSCH Premier Technologies, LLC, Exton, PA). The slurry from the milling is spray dried to form cohesive feed particles. The glass bubbles are produced from the spray dried feed through a natural gas flame. The total glass bubble density and flame conditions are listed in Table 3 below. The resulting glass bubbles have a D5 of 7 microns, a D50 of 35 microns, and a D90 of 60 microns.

Comparative example 1

Ten grams (g) of Al 1-511 powder was poured into a circular graphite mold having an inner diameter of 1.5 inches (3.81 cm). The Al 1-511 powder was sintered as follows: The mold was loaded into an HP50-7010 hot press (Thermal Technology LLC, Santa Rosa, CA) and the set environment was pumped to a vacuum with a pump. The mold was heated from room temperature to 25 degrees Celsius (degree C/min) to 600 degrees Celsius and held at this temperature for 15 minutes (min). After a temperature of 15 minutes, a force of 640 kilograms (kg) was applied at 600 degrees Celsius (800 pounds per square inch for this size) for 1 hour (hr). The pressure is then released, the chamber is filled with nitrogen, and the mold furnace is allowed to cool down to room temperature. The size and mass of the resulting sintered disc were measured to calculate an integral density of 1.91 g (g/cc) per cubic centimeter (bulk) Density), which is 29% smaller than fully dense pure aluminum. A strip having a width of about 0.5 inch (1.27 cm) and a length of 1.5 inches (3.81 cm) was cut from the middle of the disc, and the strip was subjected to the three-point bending test described above. The sample has a maximum tensile strength of 31 megapascals (MPa), giving it a strength to density ratio of 16. The results are shown in Table 5 below.

Comparative example 2

10 g of Al 1-511 powder and 1 g of glass bubbles were mixed by the above-described artificial dispersion method, and the mixture was poured into the same graphite mold as in Comparative Example 1. This setting environment was then subjected to the same sintering procedure of Comparative Example 1 described above. The resulting sintered disc had a density of 1.58 g/cc. The results of the three-point bending test are shown in Table 5 below and in Figure 2.

Comparative example 3

10 g of Al 1-511 powder and 1 g of ceramic fiber were mixed by the above-described artificial dispersion method, and the mixture was poured into the same graphite mold as in Comparative Examples 1 and 2. This setting environment was then subjected to the same sintering procedure of Comparative Example 1 described above. The resulting disc had a density of 2.11 g/cc. The results of the three-point bending test are shown in Table 5 below and in Figure 2.

Comparative example 4

9 g of Al 1-511 powder, 0.3 g of glass bubbles, and 1.7 g of ceramic fibers were roughly stirred, and the mixture was poured into phases as in Comparative Example 1 to Comparative Example 3. Same as graphite mold. This setting environment was then subjected to the same sintering procedure of Comparative Example 1 described above. The resulting disc had a density of 1.72 g/cc. The results of the three-point bending test are shown in Table 5 below and in Figure 2.

Example 5

9 g of Al 1-511 powder, 0.3 g of glass bubbles, and 1.7 g of ceramic fibers were mixed by the above-described artificial dispersion method, and the mixture was poured into the same graphite mold as in Comparative Example 1 to Comparative Example 4. This setting environment was then subjected to the same sintering procedure of Comparative Example 1 described above. The resulting disc had a density of 1.83 g/cc. The results of the three point bending test are shown in Table 5 below.

Example 6

10 g of Al powder, 0.5 g of glass bubbles, and 0.5 g of fibers were mixed by the above-described artificial dispersion method, and the mixture was poured into the same graphite mold as in Comparative Example 1 to Comparative Example 4 and Example 5. This setting environment was then subjected to the same sintering procedure of Comparative Example 1 described above. The resulting disc had a density of 1.71 g/cc. The results of the three point bending test are shown in Table 5 below.

Example 7

8 g of Al 1-511 powder, 0.45 g of glass bubbles, and 2.55 g of ceramic fibers were mixed by the above-described artificial dispersion method, and the mixture was poured into the same as in Comparative Example 1 to Comparative Example 4 and Example 5 to Example 6. Graphite mold. The setting environment is then subjected to The same sintering procedure of Comparative Example 1 above was carried out. The resulting disc had a density of 1.78 g/cc. The results of the three point bending test are shown in Table 5 below.

Example 8

7 g of Al 1-511 powder, 0.6 g of glass bubbles, and 3.4 g of ceramic fibers were mixed by the above-described manual dispersion method, and the mixture was poured into the same as in Comparative Example 1 to Comparative Example 4 and Example 5 to Example 7. Graphite mold. This setting environment was then subjected to the same sintering procedure of Comparative Example 1 described above. The resulting disc had a density of 1.63 g/cc. The results of the three point bending test are shown in Table 5 below.

Comparative example 9

10.8 grams (g) of Al 6063 powder was poured into a circular graphite mold having an inner diameter of 1.575 inches (4.00 cm). The Al 6063 powder was sintered as follows: The mold was loaded into a Toshiba Machine GMP-411VA glass molding machine (Toshiba Machine Co., Numazu-shi, Japan), and the apparatus was nitrogen-filled for 60 seconds, followed by pumping to a vacuum. The mold is heated from 40 degrees Celsius to 28 degrees Celsius (degrees C/min) to 600 degrees Celsius degree. Once the mold reached 600 degrees C, it remained at that temperature while the force on the mold gradually increased from zero to 21,000 Newtons (2400 psi (or 16.55 MPa) pressure for this size mold). The increase in force that occurs during the course of 20 minutes is approximately linear. Once the full force of 21,000 N is reached, the mold remains in this state for 1 hour at 600 degrees C. The pressure is then released and the mold is allowed to cool down to room temperature. The size of the resulting sintered disc and its mass were measured to calculate an envelope density of 2.51 grams per cubic centimeter (g/cc), which is 7% less than the fully dense aluminum 6063. A strip having a width of about 0.5 inch (1.27 cm) and a length of 1.5 inches (3.81 cm) was cut from the middle of the disc, and the strip was subjected to the three-point bending test described above. The sample has an ultimate tensile strength of 203 megapascals (MPa). The results are shown in Table 6 below and in Figure 3.

Comparative example 10

8.64 g of Al 6063 powder and 0.48 g of alumina powder were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Comparative Example 9. This setting environment was then subjected to the same sintering procedure of Comparative Example 9 described above. The resulting sintered disc had an encapsulation density of 2.34 g/cc. The results of the three point bending test are shown in Table 6 below and in Figure 3.

Comparative example 11

9.72 g of Al 6063 powder and 1.56 g of ceramic fiber were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Comparative Example 9 to Comparative Example 10. This setting environment was then subjected to the same sintering procedure of Comparative Example 9 described above. The The resulting disc had an envelope density of 2.65 g/cc. The results of the three point bending test are shown in Table 6 below and in Figure 3.

Example 12

7.56 g of Al 6063 powder, 0.48 g of alumina powder, and 1.56 g of ceramic fiber were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Comparative Example 9 to Comparative Example 11. This setting environment was then subjected to the same sintering procedure of Comparative Example 9 described above. The resulting disc had an envelope density of 2.45 g/cc. The results of the three point bending test are shown in Table 6 below and in Figure 3.

Example 13

5.4 g of Al 6063 powder, 0.96 g of alumina powder, and 1.56 g of ceramic fiber were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Comparative Example 9 to Comparative Example 11 and Example 12. This setting environment was then subjected to the same sintering procedure of Comparative Example 9 described above. The resulting disc had an envelope density of 2.11 g/cc. The results of the three point bending test are shown in Table 6 below and in Figure 3.

Example 14

5.4 g of Al 6063 powder, 0.96 g of alumina powder, and 1.56 g of ceramic fiber were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same as in Comparative Example 9 to Comparative Example 11 and Example 12 to Example 13. Graphite mold. The mold was loaded into a Toshiba Machine GMP-411VA glass molding machine (Toshiba Machine Co., Numazu-shi, Japan), and the device was nitrogened for 60 seconds, followed by pumping to vacuum. The mold is heated from 30 degrees Celsius to 30 degrees C/min to 630 degrees Celsius. Once the mold reaches 630 degrees Celsius, it remains at that temperature while the force on the mold gradually increases from zero to 34,664 Newtons (for this size the mold is 4000 psi (or 27.58 MPa)). The increase in force that occurs during the course of 20 minutes is approximately linear. Once the full force of 34,664 N is reached, the mold remains in this state for 1 hour at 630 degrees C. The pressure is then released and the mold is allowed to cool down to room temperature. The resulting disc had an encapsulation density of 2.19 g/cc. The results of the three point bending test are shown in Table 6 below and in Figure 3.

Comparative example 15

10.8 grams (g) of Al 6063 powder was poured into a circular graphite mold having an inner diameter of 1.575 inches (4.00 cm). The Al 6063 powder was sintered as follows: The mold was loaded into a Toshiba Machine GMP-411VA glass molding machine (Toshiba Machine Co., Numazu-shi, Japan), and the apparatus was nitrogen-filled for 60 seconds, followed by pumping to a vacuum. The mold is heated from Celsius at 40 degrees Celsius to 28 degrees Celsius (degrees C/min) to 615 Celsius degree. Once the mold reached 615 degrees C, it remained at that temperature while the force on the mold gradually increased from zero force to 21,000 Newtons (pressure of 1600 psi for this size mold). The increase in force that occurs during the course of 20 minutes is approximately linear. Once the full force of 21,000 N is reached, the mold remains in this state for 1 hour at 600 degrees C. The pressure is then released and the mold is allowed to cool down to room temperature. The size of the resulting sintered disc and its mass were measured to calculate an envelope density of 2.51 grams per cubic centimeter (g/cc), which is 7% less than the fully dense aluminum 6063. A strip having a width of about 0.5 inch (1.27 cm) and a length of 1.575 inches (4.00 cm) was cut from the middle of the disc, and the strip was subjected to the above three-point bending test. The sample has an ultimate tensile strength of 203 megapascals (MPa). The results are shown in Table 7 below and Figure 4.

Example 16

5.4 g of Al 1-511 powder, 0.96 g of glass bubbles, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Comparative Example 15. The mold was loaded into a Toshiba Machine GMP-411VA glass molding machine (Toshiba Machine Co., Numazu-shi, Japan), and the apparatus was nitrogen-filled for 60 seconds, followed by pumping to a vacuum. The mold is heated from 40 degrees Celsius to 30 degrees Celsius (degrees C/min) to 615 degrees Celsius. Once the mold reached 615 degrees C, it remained at that temperature while the force on the mold gradually increased from zero force to 13,954 Newtons (pressure of 1600 psi for this size mold). The increase in force that occurs during the course of 20 minutes is approximately linear. Once the full force of 13,954 N is reached, the mold remains in this state for 1 hour at 615 degrees C. The pressure is then released and the mold is allowed to cool down to room temperature. The resulting disc There is a packing density of 1.93 g/cc. The results of the three point bending test are shown in Table 7 below and in Figure 4.

Example 17

5.4 g of Al 1-511 powder, 0.96 g of glass bubbles, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The apparatus was then subjected to the same sintering procedure of Example 16 above. The resulting disc had an envelope density of 1.91 g/cc. The results of the three point bending test are shown in Table 7 below and in Figure 4.

Example 18

5.4 g of Al 1-511 powder, 0.96 g of Lightstar 106 microbeads, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The apparatus was then subjected to the same sintering procedure of Example 16 above. The resulting disc had an envelope density of 1.93 g/cc. The results of the three point bending test are shown in Table 7 below and in Figure 4.

Example 19

5.4 g of Al 1-511 powder, 0.96 g of High Alumina 106 microbeads, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The device was then subjected to the same firing of Example 16 above. End program. The resulting disc had an envelope density of 1.95 g/cc. The results of the three point bending test are shown in Table 7 below and in Figure 4.

Example 20

5.4 g of Al 1100 powder, 0.96 g of Econostar 106 microbeads, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The apparatus was then subjected to the same sintering procedure of Example 16 above. The resulting disc had an envelope density of 1.93 g/cc. The results of the three point bending test are shown in Table 7 below and in Figure 4.

Example 21

5.4 g of Al 1-511 powder, 0.96 g of partially sintered niobium carbide-bonded particles, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The apparatus was then subjected to the same sintering procedure of Example 16 above. The resulting disc has an enveloping density of 2.28 g/cc and a 190 MPa Ultimate tensile strength, and a strain-to-failure of 3.4%. The results of the three point bending test are shown in Figure 5.

Example 22

5.94 g of Al1-131 powder, 0.96 g of Lightstar 106 microbeads, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The apparatus was then subjected to the same sintering procedure of Example 16 above. The resulting disc had an envelope density of 1.98 g/cc. The results of the three-point bending test are shown in Table 8 below and in Figure 6.

Example 23

7.56 g of Al 1-131 powder, 0.6 g of Lightstar 106 microbeads, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The apparatus was then subjected to the same sintering procedure of Example 16 above. The resulting disc had an envelope density of 2.21 g/cc. The results of the three point bending test are shown in Table 8 and in Figure 6.

Example 24

7.02 g of Al 1-131 powder, 0.72 g of Lightstar 106 microbeads, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The device was then subjected to the same firing of Example 16 above. End program. The resulting disc had an encapsulation density of 2.12 g/cc. The results of the three point bending test are shown in Table 8 and in Figure 6.

Example 25

7.02 g of Al powder, 0.72 g of Lightstar 106 microbeads, and 0.78 g of ceramic fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The apparatus was then subjected to the same sintering procedure of Example 16 above. The resulting disc had an encapsulation density of 2.00 g/cc. The results of the three point bending test are shown in Table 8 and in Figure 6.

Example 26

5.94 g of Al 1-131 powder, 0.84 g of Lightstar 106 microbeads, and 1.016 g of glass fibers were mixed by the above-described acoustic dispersion method, and the mixture was poured into the same graphite mold as in Example 16. The apparatus was then subjected to the same sintering procedure of Example 16 above. The resulting disc had an envelope density of 2.00 g/cc, an ultimate tensile strength of 159 MPa, and a strain at failure of 1.8%. The results of the three point bending test are shown in Figure 7.

While the present invention has been described in detail with reference to the preferred embodiments of the invention In addition, all publications and patents mentioned herein are hereby incorporated by reference in their entirety in their entirety herein in theties Into this article. Various illustrative embodiments have been described. These and other embodiments are within the scope of the following patent claims.

10‧‧‧Metal

12‧‧‧Inorganic particles

14‧‧‧Discontinuous fiber

100‧‧‧Porous metal matrix composite

Claims (14)

A method of making a porous metal matrix composite comprising: a. mixing a metal powder, a plurality of inorganic particles, and a plurality of discontinuous fibers to form a mixture; and b. sintering the mixture to form the porous metal substrate Complex. The method of claim 1, wherein the mixture is sintered in a mold. The method of claim 1 or 2, wherein the sintering is performed at a temperature between 250 degrees Celsius and 1,000 degrees Celsius and at a temperature of 250 degrees Celsius and 1,000 degrees Celsius. The method of any one of claims 1 to 3, wherein the sintering comprises applying a pressure. The method of claim 4, wherein the sintering is carried out at a pressure between 4 megapascal and 200 megapascals and a pressure of 4 megapascals and 200 megapascals. The method of any one of claims 1 to 5, wherein the mixing is performed using an acoustic mixer, a mechanical mixer, or a roller. The method of any one of claims 1 to 6, wherein the mixture comprises the inorganic particles dispersed in the metal powder and the discontinuous fibers. The method of any one of claims 1 to 7, wherein the plurality of inorganic particles comprise porous particles, the porous particles comprising porous metal oxide particles, porous metal hydroxide particles, porous metal carbonate, porous carbon particles, Porous vermiculite particles, porous dehydrated aluminum niobate particles, porous dehydrated metal hydrate particles, zeolite particles, porous glass particles, expanded perlite particles, expanded vermiculite particles, porous sodium niobate particles, engineered porous ceramic particles, non-porous A binder of primary particles, or a combination thereof. The method of any one of claims 1 to 7, wherein the plurality of inorganic particles comprise ceramic bubbles or glass bubbles. The method of any one of claims 1 to 9, wherein the plurality of discontinuous fibers comprise glass, alumina, aluminosilicate, carbon, basalt, or a combination thereof. The method of any one of claims 1 to 10, wherein the metal comprises aluminum, magnesium, an aluminum alloy, or a magnesium alloy. The method of any one of claims 1 to 11, wherein the metal matrix composite has an encapsulation density that is at least 8% less than the density of the metal and can withstand a strain of 1% prior to rupture. The method of claim 12, wherein the metal matrix composite is resistant to a strain of 2% prior to rupture. The method of any one of claims 1 to 13, wherein the metal matrix composite has a relief strength of 50 megapascals or more.