US3535093A - Aluminum composite containing carbon fibers coated with silver - Google Patents

Aluminum composite containing carbon fibers coated with silver Download PDF

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Publication number
US3535093A
US3535093A US727898A US3535093DA US3535093A US 3535093 A US3535093 A US 3535093A US 727898 A US727898 A US 727898A US 3535093D A US3535093D A US 3535093DA US 3535093 A US3535093 A US 3535093A
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United States
Prior art keywords
silver
aluminum
carbon fibers
fibers
composite
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Expired - Lifetime
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US727898A
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English (en)
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Raymond V Sara
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BP Corp North America Inc
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Union Carbide Corp
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Assigned to AMOCO CORPORATION, A CORP. OF INDIANA reassignment AMOCO CORPORATION, A CORP. OF INDIANA ASSIGNMENT OF ASSIGNORS INTEREST. Assignors: UNION CARBIDE CORPORATION
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    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C49/00Alloys containing metallic or non-metallic fibres or filaments
    • C22C49/14Alloys containing metallic or non-metallic fibres or filaments characterised by the fibres or filaments
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C21/00Alloys based on aluminium
    • C22C21/12Alloys based on aluminium with copper as the next major constituent
    • CCHEMISTRY; METALLURGY
    • C22METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22CALLOYS
    • C22C47/00Making alloys containing metallic or non-metallic fibres or filaments
    • C22C47/02Pretreatment of the fibres or filaments
    • C22C47/04Pretreatment of the fibres or filaments by coating, e.g. with a protective or activated covering
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10STECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S264/00Plastic and nonmetallic article shaping or treating: processes
    • Y10S264/19Inorganic fiber
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12444Embodying fibers interengaged or between layers [e.g., paper, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12486Laterally noncoextensive components [e.g., embedded, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12535Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.] with additional, spatially distinct nonmetal component
    • Y10T428/12625Free carbon containing component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/12All metal or with adjacent metals
    • Y10T428/12493Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y10T428/12736Al-base component
    • Y10T428/1275Next to Group VIII or IB metal-base component
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/29Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
    • Y10T428/2913Rod, strand, filament or fiber
    • Y10T428/2918Rod, strand, filament or fiber including free carbon or carbide or therewith [not as steel]

Definitions

  • the preferred process for producing such composites comprises contacting silver coated carbon fibers with an aluminum base material followed by hot pressing the so-contacted fibers at the solidus temperature of the aluminum base material to infiltrate aluminum around the silver coated fibers and then cooling the resultant article to a completely solidified state.
  • Such composite articles are characterized by a high tensile strength coupled with a high modulus of elasticity and are especially suited as materials of construction for aerospace and hydrospace vehicles and systems.
  • the present invention relates to high strength, high modulus composite refractory articles composed of a plurality of carbon fibers which are essentially coated with a thin layer of silver and/or silver base alloys and bonded together by an aluminum base matrix and to the process of producing the same.
  • the prime object of forming such composites is to increase the strength of the metal matrix by the inclusion therein of high strength carbon fibers.
  • Aluminum has been suggested as the matrix media for carbon fiber-metal composites which are intended for use in aerospace applications, in the main, due to its low density.
  • attempts heretofore to incorporate carbon fibers in an aluminum matrix have met with little or no practical success due to the fact that carbon, especially its graphitic form, is not readily wetted by molten aluminum.
  • Patented Oct. 20, 1970 The present invention overcomes the foregoing problem by employing an intermediate coating or wetting agent which when applied to the carbon fibers enables them to be readily bonded together by an aluminum base matrix material.
  • the carbon fiber-aluminum composite article of the invention comprises a plurality of carbon fibers each of which is coated with either a thin layer of silver, a silver-aluminum base alloy or mixtures thereof and bonded together, preferably in a side-by-side or paral lel manner, with an aluminum binder or matrix material.
  • this composite article may be provided by a process which comprises coating carbon fibers with a thin but essentially continuous film of silver, contacting the so-coated fibers with a solidified aluminum base material, hot pressing the so-produced assembly at the solidus temperature of the aluminum base material to infiltrate it around the coated fibers and cooling the resultant aluminum bonded carbon fibers to produce a composite article.
  • This article can then be formed into any desired shape by known techniques which will readily suggest themselves to those skilled in the art.
  • FIG. 1 is a diagrammatical illustration of a portion of carbon fiber-aluminum composite article produced according to the preferred teachings of the invention.
  • FIG. 2 is a greatly magnified diagrammatical illustration of a single fiber found in the composite of FIG. 1.
  • FIG. 1 shows a portion of a rectangular composite article 10 consisting of aligned graphite fibers 12 (the silver coating and aluminum-silver zone thereon are not shown) bonded together by an aluminum matrix 18.
  • the graphite fibers 12 are disposed in the aluminum matrix in a parallel manner with their length dimension being perpendicular to the surface of the drawing.
  • FIG. 2 shows a single graphite fiber 12 taken from the composite 10 of FIG. 1 having on its surface a coating of silver 14 and an aluminum-silver interface zone 16 between the silver coating and the aluminum matrix 18.
  • Carbon textiles in any form can be employed in the practice of the instant invention. However, it is preferred to employ carbon fibers in yarn or multi-filament form. Carbon textiles are available commercially and are generally produced by the techniques described in US. Pats. 3,107,152 and 3,116,975, among others.
  • Silver can be deposited on the carbon fibers by a variety of methods.
  • the techniques available for accomplishing this include electrodeposition from a conductive bath, reduction of salts to the metal or sputtering.
  • the exact deposition technique to be employed is dictated by a number of factors.
  • Sputtering can be used on relatively complex shapes and results in a tenacious bond between the thin silver coating and the carbon fiber substrate. Such a bond is a highly desirable feature in carbon fibermetal matrix composites. Dipping of the carbon fibers into a silver containing solution and chemically reducing the salt to the metal can also be employed, however, with this technique it is difiicult to accurately control the thickness of the silver coating.
  • Electrodeposition of silver from a conductive bath is an ideal way of coating carbon fibers with a thin film of silver and is the preferred method since it results in a uniform, tenaciously bonded metallic coating.
  • the slightly oxidized fibers were immediately plated electrolytically with silver by placing them in a strike solution for about 5 to seconds and then into a conventional plating solution for about 5 to 10 seconds.
  • the plating current employed was about 400 milliamps for the strike solution and between about 600 to 800 milliamps for the conventional plating solution.
  • the make up of the strike and conventional plating solution was as follows:
  • KCN Potassium cyanide
  • the composite was subsequently cooled in the mold to room temperature and then formed into a inch X inch X 1 inch specimen for physical property measurements.
  • This specimen evidenced an average tensile strength of 44,100 lb./lb. and a Youngs modulus of 13.0 10 1b./in.
  • the table below shows the improvement obtained by incorporating silver coated graphite fibers in an aluminum base matrix material by the technique of the instant in- 55 vention.
  • the instant invention results in a unique type of composite comprising carbon fiber which are coated with either silver, a silver-aluminum base alloy or mixture thereof and bonded together by an aluminum base matrix.
  • the carbon fibers may be randomly orientated in the aluminum matrix if more isotropic physical properties are desired without losing the benefits of the instant invention.
  • the thickness of the silver can be varied as desired. All that is required is that it be thick enough to prevent the aluminum martix metal from coming into contact with the reinforcing carbon fibers to such an extent that there is essentially no bonding between the fibers and the matrix metal.
  • graphite fibers and fabrics are preferred in the practice of the instant invention, non-graphitic carbon fibers and fabrics may also be employed.
  • the preferred practice of the invention inyolves infiltrating the matrix metal around the filaments by heating the metal to a temperature at which it begins to melt but below that at which it becomes completely liquid, i.e., at its solidus temperature, and then forcing the so-softened matrix metal around the individual filaments by the means of an applied pressure.
  • the amount of pressure to be applied is not particularly critical and need only be sufficient to compact the fibers and matrix material into an essentially non-porous article.
  • carbon as used herein and in the appended claims is meant to include both the non-graphitic and graphitic forms of carbon.
  • a refractory composite article comprising a plurality of carbon fibers bonded together by an aluminum base matrix, said carbon fibers having an essentially continuous coating of a material selected from the group TABLE-PROPERTIES OF GRAPIIITE-FIBER, ALUMINUM COMPOSITE Aluminum Volume Yonngs Tensile layers in percent modulus, strength, composite of fibers X10 lb./in. lb./in.
  • Matrix metal 0 .10. 4 36,100 Silver-coated fibers. 1G 13. 0 44, 100 Silver-coated fibe1s 28 15. 3 56, 700

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)
  • Ceramic Products (AREA)
  • Chemical Or Physical Treatment Of Fibers (AREA)
US727898A 1968-05-09 1968-05-09 Aluminum composite containing carbon fibers coated with silver Expired - Lifetime US3535093A (en)

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US72789868A 1968-05-09 1968-05-09

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US (1) US3535093A (enrdf_load_stackoverflow)
DE (1) DE1912465B2 (enrdf_load_stackoverflow)
FR (1) FR2008114B1 (enrdf_load_stackoverflow)
GB (1) GB1187007A (enrdf_load_stackoverflow)

Cited By (24)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3717445A (en) * 1969-11-12 1973-02-20 Mitsubishi Steel Mfg Electrode holder for electric arc furnace and make the same
US3807996A (en) * 1972-07-10 1974-04-30 Union Carbide Corp Carbon fiber reinforced nickel matrix composite having an intermediate layer of metal carbide
US4132828A (en) * 1976-11-26 1979-01-02 Toho Beslon Co., Ltd. Assembly of metal-coated carbon fibers, process for production thereof, and method for use thereof
US4240830A (en) * 1978-11-30 1980-12-23 Westinghouse Electric Corp. Method for making sintered metal-coated graphite for high-current collector brushes
US4347083A (en) * 1973-03-12 1982-08-31 Union Carbide Corporation Chemically bonded aluminum coating for carbon via monocarbides
DE3144947A1 (de) * 1980-11-14 1982-09-09 Material Concepts, Inc., Columbus, Ohio Verfahren zum behandeln einer faser
US4402744A (en) * 1973-03-12 1983-09-06 Union Carbide Corporation Chemically bonded aluminum coating for carbon via monocarbides
US4416840A (en) * 1981-12-21 1983-11-22 General Electric Company Al2 O3 Ceramic composite
US4461855A (en) * 1980-08-28 1984-07-24 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Resin composite reinforced with fibers having a flat-sided triangular shape
US4546049A (en) * 1982-12-17 1985-10-08 Tokyo Shibaura Denki Kabushiki Kaisha Ornamental composite of a metal alloy surrounding a mineral powder core for use in spectacle frames
US4578287A (en) * 1984-10-09 1986-03-25 The United States Of America As Represented By The Secretary Of The Navy Process for producing graphite fiber/aluminum-magnesium matrix composites
US4609449A (en) * 1982-03-16 1986-09-02 American Cyanamid Company Apparatus for the production of continuous yarns or tows comprising high strength metal coated fibers
US4657822A (en) * 1986-07-02 1987-04-14 The United States Of America As Represented By The Secretary Of The Navy Fabrication of hollow, cored, and composite shaped parts from selected alloy powders
US4661403A (en) * 1982-03-16 1987-04-28 American Cyanamid Company Yarns and tows comprising high strength metal coated fibers, process for their production, and articles made therefrom
US4817578A (en) * 1986-07-31 1989-04-04 Honda Giken Kogyo Kabushiki Kaisha Internal combustion engine
US4853294A (en) * 1988-06-28 1989-08-01 United States Of America As Represented By The Secretary Of The Navy Carbon fiber reinforced metal matrix composites
US4909910A (en) * 1982-03-16 1990-03-20 American Cyanamid Yarns and tows comprising high strength metal coated fibers, process for their production, and articles made therefrom
US4942090A (en) * 1982-03-16 1990-07-17 American Cyanamid Chaff comprising metal coated fibers
US6548013B2 (en) 2001-01-24 2003-04-15 Scimed Life Systems, Inc. Processing of particulate Ni-Ti alloy to achieve desired shape and properties
DE102004002343A1 (de) * 2004-01-16 2005-08-11 Deutsches Zentrum für Luft- und Raumfahrt e.V. Hybridfaser, Verfahren zu ihrer Herstellung und Verwendung
WO2008089722A3 (de) * 2007-01-24 2008-12-04 Eads Deutschland Gmbh Faserverbundwerkstoff mit metallischer matrix und verfahren zu seiner herstellung
US10124402B2 (en) 2016-03-04 2018-11-13 Korea Institute Of Science And Technology Methods for manufacturing carbon fiber reinforced aluminum composites using stir casting process
US11667996B2 (en) 2017-12-05 2023-06-06 Ut-Battelle, Llc Aluminum-fiber composites containing intermetallic phase at the matrix-fiber interface
CN119265446A (zh) * 2024-12-05 2025-01-07 内蒙古恒铸智造科技有限公司 一种铝基复合材料及其制备方法和应用

Families Citing this family (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPS5138643B1 (enrdf_load_stackoverflow) * 1970-09-30 1976-10-22
US3894677A (en) * 1971-03-24 1975-07-15 Nasa Method of preparing graphite reinforced aluminum composite
FR2698582B1 (fr) * 1992-11-30 1995-02-24 Aerospatiale Matériau composite à fibres de renfort et à matrice métallique.

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3038248A (en) * 1954-11-04 1962-06-12 Kremer Henry Strengthening of metal
US3187422A (en) * 1956-08-27 1965-06-08 Owens Corning Fiberglass Corp Reinforcement of metal
US3256596A (en) * 1961-02-06 1966-06-21 William S Fiedler Process for making article of vitreous material and metal

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3038248A (en) * 1954-11-04 1962-06-12 Kremer Henry Strengthening of metal
US3187422A (en) * 1956-08-27 1965-06-08 Owens Corning Fiberglass Corp Reinforcement of metal
US3256596A (en) * 1961-02-06 1966-06-21 William S Fiedler Process for making article of vitreous material and metal

Cited By (29)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3717445A (en) * 1969-11-12 1973-02-20 Mitsubishi Steel Mfg Electrode holder for electric arc furnace and make the same
US3807996A (en) * 1972-07-10 1974-04-30 Union Carbide Corp Carbon fiber reinforced nickel matrix composite having an intermediate layer of metal carbide
US4402744A (en) * 1973-03-12 1983-09-06 Union Carbide Corporation Chemically bonded aluminum coating for carbon via monocarbides
US4347083A (en) * 1973-03-12 1982-08-31 Union Carbide Corporation Chemically bonded aluminum coating for carbon via monocarbides
US4132828A (en) * 1976-11-26 1979-01-02 Toho Beslon Co., Ltd. Assembly of metal-coated carbon fibers, process for production thereof, and method for use thereof
US4240830A (en) * 1978-11-30 1980-12-23 Westinghouse Electric Corp. Method for making sintered metal-coated graphite for high-current collector brushes
US4461855A (en) * 1980-08-28 1984-07-24 The Secretary Of State For Defence In Her Britannic Majesty's Government Of The United Kingdom Of Great Britain And Northern Ireland Resin composite reinforced with fibers having a flat-sided triangular shape
DE3144947A1 (de) * 1980-11-14 1982-09-09 Material Concepts, Inc., Columbus, Ohio Verfahren zum behandeln einer faser
US4416840A (en) * 1981-12-21 1983-11-22 General Electric Company Al2 O3 Ceramic composite
US4909910A (en) * 1982-03-16 1990-03-20 American Cyanamid Yarns and tows comprising high strength metal coated fibers, process for their production, and articles made therefrom
US4609449A (en) * 1982-03-16 1986-09-02 American Cyanamid Company Apparatus for the production of continuous yarns or tows comprising high strength metal coated fibers
US4661403A (en) * 1982-03-16 1987-04-28 American Cyanamid Company Yarns and tows comprising high strength metal coated fibers, process for their production, and articles made therefrom
US4942090A (en) * 1982-03-16 1990-07-17 American Cyanamid Chaff comprising metal coated fibers
US4546049A (en) * 1982-12-17 1985-10-08 Tokyo Shibaura Denki Kabushiki Kaisha Ornamental composite of a metal alloy surrounding a mineral powder core for use in spectacle frames
US4578287A (en) * 1984-10-09 1986-03-25 The United States Of America As Represented By The Secretary Of The Navy Process for producing graphite fiber/aluminum-magnesium matrix composites
US4657822A (en) * 1986-07-02 1987-04-14 The United States Of America As Represented By The Secretary Of The Navy Fabrication of hollow, cored, and composite shaped parts from selected alloy powders
US4817578A (en) * 1986-07-31 1989-04-04 Honda Giken Kogyo Kabushiki Kaisha Internal combustion engine
US4853294A (en) * 1988-06-28 1989-08-01 United States Of America As Represented By The Secretary Of The Navy Carbon fiber reinforced metal matrix composites
US6548013B2 (en) 2001-01-24 2003-04-15 Scimed Life Systems, Inc. Processing of particulate Ni-Ti alloy to achieve desired shape and properties
DE102004002343A1 (de) * 2004-01-16 2005-08-11 Deutsches Zentrum für Luft- und Raumfahrt e.V. Hybridfaser, Verfahren zu ihrer Herstellung und Verwendung
DE102004002343B4 (de) * 2004-01-16 2006-08-03 Deutsches Zentrum für Luft- und Raumfahrt e.V. Hybridfaser, Verfahren zu ihrer Herstellung und Verwendung
WO2008089722A3 (de) * 2007-01-24 2008-12-04 Eads Deutschland Gmbh Faserverbundwerkstoff mit metallischer matrix und verfahren zu seiner herstellung
US20100092751A1 (en) * 2007-01-24 2010-04-15 Airbus Sas Fiber composite comprising a metallic matrix, and method for the production thereof
JP2010516504A (ja) * 2007-01-24 2010-05-20 エアバス・エスエーエス 金属質母材を備えた繊維複合材料及びその製造方法
CN101636516B (zh) * 2007-01-24 2011-12-14 空中巴士公司 制备带有金属基体的纤维复合材料的方法
RU2465364C2 (ru) * 2007-01-24 2012-10-27 Эрбус Сас Волокнистый композиционный материал с металлической матрицей и способ его изготовления
US10124402B2 (en) 2016-03-04 2018-11-13 Korea Institute Of Science And Technology Methods for manufacturing carbon fiber reinforced aluminum composites using stir casting process
US11667996B2 (en) 2017-12-05 2023-06-06 Ut-Battelle, Llc Aluminum-fiber composites containing intermetallic phase at the matrix-fiber interface
CN119265446A (zh) * 2024-12-05 2025-01-07 内蒙古恒铸智造科技有限公司 一种铝基复合材料及其制备方法和应用

Also Published As

Publication number Publication date
DE1912465B2 (de) 1972-06-22
FR2008114A1 (enrdf_load_stackoverflow) 1970-01-16
FR2008114B1 (enrdf_load_stackoverflow) 1975-07-04
DE1912465A1 (de) 1970-02-26
GB1187007A (en) 1970-04-08

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