US3546769A - Method for making metal composites - Google Patents
Method for making metal composites Download PDFInfo
- Publication number
- US3546769A US3546769A US668510A US3546769DA US3546769A US 3546769 A US3546769 A US 3546769A US 668510 A US668510 A US 668510A US 3546769D A US3546769D A US 3546769DA US 3546769 A US3546769 A US 3546769A
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- US
- United States
- Prior art keywords
- fibers
- matrix
- metal
- fiber
- powder
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Classifications
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/14—Making alloys containing metallic or non-metallic fibres or filaments by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
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- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10S264/00—Plastic and nonmetallic article shaping or treating: processes
- Y10S264/19—Inorganic fiber
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- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12806—Refractory [Group IVB, VB, or VIB] metal-base component
-
- Y—GENERAL 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
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/12—All metal or with adjacent metals
- Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
- Y10T428/12771—Transition metal-base component
- Y10T428/12806—Refractory [Group IVB, VB, or VIB] metal-base component
- Y10T428/12826—Group VIB metal-base component
Definitions
- This invention relates to a method for making composite metal structures of powder metal and discrete metal fibers.
- the fibers are usually mechanically interlocked and not arranged in any particular direction.
- This concept has been utilized primarily to provide a porous body.
- the invention disclosed herein relates to a composite in which the fibers are without any structural rigidity apart from the matrix. There is no mechanical interlocking and, moreover, it is preferred that at least the majority of fibers do not touch each other to minimize stress concentration effects.
- the instant invention provides a structural material exhibiting improved strength over and above the strength of the matrix, for instance tensile strength and the modulus of elasticity, as hereafter further described.
- a particular object of the invention is the provision of light-weight, corrosion-resistant metal structures having good high temperature strength.
- a further object is the provision of improved methods for producing composite metal structures.
- An aspect of the present invention resides in the method of fabricating a composite metal structure which consists of a matrix powder metal and discrete fibers composed of another metal and distributed through the matrix without forming structural rigidity in the fiber mass independent of the matrix powder metal.
- the matrix metal in powder from and the fibers are combined, pressed, sintered and worked to produce the composite structure in which the fibers are substantially unidirectionally oriented.
- FIG. 1 is a perspective elevational view, partly in section, diagrammatically illustrating the method and articles contemplated by the invention.
- FIGS. 2, 3, 4 and 5 are graphic presentations of properties of metal structures according to the invention.
- the metallic structures embraced by the invention are bodies (e.g., rods, bars, plates, etc), of a matrix metal.
- bodies e.g., rods, bars, plates, etc
- a matrix metal e.g., titanium
- fibers of a metal e.g., molybdenum
- long fiber type The structures fall into two general categories hereinafter referred to as the long fiber type and the short fiber type. It is pointed out that the terms long and short are used relative to each other and allude to the length of the fibers, not in the completed structure but at the start of its fabrication.
- the term fiber is employed and intended to embrace small diameter filaments ranging up to a maximum initial diameter of about 0.020 inch. Theoretically there is no minimum diameter for the fibers employed in short fiber composites; however, in practice, the thinnest filaments would have a diameter in the order of a few microns or less. In the long fiber composites the minimum diameter would be dictated by the need to handle and position individual fibers as will be seen as this description proceeds.
- the fibers employed in structures on which data are given herein were of commercially available electroetched, mechanically straightened 0.010 inch diameter molybdenum wire.
- the fibers are axially disposed in a clean mild steel tube one end of which is then crimped shut on the wires and welded.
- the tube then is filled with matrix metal, in powder form.
- the tube is vibrated to insure that the powder is well tamped down around the wires.
- the open end of the tube is crimped and welded closed on the free ends of the wires thus sealing the assembly and maintaining the wires running axially through the tube.
- the tube is then heated and rolled in rod rolls.
- Working temperatures in the range of about 1450 to 1800 F. give good results for titanium matrix with molybdenum fibers, with the lower temperatures used as the piece is progressively reduced. For different combinations of metals working temperatures suited to the particular materials would be employed but care must be taken that the working temperature will not cause the powder nor the fibers to change into a liquid or semi-liquid state.
- a solid state bond is preferred since the mechanical properties of the fibers are usually detrimentally affected by contact with molten matrix materials. Placing the fibers in a liquid or semi-liquid state will cause all advantageous mechanical properties to be lost.
- the jacket is stripped and the unclad rod cold rolled to improve the surface finish.
- the finished structure comprises a compacted matrix with a multitude of very thin fibers extending through the body in one direction and individually bonded to the matrix.
- the long fiber composites comprise continuous, unidirectionally oriented fibers, they exhibit anisotropic properties. This must be taken into account in the design of articles to be fabricated from the material. In addition, this characteristic may be employed to improve the isotropy of matrix materials which are naturally anisotropic.
- the marked improvement in the composites is due at least in part to the fact that, at a given working temperature, one of the materials, e.g., the matrix is hot Worked whereas the fiber is cold worked or vice versa.
- short fibers e.g., in the order of 0.1 to 0.25 inch in length are admixed and blended with the matrix powder. At this stage, the fibers are oriented at random. The blended powder then is compacted and vacuum sintered. The sintered billets then are canned and extruded into rod as shown schematically in FIG. 1.
- FIG. 1 designates a conventional extrusion die, and 12, 12 a pair of rod rolls. The billet 14 entering the die is shown to contain randomly oriented fibers 16. In the extruded rod 14a leaving die 10 and prior to entering rolls 12, 12' fibers 16 have partia ly assumed a unidirectional orientation.
- FIG. 1 is an entirely schematic representation of one exemplary type of working technique. Actually, this working would be a two step operation. Moreover, a wide variety of working methods can be employed, e.g., forging, swaging, rolling, extrusion, direct rolling of powder, etc.
- the fibers consisted of 0.010 inch diameter molybdenurn wire varying in length from 0.1 to 0.25 inch.
- the matrix powder was unalloyed titanium or Ti-6Al-4V alloy.
- the billets were compacted at 70 tons per square inch, vacuum sintered for one hour at 1800 F., canned in mild steel and extruded to /8 inch rod at 1800 F. The case was stripped (although it can be left on) and the extruded rod re-canned in a stainless steel tube, heated to 1450 F. and hot rolled to 4 inch diameter.
- the cladding was then removed and the rod cold worked to inch diameter fo lowed by two hour anneal at 1350 F.
- FIG. 3 demonstrates the improvement in the tensile strength of respective short fiber type structures of unalloyed titanium containing 10 to 20 volume percent molybdenum fiber as compared with a control specimen of the same material subjected to the same fabrication conditions but containing no fiber. It will be readily apparent from inspection of FIGS. 2 and 3 that the properties of the matrix material are improved by the addition of either continuous or discontinuous fibers. In comparing FIGS. 2 and 3 it should be noted that, while the matrix material in each case was unalloyed titanium,
- modulus of elasticity Another important property of structural metals is the modulus of elasticity.
- the composites may be suitably coated or other means employed to prevent oxidation of the fiber. This is true of any fiber material which tends to oxidize readily under conditions of use.
- the invention is applicable to a wide range of different metal matrixes and fibers which are not physically or chemically incompatible with each other or with the fabrication techniques involved.
- the matrix metal must be one which is susceptible of being formed by powder metallurgy or must have a substantially lower melting point than the fiber; the fiber metal must be susceptible of being formed as a thin filament, and of bonding to the matrix metal with the application of heat and pressure.
- the fiber metal should possess some property or properties which it is desired to impart to the matrix. In some cases it may be necessary to employ fibers of two or more different materials to achieve the desired result.
- a method of fabricating composite metal structures consisting of a matrix powder metal and discrete fibers of another metal distributed therethrough, said fibers being composed of a material capable of imparting an increase in strength to the composite over the strength of said matrix metal, wherein said matrix metal in powder form and said fibers are combined, heated to a temperature to effect solid state bonding of said fibers to said matrix and worked to produce said structure without forming structural rigidity in the fiber mass independent of the matrix power metal.
- a method according to claim 1, wherein said fibers initially are randomly oriented and working includes the progressive elongation of said structure so as to elongate and substantially unidirectionally orient said fibers.
- a method of fabricating composite metal structure consisting of a matrix powder metal and filamentary particles of at least one other metal distributed therethrough, said fibers being composed of a material capable of imparting an increase in strength to the composite over the strength of said matrix, comprising: preparing a physical mixture consisting of said matrix metal in powder form and randomly oriented discontinuous discrete fibers of said other metal; forming a sintered compact of said mixture without forming structural rigidity in the fiber mass independent of the matrix powder metal; and heating to a temperature to effect solid state bonding of said fibers to said matrix and working said compact so as to density it and orient a major proportion of said fiber substantially to a single direction. parallel to each other and to the direction of working.
- a method of fabricating a composite metal structure composed predominantly of a titanium powder matrix and discrete fibers of molybdenum distributed therethrough comprising: preparing a mixture of titanium powder and about 3 to volume percent of molybdenum fibers having average diameters and lengths in the order of .01 and 0.1 inch, respectively; hot pressing said mixture to form a compacted billet without forming structural rigidity in the fiber mass independent of the matrix powder metal; sintering said billet at a temperature to efiect solid state bonding of said fibers to said matrix; extruding said billet into rod; and rolling said rod whereby a major proportion of initially randomly oriented fibers in said matrix are re-oriented substantially to a single direction.
- a method of fabricating a composite metal structure consisting of a matrix metal and discontinuous discrete fibers of at least one other metal extending therethrough, said fibers being composed of a material capable of imparting an increase in strength to the composite over the strength of said matrix comprising: arranging a plurality of said fiber extending axially through a malleable metal tube; filling said tube with said matrix metal in powder form; sealing the ends of said tube; and heating to a temperature to effect solid state bonding of said fibers to said matrix and working said tube to compact and densify its contents without forming structural rigidity in the fiber mass independent of the matrix powder metal.
Description
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US66851067A | 1967-09-18 | 1967-09-18 |
Publications (1)
Publication Number | Publication Date |
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US3546769A true US3546769A (en) | 1970-12-15 |
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Application Number | Title | Priority Date | Filing Date |
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US668510A Expired - Lifetime US3546769A (en) | 1967-09-18 | 1967-09-18 | Method for making metal composites |
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Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3773474A (en) * | 1971-04-26 | 1973-11-20 | W Horn | Multi-phase strip from particle and powder mixtures |
JPS5246316A (en) * | 1975-10-11 | 1977-04-13 | Sumitomo Alum Smelt Co Ltd | Process for producing aluminium base composite material reinforced wit h alumina fiber |
US4333813A (en) * | 1980-03-03 | 1982-06-08 | Reynolds Metals Company | Cathodes for alumina reduction cells |
US4587707A (en) * | 1982-03-29 | 1986-05-13 | Agency Of Industrial Science & Technology | Method for manufacture of composite material containing dispersed particles |
US4820466A (en) * | 1985-01-31 | 1989-04-11 | Zachariades Anagnostis E | Process for obtaining ultra-high modulus products |
US4961383A (en) * | 1981-06-26 | 1990-10-09 | The United States Of America As Represented By The Secretary Of The Navy | Composite tungsten-steel armor penetrators |
US6048379A (en) * | 1996-06-28 | 2000-04-11 | Ideas To Market, L.P. | High density composite material |
Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3047383A (en) * | 1955-12-27 | 1962-07-31 | Owens Corning Fiberglass Corp | Polyphase materials |
US3432295A (en) * | 1966-12-08 | 1969-03-11 | Hittman Associates Inc | Method for making oriented fiber or whisker composites |
-
1967
- 1967-09-18 US US668510A patent/US3546769A/en not_active Expired - Lifetime
Patent Citations (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3047383A (en) * | 1955-12-27 | 1962-07-31 | Owens Corning Fiberglass Corp | Polyphase materials |
US3432295A (en) * | 1966-12-08 | 1969-03-11 | Hittman Associates Inc | Method for making oriented fiber or whisker composites |
Cited By (9)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US3773474A (en) * | 1971-04-26 | 1973-11-20 | W Horn | Multi-phase strip from particle and powder mixtures |
JPS5246316A (en) * | 1975-10-11 | 1977-04-13 | Sumitomo Alum Smelt Co Ltd | Process for producing aluminium base composite material reinforced wit h alumina fiber |
JPS5538002B2 (en) * | 1975-10-11 | 1980-10-01 | ||
US4333813A (en) * | 1980-03-03 | 1982-06-08 | Reynolds Metals Company | Cathodes for alumina reduction cells |
US4961383A (en) * | 1981-06-26 | 1990-10-09 | The United States Of America As Represented By The Secretary Of The Navy | Composite tungsten-steel armor penetrators |
US4587707A (en) * | 1982-03-29 | 1986-05-13 | Agency Of Industrial Science & Technology | Method for manufacture of composite material containing dispersed particles |
US4820466A (en) * | 1985-01-31 | 1989-04-11 | Zachariades Anagnostis E | Process for obtaining ultra-high modulus products |
US6048379A (en) * | 1996-06-28 | 2000-04-11 | Ideas To Market, L.P. | High density composite material |
US6517774B1 (en) | 1996-06-28 | 2003-02-11 | Ideas To Market, L.P. | High density composite material |
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Owner name: IMPERIAL CLEVITE INC., A CORP. OF PA,ILLINOIS Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:GOULD INC., A CORP. OF DE;REEL/FRAME:003998/0236 Effective date: 19810928 Owner name: IMPERIAL CLEVITE INC., 2550 GOLF ROAD, ROLLING MEA Free format text: ASSIGNMENT OF ASSIGNORS INTEREST.;ASSIGNOR:GOULD INC., A CORP. OF DE;REEL/FRAME:003998/0236 Effective date: 19810928 |
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Owner name: CLEVITE INDUSTRIES INC., A CORP. OF DE.,STATELESS Free format text: MERGER;ASSIGNOR:IMPERIAL CLEVITE INC., A PA. CORP. (MERGED INTO);REEL/FRAME:004600/0610 Effective date: 19860615 Owner name: CLEVITE INDUSTRIES INC., A CORP. OF DE. Free format text: MERGER;ASSIGNOR:IMPERIAL CLEVITE INC., A PA. CORP. (MERGED INTO);REEL/FRAME:004600/0610 Effective date: 19860615 |