US2004035547A1PendingUtilityA1

Metal matrix composites, and methods for making the same

Assignee: 3M INNOVATIVE PROPERTIES COPriority: Aug 20, 2002Filed: Mar 31, 2003Published: Feb 26, 2004

Est. expiryAug 20, 2022(expired)· nominal 20-yr term from priority

Inventors:Michael Grether

F16D 2055/0016F16D 2200/006C22C 47/08B22D 19/14C22C 49/06B22F 2998/00C22C 47/06

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References

Claims

Abstract

A holder comprising an insert for reinforcing a metal matrix composite article and methods of making the same. In another aspect, the present invention provides metal matrix composite articles reinforced with an insert(s) and methods of making the same. Useful metal matrix composite articles comprising the inserts include brake calipers.

Claims

exact text as granted — not AI-modified

What is claimed is:

1 . An article comprising:
an insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, and a second metal on the outer surface of the first metal, the second metal having a positive Gibbs oxidation free energy above at least 200° C., the second metal having a thickness of at least 8 micrometers; and at least one metal comprising reinforcement insert secured in at least one portion for securing at least one insert.

2 . The article according to claim 1 comprising two portions for securing respectively an insert, and two of the metal comprising reinforcement inserts positioned respectively in the portions for securing respectively an insert.

3 . The article according to claim 1 further comprising a third metal between the second metal and the outer surface of the first metal.

4 . The article according to claim 1 wherein the second metal has a thickness of at least 10 micrometers.

5 . The article according to claim 1 wherein the second metal is one of gold or silver.

6 . The article according to claim 1 wherein the first metal is an aluminum alloy, and wherein the metal of the metal comprising reinforcement insert is an aluminum alloy.

7 . The article according to claim 1 wherein the first metal is a 6000 series aluminum alloy and wherein the metal of the metal comprising reinforcement insert is a 200 series aluminum alloy.

8 . An article comprising:
an insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, and a second metal on the outer surface of the first metal, the second metal having a positive Gibbs oxidation free energy above at least 200° C., the second metal having a thickness of at least 8 micrometers; and at least one crystalline ceramic comprising reinforcement insert secured in at least one portion for securing at least one insert.

9 . The article according to claim 8 wherein the second metal has a thickness of at least 10 micrometers.

10 . The article according to claim 8 wherein the second metal is one of gold or silver.

11 . The article according to claim 9 wherein the crystalline ceramic comprising reinforcement insert comprises porous, sintered ceramic oxide material and substantially continuous ceramic oxide fibers having lengths of at least 5 cm, the porous, sintered ceramic oxide material securing the substantially continuous ceramic oxide fibers in place, wherein the porous, sintered ceramic oxide material extends along at least a portion of the length of the substantially continuous fibers.

12 . An article comprising:
an insert holder including at least one portion for securing at least one insert, the insert holder comprises a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, Ni on the outer surface of the insert holder, the Ni having an outer surface; and Ag on the outer surface of the Ni, the Ag having a thickness of at least 8 micrometers; and at least one metal comprising reinforcement insert secured in the at least one portion for securing at least one insert.

13 . The article according to claim 12 wherein the Ni has a thickness of at least 1 micrometer.

14 . An article comprising:
an insert holder including at least one portion for securing at least one insert, the insert holder comprises a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, Ni on the outer surface of the insert holder, the Ni having an outer surface; and Ag on the outer surface of the Ni, the Ag having a thickness of at least 8 micrometers; and at least one crystalline ceramic comprising reinforcement insert secured in the at least one portion for securing at least one insert.

15 . The article according to claim 14 wherein the Ni has a thickness of at least 1 micrometer.

16 . The article according to claim 14 wherein the crystalline ceramic comprising reinforcement insert comprises porous, sintered ceramic oxide material and substantially continuous ceramic oxide fibers having lengths of at least 5 cm, the porous, sintered ceramic oxide material securing the substantially continuous ceramic oxide fibers in place, wherein the porous, sintered ceramic oxide material extends along at least a portion of the length of the substantially continuous fibers.

17 . An article comprising:
an insert holder including at least one portion for securing at least one insert, the insert holder comprises a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, and a second metal on the outer surface of the first metal, the second metal having a positive Gibbs oxidation free energy above at least 200° C.; and at least one metal matrix composite insert secured in at least one portion for securing at least one insert, wherein at least one of such inserts comprises:
substantially continuous ceramic oxide fibers and third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the third metal secures the substantially continuous ceramic oxide fibers in place, and wherein the third metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers, the third metal having an outer surface; and
a fourth metal on the outer surface of the third metal, the fourth metal having a positive Gibbs oxidation free energy above at least 200° C., and the fourth metal having a thickness of at least 8 micrometers.

18 . The article according to claim 17 further comprising another metal between the second metal and the outer surface of the first metal, and, further comprising another metal between the fourth metal and the outer surface of the third metal.

19 . The article according to claim 17 wherein the second and fourth metals each have a thickness of at least 10 micrometers.

20 . The article according to claim 17 wherein the second and fourth metals are one of gold or silver.

21 . The article according to claim 17 wherein the first metal is an aluminum alloy, and wherein the third metal is an aluminum alloy.

22 . The article according to claim 17 wherein the first metal is a 6000 series aluminum alloy and wherein the third metal is a 200 series aluminum alloy.

23 . An article comprising:
an insert holder including at least one portion for securing at least one insert, the insert holder comprises a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof; and at least one metal matrix composite insert positioned in the at least one portion for securing at least one insert, the insert comprising substantially continuous ceramic oxide fibers and second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the second metal secures the substantially continuous ceramic oxide fibers in place, and wherein the second metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers, the insert holder with the at least one insert secured in the at least one portion for securing at least one insert collectively having an outer surface, and a third metal on the outer surface, the third metal having a positive Gibbs oxidation free energy above at least 200° C., and the third metal having a thickness of at least 8 micrometers.

24 . The article according to claim 23 further comprising another metal between the third metal and the outer surface.

25 . The article according to claim 24 wherein the third metal has a thickness of at least 10 micrometers.

26 . The article according to claim 24 wherein the third metal is one of gold or silver.

27 . The article according to claim 24 wherein the first metal is an aluminum alloy, and wherein the second metal is an aluminum alloy.

28 . The article according to claim 24 wherein the first metal is a 6000 series aluminum alloy and wherein the second metal is a 200 series aluminum alloy.

29 . An article comprising:
an insert holder including at least one portion for securing at least one insert, the insert holder comprises a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, Ni on the outer surface of the insert holder, the Ni having an outer surface; and Ag on the outer surface of the Ni; and at least one a metal matrix composite insert secured in the at least one portion for securing at least one insert, at least one of such inserts comprising:
substantially continuous ceramic oxide fibers and second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the second metal secures the substantially continuous ceramic oxide fibers in place, and wherein the second metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers, the second metal having an outer surface;
Ni on the outer surface of the second metal, the Ni having an outer surface; and
Ag on the outer surface of the Ni, the Ag having a thickness of at least 8 micrometers.

30 . The article according to claim 29 wherein the Ni has a thickness of at least 1 micrometer.

31 . An article comprising:
an insert holder including at least one portion for securing at least one insert, the insert holder comprises a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof; and at least one metal matrix composite insert positioned in the at least one portion for securing at least one insert, the insert comprising substantially continuous ceramic oxide fibers and second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the second metal secures the substantially continuous ceramic oxide fibers in place, and wherein the second metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers, the insert holder with the at least one insert secured in the at least one portion for securing at least one insert collectively having an outer surface, Ni on the outer surface of the metal, the Ni having an outer surface of the insert holder, and Ag on the outer surface of the Ni.

32 . The article according to claim 31 wherein the Ni has a thickness of at least 1 micrometer.

33 . A metal matrix composite article comprising a first metal and an insert holder including at least one portion for securing at least one insert, wherein the first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the insert holder comprises:
a second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof; and at least one metal comprising reinforcement insert secured in the at least one portion for securing at least one insert, wherein there is an interface layer between the first metal and the insert holder, and wherein there is an interface layer peak bond strength value between the first metal and the insert holder of at least 100 MPa.

34 . The metal matrix composite article according to claim 33 wherein the peak bond strength value is at least 130 MPa.

35 . The metal matrix composite article according to claim 33 comprising two portions for securing respectively an insert, and two of the metal comprising reinforcement inserts positioned respectively in the portions for securing respectively an insert.

36 . The metal matrix composite article according to claim 33 wherein the first metal is an aluminum alloy, wherein the second metal is an aluminum alloy, and wherein the metal of the metal comprising reinforcement insert is an aluminum alloy.

37 . The metal matrix composite article according to claim 33 wherein the first metal is one of a 300 or 400 series aluminum alloy, wherein the second metal is a 6000 series aluminum alloy, and wherein the metal of the metal comprising reinforcement insert is 200 series aluminum alloy.

38 . The metal matrix composite article according to claim 33 which is a brake caliper.

39 . A disc brake for a motor vehicle comprising a rotor; inner and outer brake pads disposed on opposite sides of the rotor and movable into braking engagement therewith; a piston for urging the inner brake pad against the rotor; and the brake caliper according to claim 38 comprising a body member having a cylinder positioned on one side of the rotor and containing the piston, an arm member positioned on the other side of the rotor and supporting the outer brake pad, and a bridge extending between the body member and the arm member across the plane of the rotor.

40 . A metal matrix composite article comprising a first metal and an insert holder including at least one portion for securing at least one insert, wherein the first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the insert holder comprises:
a second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof; and at least one crystalline ceramic comprising reinforcement insert secured in the at least one portion for securing at least one insert, wherein there is an interface layer between the first metal and the insert holder, and wherein there is an interface layer peak bond strength value between the first metal and the insert holder of at least 100 MPa.

41 . The metal matrix composite article according to claim 40 wherein the peak bond strength value is at least 130 MPa.

42 . The metal matrix composite article according to claim 40 comprising two portions for securing respectively an insert, and two of the crystalline ceramic comprising reinforcement inserts positioned respectively in the portions for securing respectively an insert.

43 . The metal matrix composite article according to claim 40 wherein the first metal is an aluminum alloy and wherein the second metal is an aluminum alloy.

44 . The metal matrix composite article according to claim 40 wherein the first metal is one of a 300 or 400 series aluminum alloy, and wherein the second metal is a 6000 series aluminum alloy.

45 . The metal matrix composite article according to claim 44 wherein the crystalline ceramic comprising reinforcement insert comprises porous, sintered ceramic oxide material and substantially continuous ceramic oxide fibers having lengths of at least 5 cm, the porous, sintered ceramic oxide material securing the substantially continuous ceramic oxide fibers in place, wherein the porous, sintered ceramic oxide material extends along at least a portion of the length of the substantially continuous fibers.

46 . The metal matrix composite article according to claim 40 which is a brake caliper.

47 . A disc brake for a motor vehicle comprising a rotor; inner and outer brake pads disposed on opposite sides of the rotor and movable into braking engagement therewith; a piston for urging the inner brake pad against the rotor; and the brake caliper according to claim 46 comprising a body member having a cylinder positioned on one side of the rotor and containing the piston, an arm member positioned on the other side of the rotor and supporting the outer brake pad, and a bridge extending between the body member and the arm member across the plane of the rotor.

48 . A metal matrix composite article comprising a first metal and an insert holder including at least one portion for securing at least one insert, wherein the first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the insert holder comprises:
a second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof; and at least one metal matrix composite insert secured in the at least one portion for securing at least one insert, the metal matrix composite insert comprising:
substantially continuous ceramic oxide fibers and third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the third metal secures the substantially continuous ceramic oxide fibers in place, and wherein the third metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers,
wherein there is an interface layer between the first metal and the insert holder, wherein the interface layer is free of oxygen, wherein the interface layer includes an average amount of a fourth metal having a positive Gibbs oxidation free energy above at least 200° C., and wherein the average amount of the fourth metal in the interface layer is higher in the interface layer than that present in the first metal.

49 . The metal matrix composite article according to claim 48 comprising two portions for securing respectively an insert, and two of the metal matrix composite inserts positioned respectively in the portions for securing respectively an insert.

50 . The metal matrix composite article according to claim 48 wherein the first metal is an aluminum alloy, wherein the second metal is an aluminum alloy, and wherein the third metal is an aluminum alloy.

51 . The metal matrix composite article according to claim 48 wherein the first metal is one of a 300 or 400 series aluminum alloy, wherein the second metal is a 6000 series aluminum alloy, and wherein the third metal is a 200 series aluminum alloy.

52 . The metal matrix composite article according to claim 48 which is a brake caliper.

53 . A disc brake for a motor vehicle comprising a rotor; inner and outer brake pads disposed on opposite sides of the rotor and movable into braking engagement therewith; a piston for urging the inner brake pad against the rotor; and the brake caliper according to claim 52 comprising a body member having a cylinder positioned on one side of the rotor and containing the piston, an arm member positioned on the other side of the rotor and supporting the outer brake pad, and a bridge extending between the body member and the arm member across the plane of the rotor.

54 . A metal matrix composite article comprising a first metal and an insert holder including at least one portion for securing at least one insert, wherein the first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the insert holder comprises:
a second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof; and at least one metal matrix composite insert secured in the at least one portion for securing at least one insert, the metal matrix composite insert comprising:
substantially continuous ceramic oxide fibers and third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the third metal secures the substantially continuous ceramic oxide fibers in place, and wherein the third metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers,
wherein there is an interface layer between the first metal and the insert holder, and wherein there is an interface layer peak bond strength value between the first metal and the insert holder of at least 100 MPa.

55 . The metal matrix composite article according to claim 54 wherein the peak bond strength value is at least 130 MPa.

56 . The metal matrix composite article according to claim 54 comprising two portions for securing respectively an insert, and two of the metal matrix composite inserts positioned respectively in the portions for securing respectively an insert.

57 . The metal matrix composite article according to claim 54 wherein the first metal is an aluminum alloy, wherein the second metal is an aluminum alloy, and wherein the third metal is an aluminum alloy.

58 . The metal matrix composite article according to claim 54 wherein the first metal is one of a 300 or 400 series aluminum alloy, wherein the second metal is a 6000 series aluminum alloy, and wherein the third metal is a 200 series aluminum alloy.

59 . The metal matrix composite article according to claim 54 which is a brake caliper.

60 . A disc brake for a motor vehicle comprising a rotor; inner and outer brake pads disposed on opposite sides of the rotor and movable into braking engagement therewith; a piston for urging the inner brake pad against the rotor; and the brake caliper according to claim 59 comprising a body member having a cylinder positioned on one side of the rotor and containing the piston, an arm member positioned on the other side of the rotor and supporting the outer brake pad, and a bridge extending between the body member and the arm member across the plane of the rotor.

61 . A metal matrix composite article comprising a first metal and an insert holder including at least one portion for securing at least one insert, wherein the first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the insert holder comprises:
a second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof; and at least one metal matrix composite insert secured in the at least one portion for securing at least one insert, the metal matrix composite insert comprising:
substantially continuous ceramic oxide fibers and third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the third metal secures the substantially continuous ceramic oxide fibers in place, and wherein the third metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers,
wherein there is an interface layer between the first metal and the insert holder, wherein the interface layer is free of oxygen, and wherein the interface layer includes an average amount of Ag and Ni higher than that present in the first metal.

62 . The metal matrix composite article according to claim 61 wherein the peak bond strength value is at least 130 MPa.

63 . The metal matrix composite article according to claim 61 comprising two portions for securing respectively an insert, and two of the metal matrix composite inserts positioned respectively in the portions for securing respectively an insert.

64 . The metal matrix composite article according to claim 61 wherein the first metal is an aluminum alloy, wherein the second metal is an aluminum alloy, and wherein the third metal is an aluminum alloy.

65 . The metal matrix composite article according to claim 61 wherein the first metal is one of a 300 or 400 series aluminum alloy, wherein the second is a 6000 series aluminum alloy, and wherein the third metal is a 200 series aluminum alloy.

66 . The metal matrix composite article according to claim 61 which is a brake caliper.

67 . A disc brake for a motor vehicle comprising a rotor; inner and outer brake pads disposed on opposite sides of the rotor and movable into braking engagement therewith; a piston for urging the inner brake pad against the rotor; and the brake caliper according to claim 66 comprising a body member having a cylinder positioned on one side of the rotor and containing the piston, an arm member positioned on the other side of the rotor and supporting the outer brake pad, and a bridge extending between the body member and the arm member across the plane of the rotor.

68 . A method of making a metal matrix composite article, the method comprising:
positioning an insert holder that includes a metal comprising reinforcement insert, the insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, and a second metal on the outer surface of the first metal, the second metal having a positive Gibbs oxidation free energy above at least 200° C., the second metal having a thickness of at least 8 micrometers, and the metal comprising reinforcement insert being secured in the at least one portion for securing at least one insert; providing molten third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof into the mold; and cooling the molten third metal to provide a metal matrix composite article.

69 . The method according to claim 68 wherein the molten third metal in the mold is in the molten state for less than 75 seconds.

70 . The method according to claim 68 wherein the molten third metal in the mold is in the molten state for less than 75 seconds.

71 . The method according to claim 68 comprising two portions for securing respectively an insert, and two of the metal comprising reinforcement inserts positioned respectively in the portions for securing respectively an insert.

72 . The method according to claim 68 wherein the first metal is an aluminum alloy, wherein the third metal is an aluminum alloy, and wherein the metal of the metal comprising reinforcement insert is an aluminum alloy.

73 . The method according to claim 68 wherein the first metal is a 6000 series aluminum alloy, wherein the metal of the metal comprising reinforcement insert is a 200 series aluminum alloy, and wherein the third metal is one of a 300 or 400 series aluminum alloy.

74 . The method according to claim 68 wherein the metal matrix composite article is a brake caliper.

75 . A method of making a metal matrix composite article, the method comprising:
positioning an insert holder that includes a crystalline ceramic comprising reinforcement insert, the insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, and a second metal on the outer surface of the first metal, the second metal having a positive Gibbs oxidation free energy above at least 200° C., the second metal having a thickness of at least 8 micrometers, and the crystalline ceramic comprising reinforcement insert being secured in the at least one portion for securing at least one insert; providing molten third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof into the mold; and cooling the molten third metal to provide a metal matrix composite article.

76 . The method according to claim 75 wherein the molten third metal in the mold is in the molten state for less than 75 seconds.

77 . The method according to claim 75 wherein the molten third metal in the mold is in the molten state for less than 60 seconds.

78 . The method according to claim 75 comprising two portions for securing respectively an insert, and two of the crystalline ceramic comprising reinforcement inserts positioned respectively in the portions for securing respectively an insert.

79 . The method according to claim 75 wherein the first metal is an aluminum alloy and wherein the third metal is an aluminum alloy.

80 . The method according to claim 75 wherein the first metal is a 6000 series aluminum alloy, and wherein the third metal is one of a 300 or 400 series aluminum alloy.

81 . The method according to claim 75 wherein the crystalline ceramic comprising reinforcement insert comprising porous, sintered ceramic oxide material and substantially continuous ceramic oxide fibers having lengths of at least 5 cm, the porous, sintered ceramic oxide material securing the substantially continuous ceramic oxide fibers in place, wherein the porous, sintered ceramic oxide material extends along at least a portion of the length of the substantially continuous fibers.

82 . The method according to claim 75 wherein the metal matrix composite article is a brake caliper.

83 . A method of making a metal matrix composite article, the method comprising:
positioning an insert holder that includes a metal comprising reinforcement insert, the insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, Ni on the outer surface of the insert holder, the Ni having an outer surface; and Ag on the outer surface of the Ni, the Ag having a thickness of at least 8 micrometers, and the metal comprising reinforcement insert being secured in the at least one portion for securing at least one insert; providing molten second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof into the mold; and cooling the molten second metal to provide a metal matrix composite article.

84 . The method according to claim 83 wherein the molten second metal in the mold is in the molten state for less than 75 seconds.

85 . The method according to claim 83 wherein the molten second metal in the mold is in the molten state for less than 60 seconds.

86 . The method according to claim 83 wherein the metal matrix composite article is a brake caliper.

87 . A method of making a metal matrix composite article, the method comprising:
positioning an insert holder that includes a crystalline ceramic comprising reinforcement insert, the insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, Ni on the outer surface of the insert holder, the Ni having an outer surface; and Ag on the outer surface of the Ni, the Ag having a thickness of at least 8 micrometers; providing molten second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof into the mold; and cooling the molten second metal to provide a metal matrix composite article.

88 . The method according to claim 87 wherein the molten second metal in the mold is in the molten state for less than 75 seconds.

89 . The method according to claim 87 wherein the molten second metal in the mold is in the molten state for less than 60 seconds.

90 . The method according to claim 87 wherein the metal matrix composite article is a brake caliper.

91 . A method of making a metal matrix composite article, the method comprising:
positioning an insert holder that includes an insert in a mold, the insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, and a second metal on the outer surface of the first metal, the second metal having a positive Gibbs oxidation free energy above at least 200° C., the insert being secured in the at least one portion for securing at least one insert and comprising substantially continuous ceramic oxide fibers and third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the third metal secures the substantially continuous ceramic oxide fibers in place, and wherein the third metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers, the third metal having an outer surface; and a fourth metal on the outer surface of the third metal, the fourth metal having a positive Gibbs oxidation free energy above at least 200° C., and the fourth metal having a thickness of at least 8 micrometers; providing molten fifth metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof into the mold; and cooling the molten fifth metal to provide a metal matrix composite article.

92 . The method according to claim 91 wherein the molten fifth metal in the mold is in the molten state for less than 75 seconds.

93 . The method according to claim 91 wherein the molten fifth metal in the mold is in the molten state for less than 60 seconds.

94 . The method according to claim 91 comprising two portions for securing respectively an insert, and two of the inserts positioned respectively in the portions for securing respectively an insert.

95 . The method according to claim 91 wherein the first metal is an aluminum alloy, wherein the third metal is an aluminum alloy, and wherein the fifth metal is an aluminum alloy.

96 . The method according to claim 91 wherein the first metal is a 6000 series aluminum alloy, wherein the third metal is a 200 series aluminum alloy, and wherein the fifth metal is one of a 300 or 400 series aluminum alloy.

96 . The method according to claim 91 wherein the metal matrix composite article is a brake caliper.

97 . A method of making a metal matrix composite article, the method comprising:
positioning an insert holder that includes an insert in a mold, the insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, the insert being secured in the at least one portion for securing at least one insert and comprising substantially continuous ceramic oxide fibers and second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the second metal secures the substantially continuous ceramic oxide fibers in place, and wherein the second metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers, the insert holder and the insert collectively having an outer surface, and a third metal on the outer surface, the third metal having a positive Gibbs oxidation free energy above at least 200° C., and the third metal having a thickness of at least 8 micrometers; providing molten fourth metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof into the mold; and cooling the molten fourth metal to provide a metal matrix composite article.

98 . The method according to claim 97 wherein the molten fourth metal in the mold is in the molten state for less than 75 seconds.

99 . The method according to claim 97 wherein the molten fourth metal in the mold is in the molten state for less than 60 seconds.

100 . The method according to claim 97 comprising two portions for securing respectively an insert, and two of the inserts positioned respectively in the portions for securing respectively an insert.

101 . The method according to claim 97 wherein the first metal is an aluminum alloy, wherein the second metal is an aluminum alloy, and wherein the fourth metal is an aluminum alloy.

102 . The method according to claim 97 wherein the first metal is a 6000 series aluminum alloy, wherein the second metal is a 200 series aluminum alloy, and wherein the fourth metal is one of a 300 or 400 series aluminum alloy.

103 . The method according to claim 97 wherein the metal matrix composite article is a brake caliper.

104 . A method of making a metal matrix composite article, the method comprising:
positioning an insert holder that includes an insert in a mold, the insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, Ni on the outer surface of the insert holder, the Ni having an outer surface; and Ag on the outer surface of the Ni, the insert being secured in the at least one portion for securing at least one insert and comprising substantially continuous ceramic oxide fibers and second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the second metal secures the substantially continuous ceramic oxide fibers in place, and wherein the second metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers, the second metal having an outer surface; and Ni on the outer surface of the second metal, the Ni having an outer surface; and Ag on the outer surface of the Ni, the Ag having a thickness of at least 8 micrometers; providing molten third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof into the mold; and cooling the molten third metal to provide a metal matrix composite article.

105 . The method according to claim 104 wherein the molten third metal in the mold is in the molten state for less than 75 seconds.

106 . The method according to claim 104 wherein the molten third metal in the mold is in the molten state for less than 60 seconds.

107 . The method according to claim 104 wherein the metal matrix composite article is a brake caliper.

108 . A method of making a metal matrix composite article, the method comprising:
positioning an insert holder that includes an insert in a mold, the insert holder including at least one portion for securing at least one insert, the insert holder comprising a first metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, the insert holder having an outer surface, the insert being secured in the at least one portion for securing at least one insert and comprising substantially continuous ceramic oxide fibers and second metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof, wherein the second metal secures the substantially continuous ceramic oxide fibers in place, and wherein the second metal extends along at least a portion of the length of the substantially continuous ceramic oxide fibers, the insert holder and the insert collectively having an outer surface, Ni on the outer surface of the metal, the Ni having an outer surface of the insert holder, and Ag on the outer surface of the Ni; providing molten third metal selected from the group consisting of aluminum, alloys thereof, and combinations thereof into the mold; and cooling the molten third metal to provide a metal matrix composite article.

109 . The method according to claim 108 wherein the molten third metal in the mold is in the molten state for less than 75 seconds.

110 . The method according to claim 108 wherein the molten third metal in the mold is in the molten state for less than 60 seconds.

111 . The method according to claim 108 wherein the metal matrix composite article is a brake caliper.

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