Composite Articles and Methods

Abstract

An article comprises: a substrate having a matrix and a plurality of metallic members partially embedded in the matrix; and a metallic layer bonded to exposed portions of the metallic members.

What is claimed is: 
     
         1 . An article comprising:
 a substrate having a matrix and a plurality of metallic members partially embedded in the matrix; and   a metallic layer bonded to exposed portions of the metallic members.   
     
     
         2 . The article of  claim 1  wherein:
 the matrix is a thermoplastic material forming a majority of the substrate by weight. 
 
     
     
         3 . The article of  claim 1  wherein:
 the matrix is a matrix of a composite material, the composite material further comprising non-metallic fibers, the matrix and the non-metallic fibers forming a majority of the substrate by weight. 
 
     
     
         4 . The article of  claim 1  wherein:
 the metallic members comprise fibers. 
 
     
     
         5 . The article of  claim 1  wherein:
 the exposed portions protrude from a surface of the matrix. 
 
     
     
         6 . The article of  claim 1  wherein:
 the metallic layer comprises a plated nickel or nickel alloy. 
 
     
     
         7 . The article of  claim 1  wherein:
 the metallic layer has a thickness of 0.001 inch to 0.020 inch (0.025 mm to 0.51 mm). 
 
     
     
         8 . The article of  claim 1  further comprising:
 one or more additional layers selected from the group consisting of:
 ceramics; 
 metallic materials; and 
 elastomeric materials. 
 
 
     
     
         9 . The article of  claim 1  being a duct. 
     
     
         10 . The article of  claim 1  being a strut. 
     
     
         11 . The article of  claim 1  being an airfoil element. 
     
     
         12 . The article of  claim 11  being a blade. 
     
     
         13 . The article of  claim 11  being a vane or strut having:
 a platform; 
 a shroud; and 
 the airfoil extending between the platform and the shroud. 
 
     
     
         14 . A method for manufacturing the article of  claim 1 , the method comprising:
 providing the substrate with the metallic members embedded therein; and   processing the substrate to expose or further expose the metallic members.   
     
     
         15 . The method of  claim 14  further comprising:
 after the processing, applying the metallic layer. 
 
     
     
         16 . The method of  claim 15  further comprising:
 after applying the metallic layer, applying one or more further layers. 
 
     
     
         17 . The method of  claim 16  wherein:
 the applying one or more further layers comprises applying one or more of:
 ceramics; 
 metallic materials; and 
 elastomeric materials. 
 
 
     
     
         18 . The method of  claim 14  further comprising:
 initially forming the substrate by:
 injection molding. 
 
 
     
     
         19 . The method of  claim 14  further comprising:
 initially forming the substrate by:
 transfer molding or thermo-forming. 
 
 
     
     
         20 . The method of  claim 14  further comprising:
 initially forming the substrate by:
 composite layup.