Method of manufacturing a metal matrix composite component by use of a reinforcement preform

Abstract

The present invention relates to a method of manufacturing a metal matrix composite component ( 9 ). It comprises the use of a container ( 1 ) having a first compartment ( 2 ) and a second compartment ( 3 ) interconnected by a passage ( 4 ). A porous reinforcement preform ( 6 ) is placed in the first compartment ( 2 ), and matrix metal ( 7 ) is placed in the second compartment ( 3 ). The container ( 1 ) is then evacuated and sealed. The container ( 1 ) and its content is heated to above a melting temperature of the matrix metal ( 7 ) at least until the matrix metal ( 7 ) has melted. Then a high pressure P is applied to the outside of the container ( 1 ) so that at least the second compartment ( 3 ) is deformed to such an extent that melted matrix metal ( 7 ) is forced to flow via the passage ( 4 ) into the first compartment ( 2 ) and to infiltrate the porous reinforcement preform ( 6 ). The method may preferably be carried out in a hot isostatic pressure vessel ( 8 ). The preform ( 6 ) may be made from a ceramic or metal material and is typically made from one or more of the following: nanoparticles, microparticles, fibres, wires and 3 D woven structure.

1 . Method of manufacturing a metal matrix composite component, the method comprising the steps of:
 providing a container having a first compartment and a second compartment interconnected by a passage,   placing a porous reinforcement preform in the first compartment,   placing matrix metal in the second compartment,   evacuating and sealing the container,   heating the container and its content to above a melting temperature of the matrix metal at least until the matrix metal has melted,   applying a high pressure to the outside of the container so that at least the second compartment is deformed to such an extent that melted matrix metal is forced to flow via the passage into the first compartment and to infiltrate the porous reinforcement preform, and   cooling the container and releasing the pressure.   
     
     
         2 . Method according to  claim 1 , wherein the step of heating the container is performed under vacuum or in an inert gas atmosphere. 
     
     
         3 . Method according to  claim 1 , wherein the pressure is applied in a hot isostatic pressure vessel. 
     
     
         4 . Method according to  claim 1 , wherein the passage between the first and the second compartments represents or comprises a restriction or filter. 
     
     
         5 . Method according to  claim 1 , wherein a wall thickness of the second compartment is smaller than a wall thickness of the first compartment. 
     
     
         6 . Method according to  claim 1 , wherein the matrix metal is magnesium, aluminium, beryllium, lithium or alloys thereof. 
     
     
         7 . Method according to  claim 1 , wherein the container is made from low carbon steel. 
     
     
         8 . Method according to  claim 1 , wherein the reinforcement preform is made from a ceramic or metal material. 
     
     
         9 . Method according to  claim 1 , wherein the reinforcement preform is made from one or more of the following: nanoparticles, microparticles, fibres, wires and 3D woven structure. 
     
     
         10 . Method according to  claim 1 , wherein the reinforcement preform is produced by:
 forming a concentrated slurry of ceramic in water,   spraying the slurry into liquid nitrogen,   removing the water from the frozen droplets by freeze drying to obtain porous granules of particles,   pressing and sintering the granules to obtain the preform as a coherent structure.   
     
     
         11 . Method according to clim  1 , wherein the structure of the preform is such that the volume fraction of reinforcement in the manufactured component is 5 to 75%, such as 5 to 20%, or 20 to 50%, or 20 to 75%. 
     
     
         12 . Method according to  claim 1 , further comprising a last step of removing the container from the metal matrix composite component. 
     
     
         13 . Method according to  claim 1 , wherein the container is kept as an outer layer on the manufactured metal matrix composite component. 
     
     
         14 . Use of a component manufactured by  claim 1  for further processing including one or more of the following: extrusion, wire drawing, re-melting or re-casting. 
     
     
         15 . Use of a component manufactured by  claim 1  for a grain refiner or dissolvable master-alloy in the manufacturing of composite materials or alloys. 
     
     
         16 . Method according to  claim 1 , the method further comprising:
 producing the reinforced preform by freeze casting or by gel casting.