Metal matrix composite

Abstract

A metal matrix composite material includes a reinforcement phase dispersed in an aluminum or aluminum alloy matrix. The reinforcement phase includes particles having an average particle size (D50) of from 0.1 μm to 0.5 μm.

1 . A metal matrix composite comprising:
 an aluminum or aluminum alloy matrix; and   reinforcement particles dispersed in the matrix, the reinforcement particles having an average particle size (D 50 ) of from 0.1 μm to 0.5 μm.   
     
     
         2 . The metal matrix composite of  claim 1 , wherein the reinforcement particles comprise at least one ceramic material selected from the group consisting of carbides, oxides, silicides, borides, and nitrides. 
     
     
         3 . The metal matrix composite of  claim 1 , wherein the reinforcement particles comprise at least one ceramic material selected from the group consisting of silicon carbide, titanium carbide, boron carbide, silicon nitride, titanium nitride, and zirconium oxide. 
     
     
         4 . The metal matrix composite of  claim 1 , wherein the aluminum alloy comprises at least one element selected from the group consisting of chromium, copper, lithium, magnesium, manganese, zinc, iron, nickel, silver, scandium, vanadium and silicon. 
     
     
         5 . The metal matrix composite of  claim 1 , wherein the aluminum alloy comprises from about 91.2 wt % to about 98.6 wt % aluminum, from about 0.15 wt % to about 4.9 wt % copper, from about 0.1 wt % to about 1.8 wt % magnesium, and from about 0.1 wt % to about 1 wt % manganese. 
     
     
         6 . The metal matrix composite of  claim 1 , wherein the aluminum alloy comprises from about 91.2 wt % to about 94.7 wt % aluminum, from about 3.8 wt % to about 4.9 wt % copper, from about 1.2 wt % to about 1.8 wt % magnesium, and from about 0.3 wt % to about 0.9 wt % manganese. 
     
     
         7 . The metal matrix composite of  claim 1 , wherein the aluminum alloy comprises from about 92.8 wt % to about 95.8 wt % aluminum, from about 3.2 wt % to about 4.4 wt % copper, from 0 to about 0.2 wt % iron, from about 1.0 to about 1.6 wt % magnesium, from 0 to about 0.6 wt % oxygen, from 0 to about 0.25 wt % silicon, and from 0 to about 0.25 wt % zinc. 
     
     
         8 . The metal matrix composite of  claim 1 , wherein the aluminum alloy comprises from about 95.8 wt % to about 98.6 wt % aluminum, from about 0.8 wt % to about 1.2 wt % magnesium, and from about 0.4 wt % to about 0.8 wt % silicon. 
     
     
         9 . The metal matrix composite of  claim 1 , wherein the average particle size of the reinforcement particles is about 0.3 μm. 
     
     
         10 . The metal matrix composite of  claim 1 , wherein the composite comprises from about 15 vol % to about 50 vol % of the reinforcement particles. 
     
     
         11 . The metal matrix composite of  claim 1 , wherein the metal matrix composite has a 0.2% offset yield strength of about 400 MPa to about 680 MPa; an elastic modulus of about 80 GPa to about 150 GPa; and about 3% to about 8% elongation to failure, measured according to ASTM E8M. 
     
     
         12 . A method for making a metal matrix composite, comprising:
 high energy mixing (i) particles of an aluminum or aluminum alloy with (ii) reinforcement particles having an average particle size (D50) of from 0.1 μm to 0.5 μm; and   processing the mixture to achieve an even distribution of the reinforcement particles.   
     
     
         13 . The method of  claim 12 , wherein the high energy mixing is performed in an inert atmosphere. 
     
     
         14 . The method of  claim 12 , wherein the reinforcement particles comprise at least one ceramic material selected from the group consisting of carbides, oxides, silicides, borides, and nitrides. 
     
     
         15 . The method of  claim 12 , wherein the aluminum alloy comprises at least one element selected from the group consisting of chromium, copper, lithium, magnesium, manganese, zinc, iron, nickel, silver, scandium, vanadium and silicon. 
     
     
         16 . The method of  claim 12 , wherein the composite comprises from about 15 vol % to about 50 vol % of the reinforcement particles. 
     
     
         17 . A method for producing an article from a metal matrix composite, comprising:
 compacting the metal matrix composite to produce a billet; and   processing the billet to form the article.   
     
     
         18 . The method of  claim 17 , wherein the compacting is performed at a pressure of about 30 MPa to about 150 MPa. 
     
     
         19 . The method of  claim 17 , wherein the compacting is performed by hot isostatic pressing (HIP). 
     
     
         20 . An article formed from a metal matrix composite, the metal matrix composite comprising:
 an aluminum or aluminum alloy matrix; and   reinforcement particles dispersed in the matrix, the reinforcement particles having an average particle size (D50) of from 0.1 μm to 0.5 μm.