Metal matrix composite granules and methods of making and using the same

Abstract

Metal matrix composite granules are disclosed comprising a ceramic phase dispersed in a matrix phase. The matrix phase includes aluminum or an aluminum alloy. The granules have an average particle size in the range of from about 100 μm to about 1,000 μm. Also disclosed are methods for producing the granules or articles or processes for using the granules to produce various articles, among other things.

1 . A composition comprising granules of a metal matrix composite;
 wherein the metal matrix composite comprises a ceramic dispersed phase in an aluminum or aluminum alloy matrix; and   wherein the granules have an average particle size of from about 100 μm to about 1,000 μm.   
     
     
         2 . The composition of  claim 1 , wherein the granules have an average particle size of from about 200 μm to about 800 μm. 
     
     
         3 . The composition of  claim 1 , wherein the ceramic dispersed phase comprises at least one ceramic material selected from the group consisting of carbides, oxides, silicides, borides, and nitrides. 
     
     
         4 . The composition of  claim 1 , wherein the ceramic dispersed phase comprises at least one ceramic material selected from the group consisting of silicon carbide, titanium carbide, boron carbide, silicon nitride, titanium nitride, zirconium oxide, aluminum oxide, aluminum nitride, and titanium oxide. 
     
     
         5 . The composition of  claim 1 , wherein the aluminum alloy further comprises at least one element selected from the group consisting of chromium, copper, lithium, magnesium, manganese, nickel, iron, vanadium, zinc, and silicon. 
     
     
         6 . The composition 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 composition 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. 
     
     
         8 . The composition of  claim 1 , wherein the granules comprise from about 1 vol % to about 45 vol % of the ceramic dispersed phase. 
     
     
         9 . A method for producing granules of a metal matrix composite, the method comprising:
 high energy mixing metal particles and ceramic particles to form the granules;   wherein the granules comprise a dispersed phase formed from the ceramic particles and a matrix phase formed from the metal particles;   wherein the granules have an average particle size of from about 100 μm to about 1,000 μm; and   wherein the metal particles comprise aluminum or an aluminum alloy.   
     
     
         10 . The method of  claim 9 , wherein the granules have an average particle size of from about 200 μm to about 800 μm. 
     
     
         11 . The method of  claim 9 , wherein the ceramic particles comprise at least one ceramic material selected from the group consisting of carbides, oxides, silicides, borides, and nitrides. 
     
     
         12 . The method of  claim 9 , wherein the ceramic particles comprises at least one ceramic material selected from the group consisting of silicon carbide, titanium carbide, boron carbide, silicon nitride, titanium nitride, zirconium oxide, aluminum oxide, aluminum nitride, and titanium oxide. 
     
     
         13 . The method of  claim 9 , wherein the ceramic particles have an average particle size in the range of from about 0.2 μm to about 10 μm. 
     
     
         14 . The method of  claim 9 , wherein the ceramic particles have an average particle size in the range of from about 1 μm to about 4 μm. 
     
     
         15 . The method of  claim 9 , wherein the metal particles have an average particle size in the range of from about 5 μm to about 150 μm. 
     
     
         16 . The method of  claim 9 , wherein the metal particles have an average particle size in the range of from about 15 μm to about 75 μm. 
     
     
         17 . The method of  claim 9 , wherein the granules comprise from about 1 vol % to about 45 vol % of the dispersed phase. 
     
     
         18 . A method for producing an article comprising:
 densifying a preform;   wherein the preform comprises granules of a metal matrix composite;   wherein the metal matrix composite comprises a ceramic dispersed phase in an aluminum or aluminum alloy matrix; and   wherein the granules have an average particle size of from about 100 μm to about 1,000 μm.   
     
     
         19 . The method of  claim 18 , wherein the granules comprise from about 1 vol % to about 45 vol % of the dispersed phase. 
     
     
         20 . An article formed from granules of a metal matrix composite, the metal matrix composition comprising a ceramic dispersed phase in an aluminum or aluminum alloy matrix, and the granules having an average particle size of from about 100 μm to about 1,000 μm.