Solid phase methods for producing enhanced metal matrix composites

Abstract

A method of producing a metal matrix composite by extruding a billet including both a metallic material and a non-metallic material through a die to form a metal matrix composite extrudate, where the non-metallic material is distributed evenly along a longitudinal length of the billet, where, during extrusion, a temperature of the billet does not exceed a melting temperature of the metallic material; and where the metal matrix composite extrudate has an extrusion ratio of at least 20:1.

We claim: 
     
         1 . A method of producing a metal matrix composite, the method comprising:
 extruding a billet comprising a metallic material and a non-metallic material through a die thereby forming a metal matrix composite extrudate;   wherein the non-metallic material is distributed evenly along a longitudinal length of the billet;   wherein, during extrusion, a temperature of the billet does not exceed a melting temperature of the metallic material; and   wherein the metal matrix composite extrudate has an extrusion ratio of at least 20:1.   
     
     
         2 . The method of  claim 1 , wherein the metallic material is a Copper or Copper-Silver alloy and the non-metallic material is Graphene. 
     
     
         3 . The method of  claim 1 , further comprising drawing the metal matrix composite extrudate into a wire. 
     
     
         4 . The method of  claim 1 , wherein the metal matrix composite extrudate is extruded at an extrusion ratio of at least 80:1. 
     
     
         5 . The method of  claim 1 , wherein the billet is extruded using friction extrusion. 
     
     
         6 . The method of  claim 1 , wherein the billet is extruded using hot metal extrusion. 
     
     
         7 . The method of  claim 1 , wherein the billet comprises a plurality of metallic wires coated with the non-metallic material contained within a metallic jacket. 
     
     
         8 . The method of  claim 1 , further comprising:
 blending a metallic powder and a non-metallic powder;   pressing the blended metallic and non-metallic powders into a billet shape; and   in a protective atmosphere, sintering the pressed metallic and non-metallic powders to form the billet.   
     
     
         9 . The method of  claim 1 , wherein the billet is formed from sintered metallic and non-metallic powders. 
     
     
         10 . The method of  claim 1 , further comprising:
 cutting metallic wire forming metallic wire cut-offs;   in a dry ball mill in a protective atmosphere, milling the metallic wire cut-offs with a non-metallic powder forming coated wire cut-offs; and   pressing the coated wire cut-offs into a billet shape.   
     
     
         11 . The method of  claim 1 , wherein the billet is formed from pressed metallic wire cut-offs that are coated with a non-metallic powder. 
     
     
         12 . The method of  claim 1 , further comprising:
 cutting a metallic billet longitudinally forming a longitudinal cut surface; and   positioning non-metallic material longitudinally along the cut surface.   
     
     
         13 . The method of  claim 12 , further comprising positioning a metallic foil coated with the non-metallic material along the cut surface. 
     
     
         14 . The method of  claim 13 , wherein the metallic foil comprises the same metallic material as the billet. 
     
     
         15 . The method of  claim 1 , wherein the billet including a longitudinal cut surface that passes through the billet along the length of the billet and wherein the non-metallic material is positioned along the cut surface. 
     
     
         16 . The method of  claim 1 , further comprising;
 forming a longitudinal hole into or through a metallic billet; and   positioning the non-metallic material within the longitudinal hole.   
     
     
         17 . The method of  claim 1 , further comprising;
 forming a plurality of longitudinal holes into or through a metallic billet, wherein the plurality of longitudinal holes are spaced apart from each other and are positioned at varying distances from a center axis of the billet; and   positioning the non-metallic material within the longitudinal holes.   
     
     
         18 . The method of  claim 1 , wherein the billet comprises the metallic material and defines a hole that passes longitudinally through the billet, wherein the hole contains the non-metallic material. 
     
     
         19 . The method of  claim 1 , wherein the billet comprises a plurality of different non-metallic materials distributed evenly along the longitudinal length of the billet. 
     
     
         20 . The method of  claim 3 , further comprising:
 sectioning the previously extruded wire into segments with a length between 2 mm and 25 mm in length;   compressing the sectioned wire segments into a second billet;   extruding the second billet using a solid phase process.   
     
     
         21 . The method of  claim 2 , further comprising drawing the metal matrix composite extrudate into a wire. 
     
     
         22 . The method of  claim 21 , wherein the metal matrix composite extrudate is extruded at an extrusion ratio of at least 80:1. 
     
     
         23 . The method of  claim 21 , wherein the billet is extruded using friction extrusion. 
     
     
         24 . The method of  claim 21 , wherein the billet is extruded using hot metal extrusion.