Metal matrix composites and methods of making and use thereof

Abstract

Disclosed herein are metal matrix composites and methods of making and use thereof. For example, disclosed herein are methods of making a metal matrix composite comprising a metal matrix reinforced by a high entropy alloy. The methods comprise mixing a first powder and a second powder to form a powder mixture, wherein the first powder comprises a plurality of particles comprising a metal and the second powder comprises a plurality of particles comprising a high entropy alloy. The methods further comprise compacting the powder mixture to form a pellet and adding the pellet to a molten metal, the molten metal comprising the metal in a molten state, thereby melting the pellet to form a molten mixture. The methods further comprise subjecting the molten mixture to an ultrasonic treatment and casting the ultrasonic treated mixture to form the metal matrix composite.

What is claimed is: 
     
         1 . A metal matrix composite comprising a metal matrix reinforced by a high entropy alloy, wherein the metal matrix composite is made by a method comprising:
 mixing a first powder and a second powder to form a powder mixture, wherein the first powder comprises a plurality of particles comprising a metal and the second powder comprises a plurality of particles comprising a high entropy alloy, wherein the metal is pure aluminum or an aluminum alloy;   compacting the powder mixture to form a pellet;   adding the pellet to a molten metal, the molten metal comprising the metal in a molten state, thereby melting the pellet to form a molten mixture;   subjecting the molten mixture to an ultrasonic treatment, thereby forming an ultrasonic treated mixture; and   casting the ultrasonic treated mixture to form the metal matrix composite.   
     
     
         2 . The metal matrix composite of  claim 1 , wherein the powder mixture comprises the first powder and the second powder in a ratio of from 10:1 to 1:10 (weight:weight). 
     
     
         3 . The metal matrix composite of  claim 1 , wherein the metal comprises an aluminum alloy. 
     
     
         4 . The metal matrix composite of  claim 3 , wherein the metal comprises 7075 alloy. 
     
     
         5 . The metal matrix composite of  claim 1 , wherein the metal comprises pure aluminum. 
     
     
         6 . The metal matrix composite of  claim 1 , wherein the high entropy alloy is provided in an amount of from 1-30 wt. % relative to the final weight of the metal matrix composite. 
     
     
         7 . The metal matrix composite of  claim 1 , wherein the high entropy alloy comprises AlCrTiV. 
     
     
         8 . The metal matrix composite of  claim 1 , wherein the molten mixture is subjected to the ultrasonic treatment for an amount of time of from 1 second to 5 minutes. 
     
     
         9 . The metal matrix composite of  claim 1 , wherein the ultrasonic treatment is applied by a device comprising an ultrasonic generator, a transducer, and a horn, and wherein the horn at least partially submerged in the molten mixture to transmit the ultrasonic treatment. 
     
     
         10 . The metal matrix composite of  claim 1 , wherein the ultrasonic treatment disperses the plurality of particles comprising the high entropy alloy substantially uniformly in the molten mixture. 
     
     
         11 . The metal matrix composite of  claim 1 , wherein the metal matrix composite has an improved mechanical property relative to the metal matrix in the absence of the high entropy alloy. 
     
     
         12 . The metal matrix composite of  claim 1 , wherein the metal matrix composite has a refined grain size relative to the metal matrix in the absence of the high entropy alloy, an improved yield strength relative to the metal matrix in the absence of the high entropy alloy, an improved ultimate tensile strength relative to the metal matrix in the absence of the high entropy alloy, an improved elastic modulus relative to the metal matrix in the absence of the high entropy alloy, or a combination thereof. 
     
     
         13 . An article of manufacture comprising the metal matrix composite of  claim 1 . 
     
     
         14 . A method of use of the metal matrix composite of  claim 1 . 
     
     
         15 . The method of  claim 14 , wherein the method comprises using the metal matrix composite in an automotive or aerospace application. 
     
     
         16 . The method of  claim 14 , wherein the method comprises using the metal matrix composite in a transportation application, a defense application, or a consumer product.