Functionally Graded Matrix Alloy And Method of Fabricating Metal Matrix Composites

Abstract

The present disclosure relates to a nickel-based metal matrix composite and method of manufacturing thereof. The formulations and methods disclosed herein enable the composite to be used in applications up to 2200° F.

1 . A metal matrix composite comprises:
 a reinforcement; and   a matrix alloy comprising:
 from about 50 to about 66 wt. % nickel; 
 from about 10 to about 30 wt. % copper; 
 from about 6 to about 14 wt. % chromium; 
 from about 5 to about 14 wt. % titanium; and 
   wherein
 the matrix alloy comprises at least an inner layer and an outer layer; and 
 the inner layer has a higher concentration of copper and titanium as compared to the outer layer; and 
 the outer layer has a higher concentration of chromium as compared to the inner layer. 
   
     
     
         2 . The composite of  claim 1  wherein the matrix alloy further comprises at least one of:
 up to 10 wt. % manganese; 
 up to 5 wt. % aluminum; 
 up to 8 wt. % iron; 
 up to 8 wt. % cobalt; 
 up to 0.2 wt. % rare earth metals; 
 up to 0.6 wt. % tin; and 
 up to 5 wt. % silver; 
 up to 0.2% carbon; 
 
     
     
         3 . (Original, Line Spacing Changed) The composite of  claim 1  wherein the rare earth metals are from the group consisting of yttrium, lanthanum, gadolinium, cerium, scandium, or any combination thereof. 
     
     
         4 . The composite of  claim 1  wherein the the combined concentration of titanium and aluminum is between 6 and 16 wt. %. 
     
     
         5 . (Original, Line Spacing Changed) The composite of  claim 1  further comprising:
 manganese, wherein the composition comprises a total amount of copper and manganese of from about 10 to about 24 wt. %; an 
 an reactive element selected from the group consisting of titanium, niobium, tantalum, hafnium, zirconium, or any combination thereof in a total amount of from about 6 to about 15 wt. %; and 
 tin, and the composition comprises titanium and tin in a ratio of at least 20:1. 
 
     
     
         6 . (Original, Line Spacing Changed) The composite of  claim 1 , wherein the composition comprises nickel and copper in a ratio of from about 2.5:1 to about 6:1. 
     
     
         7 . (Original, Line Spacing Changed) The composite of  claim 1  further comprising
 one or more of niobium or tantalum in a total amount up to 5 wt. %. 
 
     
     
         8 . (Original, Line Spacing Changed) The composite of  claim 1  further comprising
 one or more of tungsten or molybdenum in a total amount up to 8 wt. %. 
 
     
     
         9 . (Original, Line Spacing Changed) The composite of  claim 1  further comprising at least one of:
 up to 0.3 wt. % boron or up to 0.1 wt. % phosphorus, and up to 0.2% carbon. 
 
     
     
         10 . (Original, Line Spacing Changed) The composite of  claim 1  wherein the reinforcement is selected from the group consisting of carbon fiber, ceramic fiber; wherein a ceramic fiber is from the group consisting of aluminum oxide, alumina-silicates, silicon carbide, or any combination thereof. 
     
     
         11 . (Original, Line Spacing Changed) A method of preparing the composite of  claim 1  comprising:
 layering copper onto at least one side of a reinforcement; 
 layering a reactive element selected from the group consisting of titanium, niobium, tantalum, hafnium, zirconium, or any combination thereof onto the copper layer; 
 layering nickel onto the reactive element layer; 
 layering an outer layer material onto the nickel layer; and 
 heating all layers from about 2000° F. to about 2300° F.;
 wherein the method provides improved resistance of degradation of mechanical properties to the composite; 
 
 wherein the outer layer material comprises from about 20 to about 28 wt. % chromium. 
 
     
     
         12 . The method of  claim 11 , wherein the reinforcement is selected from the group consisting of carbon fiber, ceramic fiber; wherein a ceramic fiber is from the group consisting of aluminum oxide, alumina-silicates, silicon carbide, or any combination thereof. 
     
     
         13 . The method of  claim 11  further comprising layering a metallic mesh on the reinforcement,
 wherein the mesh comprises nickel, cobalt or stainless steel. 
 
     
     
         14 . The method of  claim 11 , wherein the reinforcement is coated with at least one of nickel, cooper, and chromium. 
     
     
         15 . The method of  claim 11  wherein the reinforcement is coated by electroplating, chemical vapor deposition, electroless nickel, or electroless copper. 
     
     
         16 . The method of  claim 14  wherein the chromium coating is at least 0.0005″ thick. 
     
     
         17 . The method of  claim 11  further comprising a refractory element, wherein the refractor element is one of tungsten (W), molybdenum (Mo), tantalum (Ta), niobium (Nb), or a combination thereof. 
     
     
         18 . The method of  claim 17  wherein the refractory alloy is a mesh with a percent of open area of at least 50%. 
     
     
         19 . The method of  claim 11  further comprising placing the layers in a tooling prior heating the layers in a furnace. 
     
     
         20 . The method of  claim 19  further comprising coating the tooling with a parting agent wherein the parting agent comprises one or more of yttrium oxide, aluminum oxide, boron nitride, zirconium oxide, or any combination thereof.