Metal matrix composite composition and method

Details Metal matrix composite composition and method Metal matrix composite composition and method

C - Chemistry, Metallurgy

22

C

C22C 1/10 (2006.01) B22D 19/14 (2006.01) C22C 32/00 (2006.01) C22C 47/08 (2006.01) C22C 49/06 (2006.01) C22C 49/14 (2006.01)

Patent

CA 2054018

C-4285 METAL MATRIX COMPOSITE COMPOSITION AND METHOD Abstract of the Invention A new metal matrix composite of an aluminum based alloy and a ceramic, and a method of making it are provided. In the preferred method, the ceramic is silicon carbide whiskers which are heated to an elevated temperature, generally in the range of between about 750°F and 2000°F. An alloy, comprising by weight about 3 to 6 percent copper, about 0.5 to 5 percent magnesium and the balance essentially aluminum, is heated to melt the alloy. The heated silicon carbide and molten alloy are mixed or intermingled. The intermingled silicon carbide and molten alloy are then cooled at a rate sufficient to sustain supersaturation of the copper and magnesium in the aluminum down to a predetermined temperature. The predetermined temperature is selected so as to permit precipitation of a strengthening copper-rich secondary metallic phase containing copper, magnesium and aluminum and consisting essentially of about 40 to 80 percent by weight copper, magnesium in an amount between about 5 and 30 percent by weight, and the balance essentially aluminum. This forms a metal matrix composite having a silicon carbide phase, an aluminum-rich primary metallic phase and a copper-rich secondary metallic phase which has the desired composition. The primary metallic phase can contain up to 10 percent of eutectic phase which is generally present as a coarse network or as isolated islands. Preferably, cooling occurs immediately after the intermingling step and relatively rapidly to a temperature below about 550°F where precipitation of the secondary metallic phase occurs. In a preferred embodiment, a metal matrix composite of the invention comprises a ceramic phase distributed substantially uniformly throughout the composite, and a metal phase which comprises an aluminum-rich primary metallic phase and a copper-rich and magnesium-rich secondary metallic phase distributed throughout the primary metallic phase. The secondary metallic phase contains copper, magnesium and aluminum and consists essentially of about 40 to 80 percent by weight copper, magnesium in an amount between about 5 and 30 percent by weight, and the balance essentially aluminum. Preferably, the secondary metallic phase comprises cubical-shaped structures which are about 400 angstroms on a side. Preferably, the ceramic phase comprises silicon carbide whiskers.

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