Phosphate binders for metal-matrix composites

• US 5,536,686 A
• Filed: 10/20/1992
• Issued: 07/16/1996
• Est. Priority Date: 10/20/1992
• Status: Expired due to Fees

• Current Assignee: The Research Foundation for The State University of New York (State University of New York)
• Original Assignee: The Research Foundation for The State University of New York (State University of New York)
• Inventors: Chung, Deborah D. L.
• Primary Examiner(s): Straub, Gary P.
• Assistant Examiner(s): NGUYEN, NGOC YEN M
• Application Number:
  US07/963,655
• Time in Patent Office: 1,365 Days
• Field of Search: 428/614, 501/111, 501/127, 501/125, 106/690, 106/691
• US Class Current: 501/111
• CPC Class Codes: B22D 19/14 the objects being filamentary or particulate in form making alloys containing fibres or filaments by contacting the fibres or filaments with molten metal C22C47/08
• CPC Class Codes: C04B 12/02 Phosphate cements in, or for, the manufacture of ceramics C04B33/00, C04B35/00
• CPC Class Codes: C04B 2111/00922 Preforms as such
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5248 Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/526 characterised by the length of the fibers
• CPC Class Codes: C04B 2235/5264 characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/5276 Whiskers, spindles, needles or pins
• CPC Class Codes: C04B 2235/5436 micrometer sized, i.e. from 1 to 100 micron
• CPC Class Codes: C04B 2235/656 characterised by specific heating conditions during heat treatment
• CPC Class Codes: C04B 2235/96 Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 35/117 Composites
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/581 based on aluminium nitride
• CPC Class Codes: C04B 35/6263 characterised by their solids loadings, i.e. the percentage of solids
• CPC Class Codes: C04B 35/6309 Aluminium phosphates
• CPC Class Codes: C04B 35/6316 Binders based on silicon compounds
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C22C 1/059 Making alloys comprising less than 5% by weight of dispersed reinforcing phases
• CPC Class Codes: C22C 1/1036 : starting from a melt
• CPC Class Codes: Y10T 428/12486 : Laterally noncoextensive components [e.g., embedded, etc.]

Abstract

A binder for binding reinforcement materials is provided in which an aluminum and/or Group IIa-containing compound is combined, in a liquid, with a phosphorus-containing compound wherein said binder has a ratio of phosphorus to aluminum and/or Group IIa ions of 14 to 34, preferably 20 to 30. The binder is useful in binding reinforcement materials, particularly suited for preparing preforms for making metal matrix composite materials.

Claims

1. A preform for preparing metal matrix composite comprising:

a reinforcement material; and

a binder applied to said reinforcement material, said binding comprising a type A aluminum metaphosphate, a Group IIa metal metaphosphate, or combination of a type A aluminum metaphosphate and a Group IIa metal metaphosphate, wherein said binder has an excess of phosphorus in an atomic ratio of phosphorus to aluminum of 3.4 to 7 or in an atomic ratio of phosphorus to Group IIa metal of 3.4 to 7.

2. A preform according to claim 1, wherein said atomic ratio is from 3.4 to 5.

3. A preform according to claim 1, wherein said binder consists essentially of a type A aluminum metaphosphate, a Group IIa metaphosphate, or a combination of a type A aluminum metaphosphate and a Group IIa metaphosphate.

4. A preform according to claim 1, wherein said reinforcement material is selected from the group consisting of silicon carbide, boron carbide, aluminum nitride, titanium diboride, silicon, silicon nitride, silicon oxide, aluminum oxide, carbon, graphite, and mixtures thereof.

5. A preform according to claim 1, wherein said reinforcement material is selected from the group consisting of whiskers, fibers, particles, flakes, and mixtures thereof.

6. A preform according to claim 1, wherein said preform comprises 0.05 to 10 weight percent binder.

7. A preform for preparing metal-matrix composites comprising:

a reinforcement material; and

a binder comprising a type A aluminum metaphosphate, a Group IIa metal metaphosphate, or a combination of a type A aluminum metaphosphate and a Group IIa metal metaphosphate, wherein the binder is prepared by combining, in a liquid, an aluminum-containing compound, a Group IIa metal-containing compound, or a combination of an aluminum-containing compound and a Group IIa metal-containing compound, with a phosphorus-containing compound, at an atomic ratio of phosphorus to aluminum of 14 to 34 and an atomic ratio of phosphorus to Group IIa ions of 14 to 34, and heating said binder to volatilize the liquid.

8. A preform according to claim 7, wherein the binder is prepared by combining, in a liquid, an aluminum-containing compound with a phosphorus-containing compound, wherein, said heating is at 800°

C. and the binder after said heating has a phosphorus to aluminum ratio of at least 3.4.

9. A preform according to claim 7, wherein said reinforcement material is selected from the group consisting of silicon carbide, boron carbide, aluminum nitride, titanium diboride, silicon, silicon nitride, silicon oxide, aluminum oxide, carbon, graphite, and mixtures thereof.

10. A preform according to claim 7, wherein said reinforcement material is selected from the group consisting of whiskers, fibers, particles, flakes, and mixtures thereof.