Method of making fiber reinforced aluminum matrix composite wire

• US 6,336,495 B1
• Filed: 03/31/1999
• Issued: 01/08/2002
• Est. Priority Date: 06/21/1995
• Status: Expired due to Term

• Current Assignee: 3M Innovative Properties Company (3M Company)
• Original Assignee: 3M Innovative Properties Company (3M Company)
• Inventors: McCullough, Colin, Deve, Herve E., Mortensen, Andreas, Anderson, Tracy L., Werner, Paul S.
• Primary Examiner(s): WEISBERGER, RICHARD C
• Application Number:
  US09/282,858
• Time in Patent Office: 1,014 Days
• Field of Search: 164/461, 164/462, 164/463, 164/477, 164/478, 164/446, 164/97, 164/100, 164/102
• US Class Current: 164/461
• CPC Class Codes: B22F 2202/01 Use of vibrations
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: C22C 47/025 Aligning or orienting the fibres
• CPC Class Codes: C22C 47/08 by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould C22C47/16 takes precedence
• CPC Class Codes: C22C 49/06 Aluminium
• CPC Class Codes: C22C 49/14 characterised by the fibres or filaments
• CPC Class Codes: H01B 1/023 Alloys based on aluminium
• CPC Class Codes: Y10S 428/924 Composite
• CPC Class Codes: Y10S 977/84 Manufacture, treatment, or detection of nanostructure
• CPC Class Codes: Y10S 977/902 Specified use of nanostructure
• CPC Class Codes: Y10S 977/926 Topical chemical, e.g. cosmetic or sunscreen
• CPC Class Codes: Y10T 428/12007 Component of composite having metal continuous phase interengaged with nonmetal continuous phase
• CPC Class Codes: Y10T 428/12035 Fiber, asbestos, or cellulose in or next to particulate component
• CPC Class Codes: Y10T 428/12097 Nonparticulate component encloses particles
• CPC Class Codes: Y10T 428/12111 Separated by nonmetal matrix or binder [e.g., welding electrode, etc.]
• CPC Class Codes: Y10T 428/1216 Continuous interengaged phases of plural metals, or oriented fiber containing
• CPC Class Codes: Y10T 428/12181 Composite powder [e.g., coated, etc.]
• CPC Class Codes: Y10T 428/12486 Laterally noncoextensive components [e.g., embedded, etc.]
• CPC Class Codes: Y10T 428/29 Coated or structually defined flake, particle, cell, strand, strand portion, rod, filament, macroscopic fiber or mass thereof
• CPC Class Codes: Y10T 428/2913 : Rod, strand, filament or fiber
• CPC Class Codes: Y10T 428/2933 : Coated or with bond, impregnation or core
• CPC Class Codes: Y10T 428/294 : including metal or compound thereof [excluding glass, ceramic and asbestos]
• CPC Class Codes: Y10T 428/2944 : Free metal in coating

Abstract

Method of making wire comprising polycrystalline α-Al₂O₃ fibers within a matrix of substantially pure elemental aluminum, or an alloy elemental aluminum and up to about 2% copper.

Claims

1. A method of making continuous composite wire, said method comprising:

melting a metallic matrix material selected from the group consisting of aluminum and an alloy of aluminum with up to 2% by weight copper, based on the total weight of said alloy matrix, wherein said matrix material contain less than 0.05 percent by weight impurities, based on the total weight of said matrix materials, to provide a contained volume of melted metallic matrix material;

imparting ultrasonic energy to cause vibration of said contained volume of melted metallic matrix material;

immersing a plurality of continuous polycrystalline α

-Al₂O₃ fibers into said contained volume of melted metallic matrix material while maintaining said vibration to permit the melted metallic matrix material to infiltrate into and coat said plurality of fibers such that an infiltrated, coated plurality of fibers is provided; and

withdrawing said infiltrated, coated plurality of fibers from said contained volume of melted metallic matrix material under conditions which permit the melted metallic matrix material to solidify to provide a wire comprising a composite material comprising a plurality of continuous polycrystalline α

-Al₂O₃ fibers contained within a matrix comprising aluminum, wherein said matrix is substantially free of material phases or domains capable of the enhancing brittleness of said matrix, and wherein said composite material has an average tensile strength of greater than 1.17 GPa.

2. The method according to claim 1 wherein said plurality of continuous polycrystalline α

-Al₂O₃ fibers of said composite material includes at least one tow of continuous polycrystalline α

-Al₂O₃ fibers.

3. The method according to claim 2 wherein said matrix of said composite material is substantially pure elemental aluminum.

4. The method according to claim 2 wherein said matrix of said composite material is an alloy of aluminum and up to about 2% by weight copper, based on the total weight of said matrix.

5. The method according to claim 2 wherein said continuous polycrystalline α

-Al₂O₃ fibers of said composite material are free of an exterior protective coating.

6. A method of making a continuous composite wire, said method comprising:

melting a metallic matrix material selected from the group consisting of aluminum and an alloy of aluminum with up to 2% by weight copper, based on the total weight of said alloy matrix, wherein said matrix material contain less than 0.05 percent by weight impurities, based on the total weight of said matrix materials, to provide a contained volume of melted metallic matrix material;

imparting ultrasonic energy to cause vibration of said contained volume of melted metallic matrix material;

immersing a plurality of continuous polycrystalline α

-Al₂O₃ fibers into said contained volume of melted metallic matrix material while maintaining said vibration to permit the melted metallic matrix material to infiltrate into and coat said plurality of fibers such that an infiltrated, coated plurality of fibers is provided; and

withdrawing said infiltrated, coated plurality of fibers from said contained volume of melted metallic matrix material under conditions which permit the melted metallic matrix material to solidify to provide a comprising a composite material comprising a plurality of continuous polycrystalline α

-Al₂O₃ fibers within a matrix selected from the group consisting of an aluminum matrix and a matrix of an alloy of aluminum and up to about 2% by weight copper, based on the total weight of said alloy matrix, wherein said matrices contain less than 0.05 percent by weight impurities, based on the total weight of said matrices, and wherein said composite material has an average tensile strength of greater than 1.17 GPa.

7. The method according to claim 6 wherein said plurality of continuous polycrystalline α

-Al₂O₃ fibers of said composite material includes at least one tow of continuous polycrystalline α

-Al₂O₃ fibers.

8. The method according to claim 7 wherein said matrix of said composite material is substantially pure elemental aluminum.

9. The method according to claim 7 wherein said matrix of said composite material is an alloy of aluminum and up to about 2% by weight copper, based on the total weight of said matrix.

10. The method according to claim 7 wherein said continuous polycrystalline α

-Al₂O₃ fibers of said composite material are free of an exterior protective coating.