Continuous metal matrix composite consolidation

• US 7,164,096 B1
• Filed: 08/28/2002
• Issued: 01/16/2007
• Est. Priority Date: 12/08/2000
• Status: Expired due to Term

• Current Assignee: Touchstone Research Laboratory Limited
• Original Assignee: Touchstone Research Laboratory Limited
• Inventors: Gordon, Brian L., Joseph, Brian E., Witzgall, James F.
• Primary Examiner(s): JOHNSON, JONATHAN J
• Application Number:
  US10/231,765
• Time in Patent Office: 1,602 Days
• Field of Search: 219/121.85, 219/121.63, 219/121.64, 219/121.65, 219/121.66, 219/121.82, 228/178, 228/190, 228/208, 228/209, 228/210, 428/379, 428/357, 428/364, 428/375, 428/381, 428/388, 428/558
• US Class Current: 219/121.6
• CPC Class Codes: B22F 10/28 Powder bed fusion, e.g. selective laser melting [SLM] or electron beam melting [EBM]
• CPC Class Codes: B22F 10/32 of the atmosphere, e.g. composition or pressure in a building chamber
• CPC Class Codes: B22F 12/53 Nozzles
• CPC Class Codes: B22F 2202/01 Use of vibrations
• CPC Class Codes: B22F 2202/11 Use of irradiation
• CPC Class Codes: B22F 2203/03 for feed-back
• 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: B22F 3/005 Loading or unloading powder metal objects transport in general B65G
• CPC Class Codes: B22F 3/26 Impregnating making ferrous alloys by impregnation C22C33/0242
• CPC Class Codes: B23K 1/0056 soldering by means of beams, e.g. lasers, E.B.
• CPC Class Codes: B23K 2103/10 Aluminium or alloys thereof
• CPC Class Codes: B23K 26/0846 for moving elongated workpieces longitudinally, e.g. wire or strip material
• CPC Class Codes: B23K 35/002 at least one of the workpieces being of light metal
• CPC Class Codes: B23K 35/0238 layered
• CPC Class Codes: B23K 35/262 Sn as the principal constituent
• CPC Class Codes: B23K 35/282 Zn as the principal constituent
• CPC Class Codes: B23K 35/286 Al as the principal constituent
• CPC Class Codes: B32B 15/01 all layers being exclusively metallic making layered metal workpieces by pressure cladding B23K20/22; making coatings with a metallic material characterised by its composition C23C30/00
• CPC Class Codes: B32B 15/016 all layers being formed of aluminium or aluminium alloys
• CPC Class Codes: B32B 15/017 : one layer being formed of aluminium or an aluminium alloy, another layer being formed of an alloy based on a non ferrous metal other than aluminium
• CPC Class Codes: C22C 13/00 : Alloys based on tin
• CPC Class Codes: C22C 18/02 : with copper as the next major constituent
• CPC Class Codes: C22C 18/04 : with aluminium as the next major constituent
• CPC Class Codes: C22C 21/02 : with silicon as the next major constituent
• CPC Class Codes: C22C 47/06 : by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
• CPC Class Codes: C22C 47/068 : Aligning wires
• CPC Class Codes: C22C 47/14 : by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
• CPC Class Codes: C22C 47/20 : by subjecting to pressure and heat an assembly comprising at least one metal layer or sheet and one layer of fibres or filaments
• CPC Class Codes: C22C 49/06 : Aluminium
• CPC Class Codes: Y02P 10/25 : Process efficiency
• CPC Class Codes: Y10S 428/92 : Fire or heat protection feature
• CPC Class Codes: Y10T 428/12625 : Free carbon containing component
• CPC Class Codes: Y10T 428/24942 : including components having same physical characteristic in differing degree
• CPC Class Codes: Y10T 428/30 : Self-sustaining carbon mass or layer with impregnant or other layer

Abstract

A method for the fabrication of large metal matrix composite structures comprising the continuous joining by brazing or welding of aluminum matrix tape using an infrared laser to melt the surface of the tape while applying pressure to the tape and simultaneously contacting it with previously applied tape layers on a rotating mandrel. The apparatus utilized to accomplish this fabrication process may include a variety of pre and post-contact heaters and preferably includes instruments for the continuous monitoring and control of the process.

Claims

1. A method for the fabrication of structural members of metal matrix composites comprising:

providing a rotating mandrel having a mandrel surface addressed by a linearly traversing compaction wheel;

feeding a metal matrix prepeg tape having opposing surfaces between said mandrel surface and said compaction wheel, wherein as the mandrel is rotated said metal matrix prepeg tape is successively layered completely around said mandrel, thereby wrapping the prepeg tape around the mandrel, and wherein said metal matrix prepreg tape fed between said mandrel and said compaction wheel defines a V-shaped junction;

impacting said metal matrix prepeg tape with a beam of infrared radiation at said junction to melt at least one of said opposing surfaces in said junction;

simultaneously with the impacting of said beam of infrared radiation in said junction, rotating said mandrel so as to take up said prepeg tape as said at least one melted surface cools and solidifies and pressing said compaction wheel against said prepeg tape so as to cause consolidation of said prepeg tape with previously applied layers of said prepeg tape on said mandrel surface, thereby forming a consolidated metal matrix composite around the mandrel; and

removing said mandrel from said consolidated metal matrix composite to provide a metal matrix composite structural member.

2. The method of claim 1 wherein said prepeg tape comprises a matrix of aluminum or an alloy of aluminum encompassing ceramic fibers.

3. The method of claim 2 wherein said ceramic fibers comprise aluminum oxide.

4. The method of claim 1 wherein said infrared radiation is produced by a stacked multi-bar infrared laser.

5. The method of claim 4 wherein said stacked multi-bar infrared lase includes optical lenses that shape the infrared radiation into a pattern that matches the cross sectional dimensions of said prepeg tape.

6. The method of claim 1 wherein said mandrel is collapsible so as to permit removal of multiple layers of applied prepeg tape therefrom when fabrication is complete.

7. The method of claim 1 wherein said mandrel surface and said compaction wheel both comprise the same or different ceramic materials.

8. The method of claim 1 wherein said prepeg tape is preheated with infrared reflector lamps prior to entering said junction.

9. The method of claim 1 including the further step of providing an optical pyrometer that views said at least one melted surface in said junction and provides temperature feedback information for controlling the power of said infrared radiation or the speed of rotation of said mandrel.

10. The method of claim 1 further including the application of vibratory energy to said prepeg tape prior to entry into said junction at a frequency of between about 1000 and 25000 vibration per minute.

11. The method of claim 1 wherein said prepeg tape comprises a matrix of 1100 aluminum alloy or pure aluminum having aluminum oxide fibers embedded therein, said infrared radiation is provided by an infrared laser operating at a power level of from about 100 to about 1500 watts and said prepeg tape is fed at a rate of between about 0.65 and about 1.5 inches/sec.

12. The method of claim 11 wherein said prepeg tape is about 0.5 inches wide and about 0.15 inches thick.

13. The method of claim 1 wherein at least one of said opposing surface comprises a braze coating.