Patent US5004034A successfully refreshed from Google Patents.
US5004034A
Expired / Lapsed
US
⏱️ 0.0 years remaining
Method of surface bonding materials together by use of a metal matrix composite, and products produced thereby
Assignee: Lanxide Technology Co LP
•
Filing: 1988-11-10
•
Granted: 1991-04-02
•
Expires: 2008-11-10
Abstract
Abstract The present invention relates to forming a metal matrix composite (3) between at least two bodies (1) having a similar or a different chemical composition, the metal matrix composite functioning as a bonding means which bonds or fixes the bodies (1) together. Particularly, a metal matrix composite is produced by a spontaneous infiltration technique by providing a filler material (2) or preform with an infiltration enhancer and/or an infiltration enhancer precursor and/or an infiltrating atmosphere, which are in communication with the filler material or preform at least at some point during the process. Molten matrix metal then spontaneously infiltrates the filler material or preform, whereby the metal matrix composite serves to bond together two or more bodies.
Inventors
- 👤 Eugene S. Park
- 👤 Michael K. Aghajanian
- 👤 Christopher R. Kennedy
Bibliographic Details
Application Number
—
Jurisdiction
US
Data Source
google_patents
Last Synchronized
2026-11-01 09:49
CPC Classifications
C; C04; C04B; C04B37/00; C04B37/02; C04B37/023; C04B37/003; C04B37/005; C04B37/006; C04B37/025; C04B37/026; C04B2235/00; C04B2235/02; C04B2235/50; C04B2235/52; C04B2235/5208; C04B2235/5216; C04B2235/524; C04B2235/5248; C04B2235/65; C04B2235/656; C04B2235/6567; C04B2235/658; C04B2237/00; C04B2237/02; C04B2237/04; C04B2237/06; C04B2237/064; C04B2237/08; C04B2237/083; C04B2237/09; C04B2237/12; C04B2237/121; C04B2237/126; C04B2237/127; C04B2237/128; C04B2237/30; C04B2237/32; C04B2237/34; C04B2237/343; C04B2237/50; C04B2237/52; C04B2237/525; C04B2237/59; C04B2237/592; C04B2237/597; C04B2237/60; C04B2237/70; C04B2237/708; C04B2237/72
Claims Analysis
Total Claims: 47
Claim 1
Independent Claim
68 words
A method for bonding a plurality of bodies, comprising: providing a substantially nonreactive filler between at least a portion of at least two bodies which are to be bonded; spontaneously infiltrating at least a portion of the filler with molten matrix metal to form a metal matrix composite between said at least two bodies; and cooling said molten matrix metal, thereby bonding said at least two bodies together.
Claim 2
Independent Claim
68 words
A method for bonding a plurality of bodies, comprising: providing a substantially nonreactive filler between at least a portion of at least two bodies which are to be bonded; spontaneously infiltrating at least a portion of the filler with molten matrix metal to form a metal matrix composite between said at least two bodies; and cooling said molten matrix metal, thereby bonding said at least two bodies together.
Claim 3
Dependent Claim
37 words
The method of claim 1, further comprising the step of providing an infiltrating atmosphere in communication with at least one of the filler and the matrix metal for at least a portion of the period of infiltration.
Claim 4
Dependent Claim
21 words
The method of claim 2, wherein the infiltrating atmosphere comprises an atmosphere selected from the group consisting of oxygen and nitrogen.
Claim 5
Dependent Claim
37 words
The method of claim 2, further comprising the step of supplying at least one of an infiltration enhancer precursor and an infiltration enhancer to at least one of the matrix metal, the filler and the infiltrating atmosphere.
Claim 6
Dependent Claim
23 words
The method of claim 4, wherein the infiltration enhancer precursor comprises a material selected from the group consisting of magnesium, strontium and calcium.
Claim 7
Dependent Claim
34 words
The method of claim 4, wherein said at least one of said infiltration enhancer precursor and infiltration enhancer is provided in more than one of said matrix metal, said filler and said infiltrating atmosphere.
Claim 8
Dependent Claim
23 words
The method of claim 4, wherein the matrix metal comprises aluminum, the infiltration enhancer precursor comprises magnesium and the infiltrating atmosphere comprises nitrogen.
Claim 9
Dependent Claim
24 words
The method of claim 4, wherein said at least one of the infiltration enhancer precursor and infiltration enhancer is supplied from an external source.
Claim 10
Dependent Claim
41 words
The method of claim 4, wherein the infiltration enhancer is formed by reacting an infiltration enhancer precursor and at least one species selected from the group consisting of the infiltrating atmosphere, a material added to the filler and the matrix metal.
Claim 11
Dependent Claim
13 words
The method of claim 9, wherein during infiltration, the infiltration enhancer precursor volatilizes.
Claim 12
Dependent Claim
25 words
The method of claim 10, wherein the volatilized infiltration enhancer precursor reacts to form a reaction product in at least a portion of the filler.
Claim 13
Dependent Claim
19 words
The method of claim 11, wherein said reaction product is at least partially reducible by said molten matrix metal.
Claim 14
Dependent Claim
17 words
The method of claim 12, wherein said reaction product coats at least a portion of said filler.
Claim 15
Dependent Claim
14 words
The method of claim 11, wherein said reaction product comprises a nitride of magnesium.
Claim 16
Dependent Claim
23 words
The method of claim 4, wherein the matrix metal comprises aluminum, the infiltration enhancer precursor comprises zinc, and the infiltrating atmosphere comprises oxygen.
Claim 17
Dependent Claim
31 words
The method of claim 1 or 4, wherein said bodies to be bonded comprise any combination of material selected from the group consisting of metals, ceramics, ceramic composites, cermets and glass.
Claim 18
Dependent Claim
23 words
The method of claim 4, wherein the matrix metal comprises aluminum, the infiltration enhancer precursor comprises strontium and the infiltrating atmosphere comprises nitrogen.
Claim 19
Dependent Claim
23 words
The method of claim 4, wherein the matrix metal comprises aluminum, the infiltration enhancer precursor comprises calcium and the infiltrating atmosphere comprises nitrogen.
Claim 20
Dependent Claim
34 words
The method of claim 1, further comprising the step of supplying at least one of an infiltration enhancer precursor and an infiltration enhancer to at least one of the matrix metal and the filler.
Claim 21
Dependent Claim
30 words
The method of claim 19, wherein at least one of said infiltration enhancer and said infiltration enhancer precursor is provided at a boundary between said filler and said matrix metal.
Claim 22
Dependent Claim
29 words
The method of claim 19, wherein said at least one of said infiltration enhancer precursor and infiltration enhancer is provided in both of said matrix metal and said filler.
Claim 23
Independent Claim
30 words
The method of claims 1, 4 or 19, wherein said filler comprises a coating, applied on at least a portion of at least one of said bodies to be bonded.
Claim 24
Dependent Claim
17 words
The method of claim 22, wherein said coating comprises at least one of a slurry and paste.
Claim 25
Dependent Claim
41 words
The method of claim 1, further comprising the step of contacting at least a portion of the filler with at least one of an infiltration enhancer precursor and an infiltration enhancer during at least a portion of the period of infiltration.
Claim 26
Dependent Claim
11 words
The method of claim 1, wherein the filler comprises a preform.
Claim 27
Dependent Claim
17 words
The method of claim 1 or 25, wherein said filler directly contacts said bodies to be bonded.
Claim 28
Independent Claim
28 words
The method of claims 1 or 25, wherein said metal matrix composite reacts with at least a portion of at least one of said bodies to be bonded.
Claim 29
Independent Claim
27 words
The method of claims 1 or 25, wherein said metal matrix composite dissolves at least a portion of at least one of said bodies to be bonded.
Claim 30
Independent Claim
31 words
The method of claims 1 or 25, wherein said metal matrix composite is absorbed or adsorbed into at least a portion of at least one of said bodies to be bonded.
Claim 31
Independent Claim
36 words
The method of claims 1, 4 or 19, further comprising the step of providing a mass of matrix metal between said bodies to be bonded which, upon heating, provides a source or said molten matrix metal.
Claim 32
Dependent Claim
35 words
The method of claim 30, wherein said mass of matrix metal comprises an excess of matrix metal, whereby a carcass of matrix metal remains between said bodies to be bonded after spontaneous infiltration is completed.
Claim 33
Dependent Claim
30 words
The method of claim 1, further comprising the step of defining a surface boundary of the filler with a barrier, wherein the matrix metal spontaneously infiltrates up to the barrier.
Claim 34
Dependent Claim
22 words
The method of claim 32, wherein the barrier comprises a material selected from the group consisting of carbon, graphite and titanium diboride.
Claim 35
Dependent Claim
15 words
The method of claim 32, wherein said barrier is substantially non-wettable by said matrix metal.
Claim 36
Dependent Claim
39 words
The method of claim 32, wherein said barrier comprises at least one material which is sufficiently permeable to permit communication between an infiltrating atmosphere and at least one of the matrix metal, filler, infiltration enhancer and infiltration enhancer precursor.
Claim 37
Dependent Claim
37 words
The method of claim 1, wherein the filler comprises at least one material selected from the group consisting of powders, flakes, platelets, microspheres, whiskers, bubbles, fibers, particulates, fiber mats, chopped fibers, spheres, pellets, tubules and refractory cloths.
Claim 38
Dependent Claim
17 words
The method of claim 1, wherein the filler is of limited solubility in the molten matrix metal.
Claim 39
Dependent Claim
14 words
The method of claim 1, wherein the filler comprises at least one ceramic material.
Claim 40
Dependent Claim
16 words
The method of claim 1, wherein an infiltration enhancer precursor is alloyed in said matrix metal.
Claim 41
Dependent Claim
33 words
The method of claim 1, wherein said matrix metal comprises aluminum and at least one alloying element selected from the group consisting of silicon, iron, copper, manganese, chromium, zinc, calcium, magnesium and strontium.
Claim 42
Dependent Claim
38 words
The method of claim 1, wherein the temperature during spontaneous infiltration is greater than the melting point of the matrix metal, but lower than the volatilization temperature of the matrix metal and the melting point of the filler.
Claim 43
Dependent Claim
30 words
The method of claim 1, wherein the matrix metal comprises aluminum and the filler comprises at least one material selected from the group consisting of oxides, carbides, borides and nitrides.
Claim 44
Dependent Claim
36 words
The method of claim 1, wherein said metal matrix composite is tailored to have a coefficient of thermal expansion which is intermediate to coefficients of thermal expansion of said at least two bodies to be bonded.
Claim 45
Independent Claim
91 words
A method for bonding a plurality of bodies, comprising: providing a substantially nonreactive filler between at least a portion of at least two bodies which are to be bonded; contacting said filler with an aluminum matrix metal; providing a material comprising a magnesium source to at least one of said filler and said aluminum matrix metal; heating said aluminum matrix metal to render it molten; and spontaneously infiltrating at least a portion of the filler with molten matrix metal to form a metal matrix composite between said at least two bodies.
Claim 46
Independent Claim
91 words
A method for bonding a plurality of bodies, comprising: providing a substantially nonreactive filler between at least a portion of at least two bodies which are to be bonded; contacting said filler with an aluminum matrix metal; providing a material comprising a magnesium source to at least one of said filler and said aluminum matrix metal; heating said aluminum matrix metal to render it molten; and spontaneously infiltrating at least a portion of the filler with molten matrix metal to form a metal matrix composite between said at least two bodies.
Claim 47
Dependent Claim
35 words
The method of claim 44, wherein an infiltrating atmosphere comprising nitrogen is in communication with at least one of the filler and the matrix metal for at least a portion of the period of infiltration.
References Cited (Backward Citations)
US2951771A
Cited
US3031340A
Cited
US3149409A
Cited
US3396777A
Cited
US3547180A
Cited
US3608170A
Cited
US3915699A
Cited
US3868267A
Cited
US3969553A
Cited
US4082864A
Cited
DE2819076A1
Cited
US4802524A
Cited
US4677901A
Cited
US4404262A
Cited
US4376804A
Cited
US4376803A
Cited
US4473103A
Cited
JPS58144441A
Cited
JPS58163564A
Cited
US4450207A
Cited
US4570316A
Cited
GB2156718A
Cited
US4559246A
Cited
US4679493A
Cited
US4731298A
Cited
US4587177A
Cited
US4673435A
Cited
US4630665A
Cited
US4657065A
Cited
US4713111A
Cited
US4662429A
Cited
US4753690A
Cited
US4871008A
Cited
EP0340957A2
Cited
EP0364963A1
Cited
US4932099A
Cited
USPTO Annuity & Maintenance Windows
| Annuity Stage | Window Opens | Payment Deadline | Surcharge Period Until | Estimated Fee | Status |
|---|---|---|---|---|---|
| 3.5 Years (Year 4) | 1994-04-01 | 1994-10-01 | 1995-04-02 | $2000.00 | Window Closed / Lapsed |
| 7.5 Years (Year 8) | 1998-04-01 | 1998-10-01 | 1999-04-02 | $3760.00 | Window Closed / Lapsed |
| 11.5 Years (Year 12) | 2002-04-01 | 2002-10-01 | 2003-04-02 | $7700.00 | Window Closed / Lapsed |