U.S. patent application number 10/995516 was filed with the patent office on 2005-06-23 for glass fiber metal matrix composites.
This patent application is currently assigned to Touchstone Research Laboratory, Ltd.. Invention is credited to Gordon, Brian L., Hart, Kenneth A., Joseph, Brian E., Polsinelli, Joseph A., Witzgall, James F., Wolfe, Gregg W..
Application Number | 20050133123 10/995516 |
Document ID | / |
Family ID | 34652386 |
Filed Date | 2005-06-23 |
United States Patent
Application |
20050133123 |
Kind Code |
A1 |
Joseph, Brian E. ; et
al. |
June 23, 2005 |
Glass fiber metal matrix composites
Abstract
A glass fiber reinforced metal matrix composite is described.
The composite includes glass fibers distributed in a metal matrix
body. The fibers may be uniformly distributed in the metal matrix
and may include continuous lengths of the glass fibers. The glass
fibers may be glass fibers, S-glass, E-glass fibers,
soda-lime-silica fibers, basalt fibers, quartz fibers, or other
similar glassy fibers. The metal matrix may include aluminum or
alloys of aluminum as well as other metals and alloys.
Inventors: |
Joseph, Brian E.; (Wheeling,
WV) ; Gordon, Brian L.; (Wheeling, WV) ; Hart,
Kenneth A.; (Wheeling, WV) ; Polsinelli, Joseph
A.; (McMechen, WV) ; Witzgall, James F.;
(Wheeling, WV) ; Wolfe, Gregg W.; (Wheeling,
WV) |
Correspondence
Address: |
PHILIP DOUGLAS LANE
P.O. BOX 651295
POTOMAC FALLS
VA
20165-1295
US
|
Assignee: |
Touchstone Research Laboratory,
Ltd.
|
Family ID: |
34652386 |
Appl. No.: |
10/995516 |
Filed: |
November 24, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60525848 |
Dec 1, 2003 |
|
|
|
Current U.S.
Class: |
148/437 |
Current CPC
Class: |
C22C 47/068 20130101;
B22F 2998/00 20130101; C22C 49/14 20130101; B22F 2998/00 20130101;
C22C 47/08 20130101 |
Class at
Publication: |
148/437 |
International
Class: |
C22C 021/00 |
Goverment Interests
[0002] This invention was made with Government support under
contract number DAAD 19-01-2-0006 awarded by the Army Research
Laboratory. The Government has certain rights in the invention.
Claims
What is claimed is:
1. A metal matrix composite comprising: a metal matrix body
portion; and glass fibers distributed in said metal matrix body
portion.
2. The metal matrix composite of claim 1, wherein said glass fibers
are infiltrated by the metal matrix.
3. The metal matrix composite of claim 1, wherein said glass fibers
are distributed substantially uniformly in said metal matrix.
4. The metal matrix composite of claim 1, wherein at least a
portion of said glass fibers are continuous glass fibers.
5. The metal matrix composite of claim 1, wherein said glass fibers
are glass.
6. The metal matrix composite of claim 1, wherein said glass fibers
are E-glass.
7. The metal matrix composite of claim 1, wherein said glass fibers
are basalt fibers.
8. The metal matrix composite of claim 1, wherein said glass fibers
are quartz fibers.
9. The metal matrix composite of claim 1, wherein said metal matrix
comprises aluminum.
10. The metal matrix composite of claim 1, wherein said metal
matrix is selected from the group consisting of aluminum, aluminum
with 12% silicon, aluminum with 2% copper, alloys of aluminum,
zinc, and zinc alloys.
11. The metal matrix composite of claim 1, wherein said glass
fibers are in the form of woven glass fibers.
12. The metal matrix composite of claim 1, wherein said glass
fibers are in the form of non-woven glass fibers.
13. The metal matrix composite of claim 1, wherein said glass
fibers are selected from the group consisting of, S-glass and
soda-lime-silica fibers.
14. A metal matrix composite comprising a plurality of continuous
glass fibers substantially encapsulated in a metal matrix
comprising aluminum.
15. A method for producing a glass fiber reinforced metal matrix
composite, the method comprising the steps of: providing a
plurality of glass fibers; and embedding said plurality of glass
fibers in a metal matrix.
16. The method of claim 15, wherein the step of embedding includes
infiltrating said glass fibers with said metal matrix.
17. The method of claim 15, wherein said plurality of glass fibers
are supplied in a multifiber tow.
18. The method of claim 15, wherein said plurality of glass fibers
are selected from the group consisting of glass fibers, S-glass,
E-glass fibers, soda-lime-silica fibers, basalt fibers, quartz
fibers, or other similar glassy fibers.
19. The method of claim 15, wherein said metal matrix comprises
aluminum.
20. The method of claim 15, wherein said metal matrix is selected
from the group consisting of aluminum, aluminum with 12% silicon,
aluminum with 2% copper, and alloys of aluminum.
21. The method of claim 20, further comprising the step of pulling
said glass fibers through a metal bath.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims priority to U.S. Provisional
Patent Application No. 60/525,848, filed Dec. 1, 2003, specifically
herein incorporated by reference in its entirety.
FIELD OF THE INVENTION
[0003] The invention relates to fiber reinforced metal matrix
composites. More particularly, the invention relates to glass fiber
reinforced metal matrix composites and methods for making the
same.
BACKGROUND OF THE INVENTION
[0004] The next generation of high technology materials for use in
aerospace and aircraft applications will need to possess high
temperature capability combined with high stiffness and strength.
Plates and shells fabricated from laminated metal matrix
composites, as opposed to monolithic materials, provide the
potential for meeting these requirements and thereby significantly
advancing the designer's ability to meet the required elevated
temperature and structural strength and stiffness specifications
while minimizing weight.
[0005] Efforts to meet these challenges have produced metal matrix
composites having relatively long continuous lengths of a
reinforcing fibrous material, for example, a ceramic such as
aluminum oxide, in a matrix of a metal such as aluminum. However,
these composites are often expensive because of the costs of the
fibers. In order to make metal matrix composites to be more widely
accessible to various markets, there is a need to make metal matrix
composites more cost effective.
SUMMARY OF THE INVENTION
[0006] The present invention is directed to using glass fibers as
the reinforcing material in fiber reinforced metal matrix
composites. The invention includes a metal matrix composite having
a metal matrix body portion and glass fibers distributed in the
metal matrix body portion. The glass fibers may be infiltrated by
the metal matrix. Additionally, the glass fibers may be distributed
substantially uniformly in the metal matrix. Still further, at
least a portion of the glass fibers may be continuous glass fibers.
The glass fibers may be glass fibers, S-glass, E-glass fibers,
soda-lime-silica fibers, basalt fibers, quartz fibers, or other
similar glassy fibers. Further, the glass fibers may be in the form
of woven and/or braided glass fibers, or non-woven glass fibers.
The metal matrix is not particularly limited. The metal matrix may
include, but is not limited to aluminum, aluminum with 12% silicon,
aluminum with 2% copper, and other alloys of aluminum, zinc, and
zinc alloys. The invention also includes a metal matrix composite
having a plurality of continuous glass fibers substantially
encapsulated in a metal matrix comprising aluminum.
[0007] The invention also includes a method for producing a glass
fiber reinforced metal matrix composite. The method includes the
steps of providing a plurality of glass fibers and embedding the
plurality of glass fibers in a metal matrix. The step of embedding
may include infiltrating the glass fibers with the metal matrix.
The plurality of glass fibers may be supplied in a multifiber tow.
The method may also include the step of pulling the glass fibers
through a partially or fully molten metal bath.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1 is a diagrammatic view of a glass fiber reinforced
metal matrix composite in accordance with an embodiment of the
invention.
[0009] FIG. 2 is a diagrammatic view of an apparatus for making a
glass fiber reinforced metal matrix composite in accordance with an
embodiment of the invention.
DETAILED DESCRIPTION OF EMBODIMENTS OF THE INVENTION
[0010] With reference now to FIG. 1, there is shown a glass fiber
reinforced metal matrix composite in accordance with an embodiment
of the invention designated with the general reference numeral 100.
The glass fiber reinforced metal matrix composite includes a
plurality of glass fibers, representative glass fibers being
represented by the reference numeral 110. The glass fibers 110 are
embedded in a metal matrix 120. The glass fibers 110 may be
substantially uniformly distributed in the metal matrix 120.
Further, the glass fibers 110 may be continuous lengths of fibers
extending through the composite 100. The glass fibers 110 may be
infiltrated with the matrix metal such that there is substantially
no void space between the glass fibers and the metal matrix
120.
[0011] The shape of the glass fiber reinforced metal matrix
composite 100 is not particularly limited and may have any number
of cross-sectional shapes. Such shapes may include, but are not
limited to, circular, elliptical, oval, square, rectangular,
triangular, polygonal, irregular polygonal, and the like.
[0012] Generally, the glass fiber 110 may be any type of glass
fiber that can maintain some characteristics of a fiber when
exposed to the process temperatures and contact with the selected
metal. Preferably, the glass fiber improves the mechanical and/or
physical properties of the resulting metal matrix composite
compared to those of the matrix metal alone. Fibers, depending on
the selected matrix metal, may include, but are not limited to,
glass fibers, S-glass fibers, E-glass fibers, soda-lime-silica
fibers, basalt fibers, quartz fibers, other similar glassy fibers.
The diameter of the glass fibers is not particularly limited
provided that they may be encapsulated in the metal matrix. In
certain embodiments, the diameter of the glass fibers may range
from about 5 .mu.m to about 30 .mu.m.
[0013] The matrix metal 120 is not particularly limited, as long as
the matrix metal is capable of embedding the selected glass fibers
such that the glass fibers retain some characteristic of a fiber
during the formation of the composite. Matrix metals, depending on
the selected fibers, may include, but are not limited to, aluminum,
aluminum with 12% silicon, aluminum with 2% copper, zinc, and zinc
alloys including alloys and combinations thereof, as well as other
metals and metal alloys. In certain embodiments, the matrix metal
becomes fluid enough for processing at temperatures below those
temperatures at which the selected glass fibers are too soft for
processing.
[0014] A method for making a glass fiber reinforced metal matrix
composite will be described. Glass fibers are provided for
embedding in a metal matrix composite. The glass fibers may be in
the form of continuous lengths of individual fibers. Further the
glass fibers may be a plurality of fibers in the form of continuous
lengths of tows, yarns, or the like. Further, the glass fibers may
be in the form of a woven material where one or more glass fibers
are woven in an arrangement to form a fabric like structure.
Additionally, the glass fiber may be in the form of a non-woven
material. Such non-woven material may include a sheet, mat,
batting, and the like.
[0015] With reference now to FIG. 2, there is shown an apparatus
for forming a glass fiber reinforced metal matrix composite, the
apparatus being represented by the reference numeral 200. The
apparatus 200 may be used to form continuous lengths of composite
material through an infiltration process. As shown in FIG. 2, glass
fibers 210 are provided and submersed in a metal bath 220
containing the metal will become the metal matrix. The metal bath
is typically contained in a furnace 222 sufficient to maintain the
temperature of the metal above its softening point. The submersed
glass fibers 210 may be infiltrated with the metal from the metal
bath 220 by passing the glass fibers near a sonic waveguide 230.
The waveguide 230 directs sonic energy from a sonic processor 235
to the fibers and the metal bath surrounding the fibers. The sonic
processor 235 may provide ultrasonic energy. The metal wets the
fibers so that each individual fiber of the fiber bundle is
substantially surrounded or encapsulated by the metal, preferably
leaving no or minimal void spaces and forms a softened metal matrix
infiltrated glass fiber bundle 240.
[0016] The softened metal matrix infiltrated glass fiber bundle 240
may then be pulled through an optional shaping die 250 to shape the
infiltrated glass fiber bundle and control the fiber density in the
infiltrated fiber bundle. In certain embodiments, the softened
metal infiltrated glass fiber bundles may be continuously drawn
through the shaping die 250. The fibers may be drawn through the
apparatus 200 manually or by mechanically means. The shaping die
250 provides a glass fiber reinforced metal matrix composite having
a desired cross-sectional shape. Once the matrix metal has
sufficiently solidified, the glass fiber reinforced metal matrix
composite may be taken up on a reel, spool, or provided in
continuous lengths.
[0017] Without intending to limit the scope of the invention the
following example is provided to illustrate certain embodiments of
the invention.
EXAMPLE
[0018] High strength S-2 glass fibers listed in Table I were
infiltrated with a metal matrix by passing the glass fibers into an
aluminum bath, passing the fibers near an ultrasonic waveguide, and
removing the infiltrated fibers from the aluminum bath. The glass
fibers were supplied from Advanced Glassfiber Yarns.
1TABLE I Glass Fibers Loss on Filament Ignition (LOI) Yield
Filament Diameter ID (%) (yds/lb) Tex Denier Count (.mu.m)
721B-AA-750 0.65 750 660 5940 1730 14 365-225-TRL288 0.7 225 2200
19,800 1730 23 933-AA-375 0.23 375 1325 11,880 16,320 9 933-AA-750
0.23 750 660 5940 8160 9 463-AA-750 1.0 750 660 5940 8160 9
449-AA-250 0.65 250 1980 17820 24,480 9
[0019] A pure aluminum bath and an aluminum with 12% silicon bath
were used in the process. The aluminum bath temperature was held
constant at 1350.degree. C. The ultrasonic probe positioned was
varied between 0.125 and 0.250 inches from the glass fibers. The
ultrasonic amplitude was varied between settings of 30 and 60 and
the processing speed was varied between 36 inches per minute and
294 inches per minute. Under certain conditions, ultrasonic
amplitudes below 30 did not achieve infiltration and amplitudes
above 60 began to damage the fibers. All fibers produced a glass
fiber reinforced metal matrix composite. Micrographs showed good
infiltration of the glass fibers. Samples produced ultimate tensile
strengths of 46.8 ksi and an elastic modulus of 8.8 Msi.
[0020] The above examples are not to be considered limiting and are
only illustrative of a few of the many types of composites that may
be prepared. The present invention may be varied in many ways
without departing form the scope of the invention and is only
limited by the following claims.
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