Apparatuses and methods for fabricating metal matrix composite structures

Patent metadata

Field	Value
Publication number	US-10279423-B2
Application number	US-201615239386-A
Country	US
Kind code	B2
Filing date	Aug 17, 2016
Priority date	Aug 17, 2016
Publication date	May 7, 2019
Grant date	May 7, 2019

Abstract

A method for forming a metal matrix composite (MMC) structure includes forming an assembly including at least two blocks of a primary phase material sharing an interface at which a secondary phase material is disposed. The assembly has a length, a width, and a thickness. The method also includes clamping the assembly to at least one of urge the at least two blocks toward each other or maintain the at least two blocks at a predetermined position. Also, the method includes passing a rotating friction-stir pin along the interface from the front edge to the rear edge. The friction-stir pin has a mixing length extending at least the width of the assembly, and passing the friction-stir pin along the length of the assembly disperses the secondary phase material into the primary phase material and welds the at least two blocks together.

First claim

What is claimed is:

1. A method for forming a metal matrix composite (MMC) structure, the method comprising:
forming an assembly including at least two blocks of a primary phase material sharing an interface at which a secondary phase material is disposed, the assembly having a length extending from a front edge to a rear edge, a width extending perpendicular to the length, and a thickness;
clamping the assembly to at least one of urge the at least two blocks toward each other or maintain the at least two blocks at a predetermined position;
passing a rotating friction-stir pin along the interface from the front edge to the rear edge, wherein the friction-stir pin is supported at opposite ends as the friction-stir pin is passed along the interface, wherein the friction-stir pin has a mixing length extending at least the width of the assembly, wherein the passing the friction-stir pin disperses the secondary phase material into the primary phase material and welds the at least two blocks together.

2. The method of claim 1 , further comprising driving the friction-stir pin at the opposite ends as the friction-stir pin is passed alone the interface.

3. The method of claim 1 , wherein forming the assembly comprises disposing the secondary phase material within a cavity of at least one of the at least two blocks.

4. The method of claim 1 , wherein the at least two blocks comprise at least three blocks defining two interfaces.

5. The method of claim 4 , wherein the at least three blocks comprise three blocks comprised of different metals from each other.

6. The method of claim 4 , wherein the secondary phase material comprises a first secondary phase material disposed at a first interface and a second secondary phase material disposed at a second interface.

7. The method of claim 1 , wherein the primary phase material comprises Aluminum.

8. The method of claim 1 , wherein the secondary phase material comprises a ceramic powder.

Assignees

• Boeing Co

Inventors

• Verma Ravi

Classifications

• C22C1/1036 Primary

  starting from a melt · CPC title

• B23K2103/14

  Titanium or alloys thereof · CPC title

• B23K20/24

  Preliminary treatment · CPC title

• B23K20/233

  without ferrous layer · CPC title

• B23K20/16

  with interposition of special material to facilitate connection of the parts, e.g. material for absorbing or producing gas · CPC title