Anisotropically aligned carbon nanotubes in a carbon nanotube metal matrix composite

Patent metadata

Field	Value
Publication number	US-10322447-B2
Application number	US-201414787801-A
Country	US
Kind code	B2
Filing date	May 6, 2014
Priority date	May 9, 2013
Publication date	Jun 18, 2019
Grant date	Jun 18, 2019

Abstract

A method is provided for fabricating a carbon nanotube metal matrix composite. The method may include forming a molten mixture by combining carbon nanotubes with a molten solution. The carbon nanotubes combined with the molten solution may be dispersed therein. The method may also include transferring the molten mixture to a mold and applying a magnetic field to the molten mixture in the mold to substantially align at least a portion of the carbon nanotubes with one another. The method may further include solidifying the molten mixture in the mold to fabricate the carbon nanotube metal matrix composite, where at least a portion of the carbon nanotubes may be substantially aligned in the carbon nanotube metal matrix composite.

First claim

I claim:

1. A method for fabricating a carbon nanotube metal matrix composite, comprising:
treating carbon nanotubes to have a desired magnetic susceptibility;
forming a molten mixture by combining the carbon nanotubes with a molten solution, the carbon nanotubes dispersed in the molten solution;
transferring the molten mixture to a mold;
applying a magnetic field to the molten mixture in the mold to substantially align respective longitudinal axes of at least a portion of the carbon nanotubes with one another; and
solidifying the molten mixture in the mold to fabricate the carbon nanotube metal matrix composite, the at least a portion of the carbon nanotubes with the respective longitudinal axes substantially aligned with one another configured to impart an anisotropic property to the carbon nanotube metal matrix composite along the respective longitudinal axes of the carbon nanotubes.

2. The method of claim 1 , further comprising positioning an electromagnet about the mold, the electromagnets configured to apply the magnetic field to the molten mixture.

3. The method of claim 1 , further comprising positioning an electromagnet within the mold, the electromagnets configured to apply the magnetic field to the molten mixture.

4. The method of claim 1 , further comprising functionalizing the carbon nanotubes such that one or more chemical moieties are associated therewith.

5. The method of claim 1 , further comprising forming a reaction product at an interfacing surface between at least one of the carbon nanotubes and the molten solution.

6. The method of claim 5 , wherein the reaction product formed at the interfacing surface between the at least one of the carbon nanotubes and the molten solution increases wetting of the molten solution about the at least one of the carbon nanotubes.

7. The method of claim 5 , wherein the reaction product formed at the interfacing surface between the at least one of the carbon nanotubes and the molten solution increases bonding between the molten solution and the at least one of the carbon nanotubes.

8. A method for fabricating a carbon nanotube metal matrix composite, comprising:
forming a molten mixture by combining carbon nanotubes with a molten solution, the carbon nanotubes dispersed in the molten solution;
transferring the molten mixture to a mold;
rotating the mold to cause a directional flow of the molten mixture along an inner surface of the mold, the directional flow of the molten mixture substantially aligning respective longitudinal axes of at least a portion of the carbon nanotubes dispersed in the molten mixture; and
solidifying the molten mixture in the mold to fabricate the carbon nanotube metal matrix composite, the at least a portion of the carbon nanotubes with the respective longitudinal axes substantially aligned with one another configured to impart an anisotropic property to the carbon nanotube metal matrix composite along the respective longitudinal axes of the carbon nanotubes.

9. The method of claim 8 , wherein the rotation of the mold results in a flow of the molten mixture along the inner surface of the mold, the flow of the molten mixture substantially aligning the at least a portion of the carbon nanotubes dispersed in the molten mixture.

10. The method of claim 8 , wherein the mold is rotated about a rotational axis, the rotation of the mold causing migration of the carbon nanotubes in the molten mixture in a direction radial to the rotational axis.

11. The method of claim 8 , further comprising forming a reaction product at an interfacing surface between at least one of the carbon nanotubes and the molten solution.

12. The method of claim 11 , wherein the reaction product formed at the interfacing surface between the at least one of the carbon nanotubes and the molten solution increases wetting of the molten solution about the at least one of the carbon nanotubes.

13. The method of claim 11 , wherein the reaction product formed at the interfacing surface between the at least one of the carbon nanotubes and the molten solution increases bonding between the molten solution and the at least one of the carbon nanotubes.

14. A method for fabricating a carbon nanotube metal matrix composite, comprising:
forming a molten mixture by combining carbon nanotubes with a molten solution;
mixing the molten mixture to disperse the carbon nanotubes in the molten solution;
transferring the molten mixture to a mold;
aligning in the mold respective longitudinal axes of at least a portion of the carbon nanotubes with one another, the aligning in response to a magnetic field applied to the mold, or in response to a directional flow of the molten mixture along an inner surface of the mold, the directional flow of the molten mixture resulting from rotation of the mold; and
solidifying the molten mixture in the mold to fabricate the carbon nanotube metal matrix composite, the at least a portion of the carbon nanotubes with the respective longitudinal axes substantially aligned with one another configured to impart an anisotropic property to the carbon nanotube metal matrix composite along the respective longitudinal axes of the carbon nanotubes.

15. The method of claim 14 , further comprising inducing the carbon nanotubes into a magnetic state before combining the carbon nanotubes with the molten solution.

16. The method of claim 14 , wherein aligning the at least a portion of the carbon nanotubes with one another in the mold comprises applying a magnetic field to the molten mixture in the mold.

17. The method of claim 14 , wherein aligning the at least a portion of the carbon nanotubes with one another in the mold comprises rotating the mold to direct the molten mixture to an inner surface of the mold, the rotation of the mold substantially aligning the at least a portion of the carbon nanotubes dispersed in the molten mixture.

18. The method of claim 14 , further comprising forming a reaction product at an interfacing surface between at least one of the carbon nanotubes and the molten solution.

19. The method of claim 14 , wherein a reaction product formed at the interfacing surface between the at least one of the carbon nanotubes and the molten solution increases wetting of the molten solution about the at least one of the carbon nanotubes.

20. The method of claim 14 , wherein a reaction product formed at the interfacing surface between the at least one of the carbon nanotubes and the molten solution increases bonding between the molten solution and the at least one of the carbon nanotubes.

Assignees

• Dresser Rand Co
• Pillon Nicholas

Inventors

• Pillon Nicholas

Classifications

• C22C1/1036

  starting from a melt · CPC title

• B22F2202/05

  Use of magnetic field · CPC title

• C22C2026/002

  Carbon nanotubes · CPC title

• C22C47/08

  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 title

• B22F2999/00

  Aspects linked to processes or compositions used in powder metallurgy · CPC title