Chemically bonded amorphous interface between phases in carbon fiber and steel composite

Patent metadata

Field	Value
Publication number	US-11788175-B2
Application number	US-202016933333-A
Country	US
Kind code	B2
Filing date	Jul 20, 2020
Priority date	Mar 21, 2019
Publication date	Oct 17, 2023
Grant date	Oct 17, 2023

Abstract

Carbon fiber reinforced steel matrix composites have carbon fiber impregnated in the steel matrix and chemically bonded to the steel. Chemical bonding is shown by the presence of a unique amorphous carbon layer at the carbon fiber/steel interface, and by canting of steel crystal edges adjacent to the interface. Methods for forming carbon fiber reinforce steel composites include sintering steel nanoparticles around a reinforcing carbon fiber structure, thereby chemically bonding a sintered steel matrix to the carbon fiber. This unique bonding likely contributes to enhanced strength of the composite, in comparison to metal matrix composites formed by other methods.

First claim

What is claimed is:

1. A composite material comprising:
a continuous steel matrix of sintered steel nanoparticles;
at least one reinforcing carbon fiber component that is at least partially encapsulated within the continuous steel matrix; and
an interface region disposed between the continuous steel matrix and a surface of the at least one reinforcing carbon fiber component, the interface region comprising an amorphous carbon layer.

2. The composite material as recited in claim 1 , wherein the amorphous carbon layer has a thickness within a range of from about 0.5 nm to about 10 nm.

3. The composite material as recited in claim 1 , wherein a portion of the continuous steel matrix of sintered steel nanoparticles distal to the amorphous carbon layer comprises steel crystal edges defining a first array of parallel lines, and a binding region of the continuous steel matrix of sintered steel nanoparticles adjacent to the amorphous carbon layer comprises steel crystal edges defining a second array of parallel lines canted relative to the first array of parallel lines.

4. The composite material as recited in claim 3 , wherein the second array of parallel lines is canted at an angle within a range of from about 2° to about 10° relative to the first array of parallel lines.

5. The composite material as recited in claim 1 , wherein the at least one reinforcing carbon fiber component is partially encapsulated within the continuous steel matrix.

6. The composite material as recited in claim 1 , wherein the at least one reinforcing carbon fiber component comprises a plurality of spatially separated layers of reinforcing carbon fiber.

7. The composite material as recited in claim 1 , wherein the continuous steel matrix comprises an alloy of iron, carbon, and at least one element selected from a group including: Mn, Ni, Cr, Mo, B, Ti, V, W, Co, Nb, P, S, and Si.

8. A composite material comprising:
at least one reinforcing carbon fiber component;
a continuous steel matrix, of sintered steel nanoparticles, disposed around the at least one carbon fiber component; and
an interface region disposed between the continuous steel matrix and a surface of the at least one reinforcing carbon fiber component, the interface region comprising an amorphous carbon layer.

9. The composite material as recited in claim 8 , wherein the amorphous carbon layer has a thickness within a range of from about 0.5 nm to about 10 nm.

10. The composite material as recited in claim 8 , wherein a portion of the continuous steel matrix of sintered steel nanoparticles distal to the amorphous carbon layer comprises steel crystal edges defining a first array of parallel lines, and a binding region of the continuous steel matrix of sintered steel nanoparticles adjacent to the amorphous carbon layer comprises steel crystal edges defining a second array of parallel lines canted relative to the first array of parallel lines.

11. The composite material as recited in claim 10 , wherein the second array of parallel lines is canted at an angle within a range of from about 2° to about 10° relative to the first array of parallel lines.

12. The composite material as recited in claim 8 , wherein the continuous steel matrix comprises an alloy of iron, carbon, and at least one element selected from a group including: Mn, Ni, Cr, Mo, B, Ti, V, W, Co, Nb, P, S, and Si.

13. A method for making a composite material, the method comprising:
providing steel nanoparticles;
combining the steel nanoparticles with a reinforcing carbon fiber component to produce an unannealed combination; and
sintering the steel nanoparticles to convert the steel nanoparticles to a continuous steel matrix, and to form an interface between the continuous steel matrix and the reinforcing carbon fiber component, the interface comprising an amorphous carbon layer chemically bonding a surface of the reinforced carbon fiber component with the continuous steel matrix.

14. The method as recited in claim 13 , wherein the amorphous carbon layer has an average thickness within a range of from about 0.25 nm to about 10 nm.

15. The method as recited in claim 13 , wherein sintering the steel nanoparticles forms a binding region in the continuous steel matrix, adjacent to an interface of carbon and steel portions of the composite material, the binding region having parallel steel edges canted relative to a bulk region of the continuous steel matrix distal to the interface.

16. The method as recited in claim 13 , wherein the steel nanoparticles have an average maximum dimension less than about 20 nm.

17. The method as recited in claim 13 , comprising synthesizing the steel nanoparticles by:
contacting an Anionic Element Reagent Complex (AERC) with a solvent, the AERC having a formula:
Fe a C b M d ·X y ,

where Fe is elemental iron, formally in oxidation state zero; C is elemental carbon, formally in oxidation state zero; M represents one or more elements in oxidation state zero, each of the one or more elements selected from a group including Mn, Ni, Cr, Mo, B, Ti, V, W, Co, Nb, P, S, and Si; X is a hydride molecule; a is a fractional or integral value greater than zero; b is a fractional or integral value greater than zero; d is a fractional or integral value greater than or equal to zero; and y is a fractional or integral value greater than or equal to zero.

18. The method as recited in claim 17 , comprising forming the AERC by ball-milling a mixture comprising:
a powder of a hydride molecule; and
a pre-steel mixture that includes
iron powder; and
carbon powder.

19. The method as recited in claim 18 , wherein the pre-steel mixture comprises a powder of one or more elements selected from a group including Mn, Ni, Cr, Mo, B, Ti, V, W, Co, Nb, P, S, and Si.

20. The method as recited in claim 13 , wherein providing steel nanoparticles includes synthesizing steel nanoparticles by a process comprising:
contacting a steel anionic reagent complex (steel-AERC) with a ligand, the steel-AERC having a formula:
Fe a C b M d ·X y ,

where Fe is elemental iron, formally in oxidation state zero; C is elemental carbon, formally in oxidation state zero; M represents one or more elements in oxidation state zero, each of the one or more elements selected from a group including Mn, Ni, Cr, Mo, B, Ti, V, W, Co, Nb, P, S, and Si; X is a hydride molecule; a is a fractional or integral value greater than zero; b is a fractional or integral value greater than zero; d is a fractional or integral value greater than or equal to zero; and y is a fractional or integral value greater than zero.

Assignees

• Toyota Eng & Mfg North America

Inventors

• Rowe Michael Paul
• Singh Nikhilendra

Classifications

• C22C33/0207 Primary

  Using a mixture of pre-alloyed powders or a master alloy · CPC title

• B22F1/054

  Nanosized particles · CPC title

• B22F7/008

  characterised by the composition · CPC title

• B22F7/02

  of composite layers {(B22F7/002 takes precedence)} · CPC title

• B22F2007/042

  characterised by the layer forming method · CPC title