Method to produce low-cost metal matrix composites for industrial, sports, and commercial applications

Patent metadata

Field	Value
Publication number	US-12435403-B2
Application number	US-202318131549-A
Country	US
Kind code	B2
Filing date	Apr 6, 2023
Priority date	Apr 6, 2023
Publication date	Oct 7, 2025
Grant date	Oct 7, 2025

Abstract

A method of forming a metal matrix composite component includes positioning a preform including an electrically non-conductive fibrous material in a shaping tool. The fibrous material is pre-coated. The method includes flowing a molten metal comprising zinc into the shaping tool so that at least a portion of the preform is enveloped by the molten metal to form the metal matrix composite component; and cooling the metal matrix composite component.

First claim

What is claimed is:

1. A method of forming a metal matrix composite component, the method comprising:
positioning a preform comprising an electrically non-conductive fibrous material in a shaping tool, wherein the fibrous material is pre-coated, wherein the preform comprises a metallic wire;
flowing a molten metal comprising zinc into the shaping tool so that at least a portion of the preform is enveloped by the molten metal to form the metal matrix composite component;
cooling the metal matrix composite component; and
compressing the molten metal and the portion of the preform;
wherein the shaping tool comprises a mold tool and a bag that at least partially encloses the mold tool, and compressing the molten metal and the portion of the preform includes: reducing a pressure within the bag with the molten metal and the portion of the preform on the mold tool.

2. The method of claim 1 , further comprising coating a fibrous material with nickel via electroless nickel plating to form the fibrous material that is pre-coated.

3. The method of claim 1 , wherein the wire comprises at least one of zinc, titanium, aluminum, steel, or copper.

4. The method of claim 1 , wherein the wire has a coating comprising nickel.

5. The method of claim 1 , further comprising infusing the molten metal with at least one of boron, titanium, zirconium, hafnium, silicon, manganese, phosphorous, or a rare earth element.

6. The method of claim 1 , wherein the fibrous material is at least one of polyamide fiber, carbon fiber, silica fiber, silicon carbide fiber, aluminum oxide fiber, magnesium oxide fiber, or basalt fiber.

7. The method of claim 1 , wherein the shaping tool defines a cavity in which the preform is positioned and includes an inlet and an outlet in fluid communication with the cavity, and introducing the molten metal into the shaping tool includes: lowering a pressure at the outlet.

8. The method of claim 7 , wherein introducing the molten metal into the shaping tool includes: pumping the molten metal into the inlet.

9. The method of claim 1 , wherein the molten metal does not include magnesium.

10. The method of claim 1 , wherein the preform comprises at least two different types of fibrous material.

Assignees

• Spirit Aerosys Inc

Inventors

• Nasserrafi Rahbar
• Dando Kerrick
• Hicks Gerald

Classifications

• C22C47/04

  by coating, e.g. with a protective or activated covering · CPC title

• B22D30/00

  Cooling castings, not restricted to casting processes covered by a single main group (accessories for cooling cast stock in continuous casting of metals B22D11/124; controlling or regulating processes or operations for cooling cast stock or mould in continuous casting of metals B22D11/22; chill casting B22D15/00) · CPC title

• B22D19/14

  the objects being filamentary or particulate in form (making alloys containing fibres or filaments by contacting the fibres or filaments with molten metal C22C47/08) · CPC title

• B22D18/06

  Vacuum casting, i.e. making use of vacuum to fill the mould · CPC title

• B22D17/00

  Pressure die casting or injection die casting, i.e. casting in which the metal is forced into a mould under high pressure · CPC title