METAL MATRIX COMPOSITES AND METALLIC COMPOSITE FOAMS WITH IN-SITU GENERATED CARBONACEOUS FIBROUS REINFORCEMENTS
An exemplary embodiment discloses a thermoformed composite powder metallurgy based material including a matrix of sintered metal particles including at least one of a metal and metal alloy; and carbon fibers within said matrix having an orientation and shape derived from a precursor fibrous matte.
1 . A thermoformed composite powder metallurgy based material comprising:
a matrix of sintered metal particles comprising at least one of a metal and metal alloy; and
carbon fibers within said matrix having an orientation and shape derived from a precursor fibrous matte.
2 . The composite material of claim 1 , wherein said matrix of sintered metal particles comprises a cellular microstructure.
3 . The composite material of claim 1 , wherein at least one of said orientation and shape of the reinforcing carbon fibers over at least a portion of said composite material is substantially the same as said precursor fibrous matte.
4 . The composite material of claim 1 , wherein said orientation of carbon fibers is derived from a weave pattern comprising said precursor fibrous matte.
5 . The composite material of claim 1 , wherein said orientation of carbon fibers comprises a major portion of said carbon fibers having lengthwise directions oriented from about 10 degrees to about 90 degrees with respect to one another.
6 . The composite material of claim 1 , wherein the melting point of said metal and/or metal alloy is greater than about 300° C.
7 . The composite material of claim 1 , wherein the melting point of said metal and/or metal alloy is less than about 950° C.
8 . The composite material of claim 1 , wherein the melting point of said metal and/or metal alloy is from about 400° C. to about 700° C.
9 . The composite material of claim 1 , wherein said metal and/or metal alloy comprises at least one of magnesium and aluminum.
10 . The composite material of claim 1 , wherein the metal matrix comprises organic or inorganic additive material.
11 . The composite material of claim 1 , wherein the metal matrix comprises at least one of particulate and fibrous inorganic reinforcement material in addition to said carbon fibers.
12 . The composite material of claim 1 , wherein the metal matrix comprises an adhesive material.
13 . The composite material of claim 1 , wherein the thermoformed material comprises an automobile part.
14 . A method of forming thermoformed composite powder metallurgy based material comprising:
providing a composite preform assembly (lay-up) of metal particles comprising at least one type of metal particles, said metal particles supported on and at least partially around a fibrous matte having a first orientation and shape, said fibrous matte comprising a plurality of layers of organic polymer containing fibers; and,
subjecting said composite preform assembly (lay-up) to a thermoforming process at a temperature such that said metal particles sinter to form a continuous phase, and said fibrous matte at least partially carbonizes to form carbon fibers having a second orientation and shape derived from said first orientation and shape, —thus resulting in a carbon fiber reinforced metal matrix composite part.
15 . The method of claim 14 , further comprising the step of heating said composite preform assembly (lay-up) at an intermediate temperature prior to said thermoforming process, said intermediate temperature below a temperature of carbonization of said fibrous matte.
16 . The method of claim 14 , wherein said step of heating comprises a controlled atmosphere and pressure.
17 . The method of claim 14 , wherein said thermoforming process comprises a controlled atmosphere and pressure.
18 . The method of claim 14 , wherein said temperature of said thermoforming process is greater than a melting point of at least one metal comprising said metal matrix.
19 . The method of claim 18 , wherein said melting point of said at least one metal is greater than about 300° C.
20 . A composite powder metallurgy based precursor material for forming a thermoformed part therefrom comprising:
an assembly of matrix metal particles comprising at least one metal; and
a fibrous matte substrate supporting and at least partially surrounded by said matrix metal particles, said fibrous matte substrate comprising a plurality of layers of organic polymer containing fibers, said fibrous matte having a predetermined orientation, said metal particles adhered to said fibrous matte.