Metal-bonded graphite foam composites
A metal-bonded graphite foam composite includes a ductile metal continuous phase and a dispersed phase that includes graphite foam particles.
1. A metal-bonded graphite foam composite comprises: a continuous phase comprising a ductile metal; and a dispersed phase comprising graphite foam particles.
2. A metal-bonded graphite foam composite in accordance with claim 1 , wherein said ductile metal comprises at least one of the group consisting of aluminum, titanium, steel, stainless steel, iron, nickel, copper, bronze, and brass.
3. A metal-bonded graphite foam composite in accordance with claim 1 , wherein said composite comprises said graphite foam particles in a volume fraction in the range of 1% to 90%.
4. A metal-bonded graphite foam composite in accordance with claim 3 , wherein said composite comprises said graphite foam particles in a volume fraction in the range of 10% to 80%.
5. A metal-bonded graphite foam composite in accordance with claim 4 , wherein said composite comprises said graphite foam particles in a volume fraction in the range of 25% to 75%.
6. A metal-bonded graphite foam composite in accordance with claim 5 , wherein said composite comprises said graphite foam particles in a volume fraction in the range of 35% to 75%.
7. A metal-bonded graphite foam composite in accordance with claim 6 , wherein said composite comprises said graphite foam particles in a volume fraction in the range of 55% to 75%.
8. A metal-bonded graphite foam composite in accordance with claim 1 wherein said composite comprises said graphite foam particles in a volume fraction that varies through said composite in at least one direction to form a functionally graded composite.
9. A metal-bonded graphite foam composite in accordance with claim 1 , further comprising at least one additive material.
10. A metal-bonded graphite foam composite in accordance with claim 9 , wherein said at least one additive material comprises at least one material selected from the group consisting of: carbon, ceramic, metal, glass, and mineral.
11. A metal-bonded graphite foam composite in accordance with claim 10 , wherein said material is characterized by at least one form selected from the group consisting of: amorphous particles, random-shaped particles, rounded particles, crystals, whiskers, needles, fibers, and tubes.
12. A method of making a metal-bonded graphite foam composite comprising:
a. providing ground graphite foam powder;
b. mixing said graphite foam powder with a ductile metal powder to form a mixture; and
c. consolidating said mixture to form a metal-bonded graphite foam composite.
13. A method of making a metal-bonded graphite foam composite in accordance with claim 12 , wherein said consolidating comprises hot pressing.
14. A method of making a metal-bonded graphite foam composite in accordance with claim 13 , further comprising roll compacting said mixture into a sheet prior to said hot pressing.
15. A method of making a metal-bonded graphite foam composite in accordance with claim 12 , further comprising varying a ratio of ductile metal powder to ground graphite foam through at least one dimension to form a functionally graded composite.
16. A method of making a metal-bonded graphite foam composite in accordance with claim 12 , further comprising, before consolidating said mixture, adding to said mixture at least one additive material.
17. A method of making a metal-bonded graphite foam composite in accordance with claim 16 , wherein said at least one additive material comprises at least one material selected from the group consisting of: carbon, ceramic, metal, glass, and mineral.
18. A method of making a metal-bonded graphite foam composite in accordance with claim 17 , wherein said material is characterized by at least one form selected from the group consisting of: amorphous particles, random-shaped particles, rounded particles, crystals, whiskers, needles, fibers, and tubes.