Toughened and corrosion- and wear-resistant composite structures and fabrication methods thereof

1. A method of making a composite structure, the method comprising the steps:

(a) heating at least a surface portion of a substrate to a temperature above the melting point of the substrate;

(b) disposing a precursor material comprising titanium and a boron source on the at least a surface portion of the substrate; and

(c) forming a reinforced material with the precursor material interjoined with the at least a surface portion of the substrate to provide the composite structure.

2. The method of claim 1 wherein:

step (a) comprises melting an entire portion of the substrate; and

step (b) comprises flowing the melted substrate into a mold cavity coated with the precursor material.

3. The method of claim 1 wherein step (b) comprises disposing a precursor material comprising titanium diboride and a β-titanium stabilizer on the at least a portion of the substrate.

4. The method of claim 1 wherein step (b) comprises disposing a slurry, glaze, or paste comprising titanium diboride on the heated surface portion of the substrate.

5. The method of claim 1 wherein the substrate is a titanium-bearing substrate.

6. The method of claim 1 wherein the substrate is an iron-bearing substrate.

7. The method of claim 1 wherein the substrate is an aluminum-bearing substrate.

8. The method of claim 1 wherein the substrate is a non-titanium bearing substrate.

9. The method of claim 1 wherein the reinforced material includes a compound selected from the group consisting of titanium monoboride, titanium diboride, and combinations thereof disposed at least partially below the surface portion of the composite structure.

10. A method of making a composite structure, the method comprising the steps:

(a) coating a mold cavity with a precursor material comprising titanium and a boron source;

(b) melting a substrate;

(c) flowing the melted substrate into the mold cavity; and

(d) forming a reinforced material in the mold cavity with the precursor material interjoined with a surface portion of the substrate to provide the composite structure.

11. The method of claim 10 wherein the precursor material includes a slurry, glaze, or paste comprising titanium diboride.

12. The method of claim 10 wherein the substrate is a titanium-bearing substrate.

13. The method of claim 10 wherein the substrate is an iron-bearing substrate.

14. The method of claim 10 wherein the substrate is an aluminum-bearing substrate.

15. The method of claim 10 wherein the substrate is a non-titanium bearing substrate.

16. The method of claim 10 wherein the reinforced material includes a compound selected from the group consisting of titanium monoboride, titanium diboride, and combinations thereof disposed at least partially below the surface portion of the composite structure.

17. A method of making a composite structure, the method comprising the steps:

(a) heating at least a surface portion of a substrate to a temperature above the melting point of the substrate;

(b) disposing a precursor material comprising titanium and a boron source on the at least a surface portion of the substrate;

(c) maintaining the temperature of the at least a surface portion of the substrate above the melting point of the substrate until the precursor material diffuses into the at least a surface portion of the substrate; and

(d) forming a reinforced material with the precursor material intermingled with the at least a surface portion of the substrate to provide the composite structure.

18. The method of claim 17 wherein the maintaining step includes exposing the at least a surface portion of the substrate to the temperature slightly above the melting point of the substrate from 1 to 300 seconds.

19. The method of claim 17 wherein the maintaining step includes exposing the at least a surface portion of the substrate to the temperature slightly above the melting point of the substrate from 30 to 60 seconds.

20. The method of claim 17 wherein the maintaining step includes maintaining the temperature slightly above the melting point of the substrate for up to a few seconds.

21. The method of claim 17 wherein the substrate is one of a titanium-bearing substrate and an iron-bearing substrate.

22. The method of claim 17 wherein the substrate is an aluminum-bearing substrate.