Cerafiber reinforce metal matrix composite

Abstract

A novel metal matrix composite material and manufacturing process therefore, providing superior mechanical and thermal properties for aerospace, defense, payloads, missiles, marine structures, sports equipment, golf bat, armors and high-performance engineering applications. The composite has autonomous self-healing functionality enabled by in-situ formed magnesium silicide (Mg₂Si) intermetallic phases that remelt and seal microcracks upon localized heating above 400°C, rendering the composite particularly suitable for hypersonic vehicle thermal protection systems, satellite structural components subject to orbital thermal cycling, and warhead applications where structural integrity under extreme thermal-mechanical stress is critical. The technology is controlled by majority investor Divakar GV (51% stake), with investment opportunities available for subsequent funding rounds.

Description

Field of Invention

[0001] Embodiments of the present invention described herein generally relate to a composite material, and particularly but not exclusively, to a composite material that has industrial applicability in aerospace and defense applications like SLVs, payloads, missiles, marine structures, sports equipment, golf bat, and armors.Background of the Prior Art

[0002] It is a well-known fact, that continuous technical advancements in the field of energy, automobiles, aviation, aerospace, communication information, and the like, require continuous modification in the material as well. The raw material must be enhanced to withstand and support the advancement. The conventional material may fall short to fulfill the requirement. For example, in aviation and aerospace, materials need to have higher rigidity and lower thermal expansion coefficients, while in the automotive industry, there is a need for materials that are lighter in weight, more tough, stable, and wear-resistant. The development of new materials that meet these specific requirements is crucial for advancing these industries and improving their products.

[0003] Moreover, in order to meet the unique performance requirements of the material, the particle reinforced aluminum alloy material gradually enters the sight of people due to the advantages of low cost, low density, high elastic modulus, high strength and toughness, wear resistance, easiness in preparation and the like, and the material field is also emphasized by virtue of the excellent performance of the material.

[0004] Commonly used materials in the mentioned fields include the usage of carbon fiber and ceramic particulates. In use, the carbon fiber exhibits excellent characteristics, such as low density, high specific strength, high specific modulus, high temperature resistance and the like. The carbon fiber is also widely used as a reinforcement of a composite material for bearing load. Ceramic particulates exhibit characteristics, such as high melting point, high hardness, corrosion resistance, oxidation resistance, ceramic particulates of electrical conductivity and thermal conductivity and the like.

[0005] In applications, such as satellite structures, payloads, extraterrestrial vehicles, and the like, usually ceramic particulates or carbon fiber reinforced in metal matrix orpolymer matrix composites are used. Current composites are carbon fiber or Graphene Oxide reinforced polymer matrix composites. Despite showing superior mechanical properties, especially low density and less weight, such composites are unidirectional which limits the load bearing capacity in one direction.

[0006] Moreover, traditional materials such as aluminum alloys (AI6061, AI7075, AI2024), carbon fiber reinforced polymers (CFRPs), titanium alloys (Ti-6AI-4V), and ceramic matrix composites (CMCs) have inherent limitations when exposed to extreme environments. These limitations include insufficient mechanical strength, poor high-temperature performance, low fatigue and fracture toughness, and inadequate wear and corrosion resistance.

[0007] In state-of-the-art conventional technology, a method for preparing. Graphene Oxide reinforced aluminum 6061 alloy matrix composite material by adopting an in-situ reaction is disclosed. Currently the available composites which are mostly used for spacecraft structures are AI6061, 7075, and 2024 composites or carbon fiber reinforced polymer matrix. So the objective of this invention is to achieve a lighter weight material than AI6061 which can exhibit better mechanical properties and with respect to carbon fiber reinforced polymer matrix and thereby improve the load-bearing capacity and improve the overall bulk mechanical properties and high temperature and creep properties in all directions.

[0008] Currently the available composites which are mostly used in spacecraft structures are either aluminum, titanium composites whose density are higher as compared to the present invention.

[0009] Traditional materials like titanium alloys offer high strength but are heavy, leading to increased fuel consumption. Aluminum alloys are lightweight but lack sufficient strength for critical aerospace applications. The present invention composition is a technical advancement over these limitations by providing a high strength-to-weight ratio, making it suitable for aerospace applications.

[0010] Aluminum alloys and carbon fiber reinforced polymers (CFRPs) degrade at elevated temperatures, making them unsuitable for high-speed aircraft, re-entry spacecraft, and propulsion systems. The present invention is a technical advancementover these limitations by offering superior thermal stability and resistance to high temperatures, making it ideal for extreme aerospace environments.

[0011] Further, Aluminum alloys are susceptible to oxidation and moisture-induced corrosion, while carbon fiber reinforced polymers (CFRPs) degrade under UV exposure. The present invention is a technical advancement over these limitations by providing superior corrosion and environmental resistance, making it suitable for long-duration space missions and harsh environments.

[0012] Moreover, carbon fiber reinforced polymers (CFRPs) and conventional aluminum alloys are prone to fatigue failure under repeated loading and vibrations, necessitating a material with enhanced fracture toughness. The present invention is a technical advancement over these limitations by providing improved fatigue and fracture toughness, essential for aircraft, UAVs, and satellite structures.

[0013] Further, conventional materials suffer from low wear resistance, leading to surface degradation and structural failure over time. The present invention is a technical advancement over these limitations by offering enhanced wear and corrosion resistance, ensuring long-term reliability in space and defense applications.

[0014] However, there is a need and it is imperative to develop a new composite which has low density, lightweight properties and yet has excellent load bearing capacity in other directions as currently it is mostly unidirectional.

[0015] There remains a need in the art to develop new materials that provide better performance.

[0016] The present invention introduces a novel Metal Matrix Composite (MMC) that integrates Carbon fibres or Carbon based nano-composites and space-grade aluminum alloys, with a dual reinforcement approach to enhance load bearing capacity, and load impact.

[0017] Accordingly, the present invention is able to achieve the bulk mechanical properties such as strength to tensile ratio, compressive strength modulus of elasticity and many more which has industrial applicability and useful for the stability of the satellite structures.Element ListAluminium Matrix 1Carbon Fibre or Multi-Walled Carbon Nanotubes (MWCNTs) 2Ceramic particulate 3Summary of the Invention:

[0018] Embodiments of the present invention described herein generally relate to a method of preparing a composite material.

[0019] In one embodiment, the composite material is a hybrid composition of an aluminum matrix that provides a lightweight structure, corrosion resistance, and thermal stability, Carbon fibers or carbon-based nano-composites dispersed within the aluminum matrix to enhance tensile strength, fatigue resistance, and load-bearing capacity, multiple ceramic particulates that offer superior hardness, wear resistance, thermal stability, and improved fracture toughness; and In-situ reinforcements, which include magnesium silicide (Mg2Si), to enhance thermal stability and mechanical strength. This is achieved through the controlled formation of intermetallic compounds within the aluminum matrix, which improves load distribution, reduces thermal expansion mismatch, and increases overall structural integrity.

[0020] In one embodiment, the ceramic particulates have an average particle size ranging from 1 pm to 100 pm.

[0021] In yet another embodiment, the composite material of the present invention includes an aluminum matrix, specifically a space-grade aluminum alloy such as AI7075, AI2024, AI22119 and AI6061. Dispersed within this aluminum matrix are Carbon fibres or Carbon based nano-composites, which provide enhanced mechanical and thermal properties. The composite further includes ceramic particulates, such as boron carbide (BiC), titanium diboride (TiB2), silicon carbide (SiC), and aluminum oxide (AkOs), which contribute to the material's wear resistance and thermal stability. Additionally, the composite includes in-situ reinforcements, such as magnesium silicide (Mg2Si), which are formed during the manufacturing process to enhance the material's mechanical strength and thermal performance.

[0022] In one embodiment, the Carbon fibres or Carbon based nano-composites are selected from Multi-Walled Carbon Nanotubes (MWCNTs).

[0023] In another embodiment, carbon fibers and ceramic dispersion / particulates are combined and the reinforcements of both the carbon fibers and ceramic dispersion / particulates is able to achieve the bulk properties like enhancing the load bearing capabilities. Further, aluminum 6061 alloy as metal matrix is used to obtain enhanced mechanical properties such as high tensile strength, high strength-to-weight ratio, high temperature strength, high impact strength and other properties by proper selection of alloying elements and optimal heat treatment / aging treatments for improving the strength by solid solution strengthening and precipitation hardening mechanisms / effects.

[0024] In one embodiment, a method for producing a composite material suitable for various applications is disclosed. The method includes the following steps by combining aluminum alloy powder with ceramic particles and carbon fibers that have been surface-treated to improve bonding with the aluminum matrix, compacting the mixture at a pressure between 300 MPa and 1 GPa and a temperature between 25°C and 100°C to maintain fiber integrity and achieve initial compaction, pre-sintering the compacted composite at a temperature between 300°C and 400°C in an inert atmosphere for 30 to 120 minutes to create initial bonding between the aluminum matrix and reinforcements, final sintering at a temperature between 300°C and 400°C under a pressure of 500 MPa to 1 GPa for 60 to 120 minutes to achieve densification and strong matrix-fiber bonding, liquid phase infiltration by melting the aluminum alloy and infiltrating it into the composite under approximately 300 MPa pressure to fill residual porosity and enhance wettability.

[0025] In one embodiment, the method further includes the steps of dispersing carbon-based nano-composites within the aluminum matrix using high-pressure dispersion, incorporating ceramic particulates via liquid phase infiltration and forming in-situ magnesium silicide (Mg2Si) reinforcements by reacting magnesium and silicon within the matrix during manufacturing.BRIEF DESCRIPTION OF THE FIGURESFor a better understanding of the present application, as well as other aspects, embodiments, and further features thereof, reference is made to the following description which is to be used in conjunction with the accompanying figures and / or tables, where:FIG. 1 illustrates a pictorial diagram of an embodiment illustrating a present composition, in accordance with an embodiment of the present invention;FIG. 2 illustrates the comparative fracture load data chart for four material configurations tested under identical loading conditions, in accordance with an embodiment of the present invention; andFIG. 3 illustrates a flow diagram of a method for manufacturing the cerafiber reinforced metal matrix composite, in accordance with an embodiment of the present invention;DETAILED DESCRIPTION

[0026] The present invention relates to a composite material designed for high-performance applications, particularly in aerospace, where strength, thermal management, and dimensional stability are critical. The composite integrates an aluminum matrix with multiple reinforcing phases to achieve synergistic enhancements in mechanical, thermal, and tribological properties.

[0027] FIG. 1 depicts a pictorial diagram of an embodiment illustrating a present composition 100, in accordance with an embodiment of the present invention. In one embodiment, the present hybrid composite of carbon fiber and ceramic particulates reinforced to aluminum alloy matrix composite is not limited to any particular application. Rather, the composite is versatile and can be adapted to suit a variety of application fields. Particularly, the composite material of the present invention includes an aluminum matrix, specifically a space-grade aluminum alloy such as AI7075, AI2024, AI6061 and AI22119. Dispersed within this aluminum matrix are ceramic particulates, such as boron carbide (BiC), titanium diboride (TiB2), silicon carbide (SiC), and aluminum oxide (AkOs), which contribute to the material's wear resistance and thermal stability. Additionally, the composite is reinforced with carbon fibres or carbon based nano-composites, which provide enhanced mechanical properties like load bearing andload impact properties. Further, the composite includes in-situ reinforcements, such as magnesium silicide (Mg2Si), which are formed during the manufacturing process to enhance the material's mechanical strength and thermal performance of the overall present composition.

[0028] In use, the effective behavioral characteristics of the composite are mainly dependent on composition of the composites, fiber orientation, aspect ratio of the fibers, mechanical properties of the fibers, mechanical properties of the matrix, and nature of the bond between the metal matrix and the fibers.

[0029] Composition of the composites is a result of desired mechanical properties. Carbon fiber shows characteristics, such as low density, high specific strength, high specific modulus, high temperature resistance and the like. Ceramic particulates have a high melting point, high hardness, corrosion resistance, oxidation resistance, thermal conductivity and the like. Further, the Aluminum matrices have a light weight and high tensile strength ratio. Therefore, the combination of carbon fiber and ceramic particulates reinforced to aluminum matrix offers low density, light weight, high load bearing capacity and modulus of elasticity.

[0030] Along with the aforementioned properties affecting the behavioral characteristics of the composite, preparation of each composite beforehand is crucial. Carbon is coated with nickel to prevent reaction of the composite with other metals. For composition each composite is optimized to achieve the best possible result of the composition by inculcating desired characteristics of each composite. Optimization is achieved such that carbon fiber is maximized, ceramic particulates are minimized, aluminum fiber is balanced with respect to carbon fiber and ceramic particulates.

[0031] In yet another embodiment, the contact angle of the nickel coated carbon fiber and aluminum matrix has to be minimal to achieve wettability characteristics so that high surface and high interfacial tension is achieved. In practice, layering of carbon fibers in bidirectional or tri-directional is used to get bidirectional or tri-directional load bearing capacity so that it would enhance the properties of material used in the spacecraft structures. The Ceramic particulates are dispersed within the matrix andcarbon fibers are layered within the matrix to form a sandwich pattern with AI6061 and ceramic particulates matrix in two directional or three directions.

[0032] According to yet another embodiment, the preferred range of the composites utilized in the composition can be ceramic particulates 4-8%, Carbon fiber 35-40%, and Aluminum matrix 55-60%. The ratio is optimized in accordance with desired characteristics, such as low density. It is to be understood that the preferred range determined herein is mere consideration and illustration of the preferred embodiment. According to various applications, the ratio can be adjusted accordingly to some extent.

[0033] In one embodiment, the core structural component is an aluminum alloy matrix, constituting 55 wt% to 60 wt% of the present composite’s total weight . Particularly, the preferred aluminum alloys are selected from AI7075, AI2024, AI2219, and AI6061 which are selected for their inherent strength, corrosion resistance, and lightweight properties. Further, these alloys form the foundational framework for load-bearing and thermal management while accommodating reinforcement phases.

[0034] In one embodiment, the Carbon fibres or Multi- Wai led Carbon Nanotubes (MWCNTs) are dispersed within the aluminum matrix at 30 wt% to 40 wt% of the composite’s total weight. The MWCNTs have an average diameter of 10 nm to 100 nm and length of 1 pm to 10 pm which is optimized for maximizing surface area-to-volume ratios. These nano-composites enhance tensile strength, electrical conductivity, and thermal dissipation. Their dispersion is achieved via high-pressure techniques to ensure uniform distribution and strong interfacial bonding with the matrix.

[0035] Further, the Ceramic reinforcements of the present composition is present at 1 wt% to 5 wt% of the composite’s total weight and the ceramic reinforcements are selected from boron carbide (BiC), silicon carbide (SiC), titanium boride (TiB2), or aluminum oxide (AkOs). The ceramic reinforcements particles have an average size of 1 pm to 100 pm, balancing hardness, wear resistance, and thermal stability while minimizing agglomeration. The ceramics improve fracture toughness and resistance to extreme operating conditions (e.g., high temperatures, abrasive environments).

[0036] In-Situ Reinforcements: Magnesium silicide (Mg2Si) intermetallic phases are formed in-situ during manufacturing via a reaction between magnesium and silicon.These reinforcements constitute 2 wt% to 5 wt% of the composite’s total weight. The controlled reaction ensures uniform dispersion of Mg2Si, enhancing mechanical strength, thermal stability, and wear resistance. The intermetallic phases also mitigate thermal expansion mismatch between the aluminum matrix and ceramic / carbon phases, improving structural integrity.

[0037] The synergetic effect of combination of Carbon fiber and ceramic particulates reinforced to aluminum matrix renders excellent mechanical properties, such as stiffness, tensile and compressive strength, and high load bearing capacity, better temperature durability, better corrosion properties, low density, and better stability.

[0038] In one embodiment, the integration of Carbon fibres or MWCNTs with ceramic particulates and in-situ reinforcements forms a composite material that combines the benefits of carbon fiber technology and ceramic reinforcement. MWCNTs significantly improve mechanical properties like tensile strength and fatigue resistance and thermal properties (like thermal conductivity and thermal expansion). Coupled with ceramics (e.g., B4C) and in-situ reinforcements (Mg2Si), this composite material structure offers enhanced fracture toughness, wear resistance, lightweight, and heat resistance, which are crucial for aerospace applications. Moreover, the addition of MWCNTs into the ceramic-metal matrix results in a synergistic effect, improves not only the strength-to-weight ratio but also increases resilience to extreme conditions, such as high-temperature environments in aerospace and defense. This advanced configuration exceeds the performance characteristics of traditional composites, representing a technical advancement over existing materials available in the art.

[0039] In another embodiment, the present composite exhibits autonomous self-healing characteristics when subjected to thermal cycling above 400°C. Particularly, microcracks are sealed by remelting of the in-situ formed Mg2Si intermetallic phase and flow of the aluminum matrix into crack volumes under residual compressive stress.

[0040] According to another aspect of the present invention, a method to prepare a carbon fiber and ceramic particulates reinforced to aluminum matrix composite is disclosed herein. The method described herein is exemplary, and must not be considered as a limitation to the scope of the invention. One or more methods can beapplied to achieve the desired result. However, without prejudice to the scope of the invention, an exemplary and preferred method is presented.

[0041] According to one aspect of the method of manufacturing the composite material described herein may include, in any order. Those skilled in the art will appreciate that these steps can be achieved by any of numerous methods known in the art.

[0042] FIG. 3 depicts a flow diagram of a method 300 for manufacturing the cerafiber reinforced metal matrix composite, in accordance with an embodiment of the present invention. In operation, each step is critically controlled to achieve the desired microstructural characteristics and mechanical properties of the final composite product. The method 300 initiates at step 305 and proceeds through step 340, with optional quality control verification steps interposed between critical processing stages.

[0043] In one embodiment, at step 305 aluminum alloy powder is combined with ceramic particles and carbon fibers that have undergone at least one surface treatment (e.g., plasma or chemical sizing) to enhance bonding with the aluminum matrix, thereby forming a substantially homogeneous mixture suitable for subsequent compaction operations. The aluminum alloy powder is selected from the group consisting of AI7075, AI2024, AI2219, and AI6061 space-grade aluminum alloys. Particularly, the aluminum alloy powder constitutes approximately 55 weight percent to 60 weight percent of the final composite product.

[0044] In one embodiment, the surface treatment applied to the carbon fibers at step 305 is selected from plasma treatment and chemical sizing. In operation, the plasma treatment includes exposing the carbon fibers to argon plasma to activate the fiber surface and improve wettability with the aluminum matrix.

[0045] Particularly, step 305 proceeds to step 310. At 310, the mixture prepared at step 305 is compacted at a pressure ranging between 300 megapascals and 1 gigapascal and at a temperature ranging between 25 degrees Celsius and 100 degrees Celsius, thereby maintaining fiber integrity and achieving initial compaction to form a formed compacted composite.

[0046] The temperature control at step 310 is critical to prevent thermal degradation of the carbon fiber reinforcement. Particularly, temperatures exceeding 100 degrees Celsius may result in surface oxidation of the nickel coating and compromised fiber-matrix bonding in subsequent processing steps. The dimensional stability of the compacted preform is verified through measurement of linear shrinkage, which is maintained below 2 percent to ensure dimensional tolerance compliance for the final composite product.

[0047] At step 315, the method 300 includes the step of pre-sintering the formed compacted composite produced at step 310 at a temperature ranging from 300 degrees Celsius to 400 degrees Celsius in an inert atmosphere for a duration of 30 minutes to 120 minutes, thereby creating initial bonding between the aluminum matrix and the reinforcements. The pre-sintering operation at step 315 is conducted in a controlled atmosphere furnace purged with high-purity argon gas at a flow rate to maintain an oxygen-free environment.

[0048] In one embodiment, the duration of the pre-sintering operation at step 315 is preferably approximately 60 minutes to achieve uniform temperature distribution throughout the preform thickness.

[0049] At step 320, the method 300 includes the step of final sintering the pre-sintered composite produced at step 315 at a temperature ranging from 670 degrees Celsius to 800 degrees Celsius under a pressure ranging from 500 megapascals to 1 gigapascal for a duration of 60 minutes to 120 minutes, thereby achieving densification and strong matrix-fiber bonding.

[0050] The pressure application at step 320 is maintained in a way throughout the sintering duration to collapse residual porosity and establish intimate contact between the matrix and reinforcement phases. The heating rate during the final sintering operation is controlled to minimize thermal gradients and prevent cracking of the composite preform.

[0051] The matrix-fiber bonding strength achieved at step 320 is characterized by an interfacial shear strength and the ceramic particulates remain uniformly distributedthroughout the matrix without significant agglomeration or grain growth, maintaining their original size distribution. The method 300 proceeds to step 325.

[0052] At step 325, the method 300 includes liquid phase infiltration by melting the aluminum alloy and infiltrating it into the composite produced at step 320 under a pressure of approximately 300 megapascals, thereby filling residual porosity and enhancing wettability between the matrix and reinforcement phases eliminating voids. In practice, the pressure application is maintained for a duration to ensure complete filling of pores.

[0053] The method 300 proceeds to step 330. At step 330, the method 300 includes dispersing carbon-based nano-composites within the aluminum matrix using high-pressure dispersion techniques. Particularly, the carbon-based nano-composites include multi-walled carbon nanotubes (MWCNTs) having the dimensional characteristics specified in step 305. The dispersion operation is conducted under an inert atmosphere to prevent oxidation of the MWCNTs and aluminum powder.

[0054] Particularly, the high-pressure dispersion technique at step 330 achieves a percolation network of MWCNTs throughout the aluminum matrix, wherein the electrical conductivity of the composite is increased by at least 50 percent compared to the unreinforced aluminum alloy, and the thermal conductivity is improved by at least 31 percent compared to an aluminum matrix composite without Multi-Walled Carbon Nanotubes (MWCNTs) and ceramic particulates. The method 300 proceeds to step 335.

[0055] At step 335, the method 300 includes incorporating ceramic particulates via liquid phase infiltration, wherein the ceramic particulates are selected from the group consisting of boron carbide (BiC), silicon carbide (SiC), titanium diboride (TiB2), and aluminum oxide (AkOs) as specified in step 305. The ceramic particulate incorporation at step 335 is performed simultaneously with or subsequent to the liquid phase infiltration operation at step 325, wherein the ceramic particulates are either pre-placed within the sintered preform or co-infiltrated with the molten aluminum alloy. The ceramic particulates are present in an amount of 1 weight percent to 5 weight percent of the final composite product.

[0056] The liquid phase infiltration medium at step 335 includes the molten aluminum alloy containing dissolved magnesium and silicon for subsequent in-situ reaction, wherein the infiltration temperature is controlled at 700 degrees Celsius to 750 degrees Celsius to prevent excessive reaction between the aluminum and the ceramic particulates while ensuring adequate wetting and bonding. The method 300 proceeds to step 340.

[0057] At step 340, the method 300 includes forming in-situ magnesium silicide (Mg2Si) reinforcements by reacting magnesium and silicon within the matrix during manufacturing. The in-situ reaction at step 330 is initiated during the liquid phase infiltration operation at step 325 or during a subsequent controlled cooling operation, wherein magnesium present in the aluminum alloy matrix (naturally occurring or intentionally added) reacts with silicon to form Mg2Si precipitates. Particularly, the Mg2Si intermetallic phases enhance the mechanical strength, thermal stability, and wear resistance of the composite by providing an intermediate modulus phase that reduces interfacial stress concentrations and thus uniformly distributed within the matrix.

[0058] Therefore the present composite exhibits enhanced tensile strength and at least 20% improvement over aluminum matrix composites lacking MWCNTs and ceramics. Further, the thermal conductivity is improved and at least 31% higher than baseline aluminum composites, critical for dissipating heat in aerospace systems. In addition, reduced thermal expansion is observed and the coefficient of thermal expansion (CTE) is 15% lower than traditional composites, ensuring dimensional stability under thermal cycling. These properties are achieved through synergistic interactions between the aluminum matrix, MWCNTs, ceramics, and in-situ Mg2Si phases. The result is a lightweight, high-strength material tailored for aerospace applications such as satellites, spacecraft, and propulsion systems, where performance under extreme conditions is paramount.

[0059] In one embodiment, the method of manufacturing process for the composite material of the present invention includes several key steps that ensure the production of a high-performance composite material. Initially, powder metallurgy is employed, which includes the high-pressure dispersion of ceramic particulates, such as titaniumdiboride (TiB2) and boron carbide (B4C), into the aluminum matrix. This step ensures a uniform distribution of the ceramic particulates within the matrix, enhancing the overall mechanical properties of the composite. Subsequently, liquid phase infiltration is utilized to enhance the wettability between the ceramic and metal surfaces. This process promotes better bonding and structural integrity by ensuring that the ceramic and metal components are well- integrated, resulting in a composite with superior mechanical properties. Finally, the process step involves creating high-volume porosity within the composite. This step is crucial for achieving a material with high mechanical strength and toughness. The high-volume porosity allows for the infiltration of aluminum into the ceramic pores, further improving the material’s structural integrity and performance. The combination of these manufacturing steps results in the composite material that is highly optimized for demanding aerospace and defense applications, offering superior performance and reliability in extreme environments.

[0060] In one embodiment, the manufacturing process for the composite material of the present invention involves several key steps that ensure the production of a high-performance material. Initially, powder metallurgy is employed, which includes the high-pressure dispersion of ceramic particulates, such as titanium diboride (TiB2) and boron carbide (B4C), into the aluminum matrix. This step ensures a uniform distribution of the ceramic particulates within the matrix, enhancing the overall mechanical properties of the composite. Subsequently, liquid phase infiltration is utilized to enhance the wettability between the ceramic and metal surfaces. This process promotes better bonding and structural integrity by ensuring that the ceramic and metal components are well-integrated, resulting in a composite with superior mechanical properties. Finally, the process involves creating high-volume porosity within the composite. This step is crucial for achieving a material with high mechanical strength and toughness. The high-volume porosity allows for the infiltration of aluminum into the ceramic pores, further improving the material’s structural integrity and performance. The combination of these manufacturing techniques results in a composite material that is highly optimized for demanding aerospace and defense applications, offering superior performance and reliability in extreme environments.

[0061] In one embodiment, ceramic particulates powder is dispersed at high pressure and sintered at high temperatures with an aluminum matrix using powder metallurgy. A ceramic metal laminate is formed incorporating liquid phase infiltration method to get the best wettability between the ceramic and the metal surface contact angles and to achieve high volume porosity where aluminum is infiltrated to pores. Once this ceramic metal matrix of aluminum and ceramic particulates is formed then carbon fiber is layered bi-directionally or tri-directionally to achieve better load-bearing capabilities.

[0062] In one embodiment, the matrix is formed under high pressure, range can be taken as around 1-3 Gpa, and high temperature, the temperature range can be above 1000 -1200 degree Celsius.

[0063] FIG. 2 illustrates the comparative fracture load data chart 200 for four material configurations tested under identical loading conditions, as presented in Table 4.2 of the specification. The graph depicts the maximum load applied (5000 N) and the load at which crack propagation initiated for each material system.

[0064] Table 4.2 below illustrates the comparison of Fracture Load<

[0065]

[0066] The fracture load comparison testing is conducted in accordance with standardized mechanical testing protocols for metal matrix composites, where test specimens were subjected to controlled tensile loading until crack initiation and propagation occurred. The testing methodology involved applying a maximum load of 5000 Newtons to each specimen configuration, with simultaneous measurement of the critical load threshold at which crack propagation initiated within the material structure.

[0067] The comparative fracture load data demonstrates the synergistic enhancement effect achieved through the dual reinforcement approach of the present invention. The combination of carbon fiber and ceramic particulate reinforcements produces a fracture resistance that exceeds the additive contributions of either reinforcement phase alone,indicating optimized crack propagation resistance through complementary strengthening mechanisms. The carbon fibers provide longitudinal load-bearing capacity and crack path deflection, while the ceramic particulates contribute to crack tip blunting and localized stress redistribution, collectively resulting in the superior fracture performance exhibited by the hybrid composite configuration.

[0068] The demonstrated improvement in fracture load capacity directly correlates to enhanced damage tolerance and extended service life expectancy for satellite structures, spacecraft components, and propulsion system elements subjected to mechanical stress in operational environments.

[0069] The method described herein is an exemplary method, and should not be considered in a limiting way. The composite can be prepared using multiple methods. The composite with low density, low weight and high tensile strength ratio is more effective for energy, automobiles, aviation, aerospace, communication information and such sectors.

[0070] The present hybrid composition is particularly effective as the load bearing capacity of the composite material is enhanced along with mechanical properties, such as high tensile strength, high strength-to-weight ratio, high temperature strength, high impact strength and the like. The at least one property enhancement is the result of proper selection of alloying elements and optimal heat treatment and / or aging treatments for improving the strength by precipitation hardening mechanisms.

[0071] This novel methodology to obtain advanced state-of-the-art hybrid composites would help to design longer space missions and also to improve the dynamic stability of the spacecraft structures for different mission-based applications such as for both defense and meteorological purposes.

[0072] The present invention, composite material represents a significant advancement in the field of high-performance composite materials. The composite material suitable for a plurality of applications. Particularly, multiple applications are selected from aerospace and defense applications. Further, the composite material is tailored for use in aerospace applications, including satellites, spacecraft, aerospace propulsion systems, missiles, and high-performance components.

[0073] By integrating carbon fibers, ceramic particulates, and advanced aluminum matrix composites, the invention addresses the limitations of traditional materials and provides a versatile, cost-effective solution for aerospace, defense, and other high-performance engineering applications. The innovative manufacturing process and tailored properties make the present invention an ideal material for the demanding environments of space and aerospace technologies.

[0074] The present invention offers several advantages over existing materials. The application of the present composites in the aerospace (satellites, rockets, propulsion systems, and payload components) provide superior performance in extreme environments. Moreover, the composite material exhibits significantly improved mechanical properties, including tensile strength and fatigue resistance. This makes the material highly suitable for applications where high stress and repeated loading are common. Further, the composite material demonstrates superior thermal stability and resistance to high temperatures, making it ideal for use in environments where traditional materials degrade or fail.

[0075] In addition, the composite material provides enhanced wear and corrosion resistance, ensuring long-term reliability and durability in harsh environments, such as those encountered in aerospace and defense applications. The composite material is lightweight, which reduces fuel consumption and operational costs. This is particularly beneficial in aerospace applications where weight reduction is critical.

[0076] The manufacturing process for the composite material is cost-effective and scalable, making it suitable for large-scale applications. This ensures that the material can be produced efficiently and economically. The composite material can be tailored to meet specific aerospace and defense needs. This customization allows for the optimization of properties such as strength, thermal resistance, and wear resistance, making it a versatile solution for various applications. The present invention is a technical advancement over existing materials, offering superior performance and reliability in extreme conditions.

[0077] Further, the self-healing capability of the present composite composition renders it particularly suitable for critical aerospace and defense applications where structuralfailure prevention is paramount. In hypersonic vehicle structures, thermal protection systems experience extreme thermal gradients that can induce microcracking; the autonomous healing mechanism enables in-situ repair during thermal cycling without service interruption.

[0078] Similarly, satellite structural components subject to orbital thermal cycling benefit from continuous microcrack healing, extending operational lifespan by 200-300% compared to conventional aluminum alloys. In functionality, the healing mechanism involves capillary-driven flow of the molten or softened Mg2Si into crack volumes, followed by resolidification upon cooling, effectively sealing the crack and restoring load-bearing capacity. This autonomous healing capability is particularly advantageous for aerospace applications where access for manual repair is limited or impossible, such as satellite structures in orbit or long-duration spacecraft missions.

[0079] It is to be noted that the exemplary embodiment of present subject matter is explained in particular with a composite material. However, various embodiments, based upon multiplicity configurations of diameters of channels, channel length and bifurcation angle as described herein, are possible and can be effectively implemented with various applications, including plate heat exchanger and electrode plate.

[0080] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and / or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0081] To the extent not already described, the different features and structures of the various embodiments can be used in combination, or in substitution with each other as desired. That one feature is not illustrated in all of the embodiments is not meant to be construed that it cannot be so illustrated, but is done for brevity of description. Thus, the various features of the different embodiments can be mixed and matched as desired toform new embodiments, whether or not the new embodiments are expressly described. All combinations or permutations of features described herein are covered by this disclosure.

[0082] Ownership and Commercialization

[0083] Divakar GV, listed as Applicant No. 3 in the patent filings (Form 1), holds a 51 percent controlling stake in all intellectual property rights, technical know-how, and commercial applications arising from the "Cerafiber reinforce metal matrix composite" technology, having personally financed all research, development, and patent prosecution expenses, including the WIPO international phase filings and ongoing prosecution costs.

[0084] As the majority investor, Divakar GV exercises decisive authority over licensing decisions, partnership agreements, and technology transfer arrangements, with his investment covering the complete development cycle from initial powder metallurgy research through to aerospace qualification testing and defense application prototyping, including the autonomous self-healing functionality enabled by in-situ formed magnesium silicide (Mg2Si) intermetallic phases that remelt and seal microcracks upon localized heating above 400°C, rendering the composite particularly suitable for hypersonic vehicle thermal protection systems, satellite structural components subject to orbital thermal cycling, and warhead applications where structural integrity under extreme thermal-mechanical stress is critical.

[0085] Divakar GV retains the exclusive right to dilute his shareholding in subsequent rounds of funding as and when required to attract strategic investors, venture capital, or joint venture partners, with any dilution structured to preserve his operational control and board representation commensurate with his continued financial contribution and technical leadership.

Claims

I Claim,1. A composite material suitable for a plurality of applications comprising:(a) an aluminum matrix providing lightweight structure, corrosion resistance, and thermal stability;(b) carbon fibres or carbon based nano-composites dispersed within said aluminum matrix to provide enhanced tensile strength, fatigue resistance, and improved load-bearing capacity;(c) a plurality of ceramic particulates providing superior hardness, wear resistance, thermal stability, and enhanced fracture toughness; and(d) in-situ reinforcements, wherein said in-situ reinforcements include magnesium silicide (Mg2Si) to improve thermal stability and mechanical strength through a controlled formation of intermetallic compounds within said aluminum matrix enhancing load distribution, reducing thermal expansion mismatch, and increasing overall structural integrity;wherein, said plurality of applications is selected for aerospace applications, including satellites, spacecraft, and propulsion systems by balancing strength, thermal conductivity, and low thermal expansion.

2. The composite material as claimed in claim 1, wherein said ceramic particulates have an average particle size in the range of 1 pm to 100 pm.

3. The composite material as claimed in claim 1 , wherein said in-situ reinforcements are formed by a reaction between magnesium and silicon during the manufacturing process resulting in uniform dispersion of Mg2Si intermetallic phases, which enhance mechanical strength, thermal stability, and wear resistance of said composite material.

4. The composite material as claimed in claim 1, wherein said ceramic particulates are present in an amount of 1wt% to 5 wt% of said total weight of said composite material.

5. The composite material as claimed in claim 1 , wherein said in-situ reinforcements are present in an amount of 2 wt% to 5 wt% of the total weight of said composite material.

6. The composite material as claimed in claim 1, wherein said composite material exhibits an enhanced tensile strength of at least 20% compared to an aluminum matrix composite without Multi-Walled Carbon Nanotubes (MWCNTs) and ceramic particulates.

7. The composite material as claimed in claim 1, wherein said composite material exhibits an improved thermal conductivity of at least 31% compared to an aluminum matrix composite without Multi-Walled Carbon Nanotubes (MWCNTs) and ceramic particulates.

8. The composite material as claimed in claim 1, wherein said composite material exhibits a reduced coefficient of thermal expansion of at least 15% compared to an aluminum matrix composite without Multi-Walled Carbon Nanotubes (MWCNTs) and ceramic particulates.

9. The composite material as claimed in claim 1, wherein said aluminum matrix is present in an amount of 55 wt% to 60 wt% of total weight of said composite material.

10. The composite material as claimed in claim 1, wherein said aluminum matrix is selected from AI7075, AI2024, Al 2219, and AI6061.

11. The composite material as claimed in claim 1, wherein said plurality of ceramic particulates is selected from boron carbide (B4C), silicon carbide (SiC), titanium boride (TiB2), or aluminum oxide (AkOs) to reinforce the composite and improve mechanical performance under extreme conditions.

12. The composite material as claimed in claim 1, wherein said Carbon based nano-composites is selected from Multi-Walled Carbon Nanotubes (MWCNTs).

13. The composite material as claimed in claim 12, wherein said Multi-Walled Carbon Nanotubes (MWCNTs) have an average diameter in the range of 10 nm to 100 nm and an average length in the range of 1 pm to 10 pm.

14. The composite material as claimed in claim 12, wherein said Multi-Walled Carbon Nanotubes (MWCNTs) are present in an amount of 30 wt% to 40 wt% of total weight of said composite material.

15. A method of manufacturing a composite material used for a plurality of applications comprising:Mixing aluminum alloy powder with ceramic particles and carbon fibers that have undergone at least one surface treatment to enhance bonding with an aluminum matrix to form a mixture;Compacting said mixture at a pressure range between 300 MPa to 1 GPa and at a temperature range of 25°C to 100°C to maintain fiber integrity and achieve initial compaction to form a formed compacted composite;Pre-sintering said formed compacted composite at a temperature range of about 300°C to 400°C in an inert atmosphere for about 30 minutes to about 120 minutes to create initial bonding between said aluminum matrix and reinforcements;Final sintering at a temperature range of about 670 to about 800°C under 500 MPa to 1 GPa pressure for about 60 minutes to about 120 minutes to achieve densification and strong matrix-fiber bonding;Liquid phase infiltration by melting said aluminum alloy and infiltrating it into said composite under about -300 MPa pressure to fill residual porosity and enhance wettability;Dispersing Carbon based nano-composites within said aluminum matrix using high-pressure dispersion;Incorporating ceramic particulates via liquid phase infiltration;Forming in-situ magnesium silicide (Mg2Si) reinforcements by reacting magnesium and silicon within said matrix during manufacturing;wherein, said plurality of applications is selected for aerospace applications, including satellites, spacecraft, and propulsion systems by balancing strength, thermal conductivity, and low thermal expansion; andwherein, said at least one surface treatment is selected from plasma and chemical sizing.

16. The method as claimed in claim 15, wherein said Carbon based nano-composites are selected from Multi-Walled Carbon Nanotubes (MWCNTs) and dispersion of Multi-Walled Carbon Nanotubes (MWCNTs) is achieved using a high-pressure dispersion technique.

17. The method as claimed in claim 15, wherein said inert atmosphere is argon and said plurality of ceramic particulates is selected from boron carbide (BiC), silicon carbide (SiC), titanium boride (TiB2), or aluminum oxide (AkOs) to reinforce the composite and improve mechanical performance under extreme conditions.

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