Metal Matrix Composite Laminate Consolidation for High-Temperature Strength
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Solution Overview
Problem
Conventional materials used in aerospace and hypersonic applications face limitations in high-temperature strength, creep resistance, and oxidation resistance, with existing materials being either heavy or brittle, and susceptible to stress corrosion cracking and hydrogen embrittlement.
Innovation Solution
The development of metal matrix composite (MMC) parts by plating dry reinforcement fibers with electroless or electrodeposited nickel or cobalt matrices, followed by diffusion bonding and consolidation in a vacuum sealed metallic sheath, to create strong, lightweight components with enhanced high-temperature capabilities.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If aluminum and magnesium alloys are used for lightweight structures, then weight is reduced, but elevated temperature strength and creep resistance deteriorate
Solution Approach 1:
The patent uses carbon fiber reinforced metal matrix composites (MMC) where carbon fibers provide reinforcement for high temperature strength while the metal matrix (nickel or cobalt) provides ductility and toughness. This composite structure achieves both lightweight properties and elevated temperature strength capability that neither aluminum/magnesium alloys alone nor ceramic matrix composites alone can provide.
2Strength
If titanium alloy structures are used for high strength applications, then strength is improved, but susceptibility to stress corrosion cracking and hydrogen embrittlement worsens
Solution Approach 1:
The metal matrix composite structure with carbon fibers embedded in nickel or cobalt matrix provides both high strength and improved resistance to stress corrosion cracking and hydrogen embrittlement compared to titanium alloys, while maintaining lightweight properties.
3Strength
If nickel and cobalt base superalloys are used for elevated temperature applications, then elevated temperature strength and creep resistance are improved, but weight increases
Solution Approach 1:
By using carbon fiber reinforced metal matrix composites with nickel or cobalt matrix, the patent achieves elevated temperature strength and creep resistance comparable to superalloys while reducing weight through the high strength-to-density ratio of carbon fibers.
4Temperature
If ceramic matrix composites are used for high temperature applications, then oxidation resistance and elevated temperature properties are improved, but impact strength and fracture toughness worsen
Solution Approach 1:
The patent combines carbon fibers with metal matrix (nickel or cobalt) to create a composite that maintains the oxidation resistance of ceramics while providing the ductility and toughness of metals. The metal matrix prevents catastrophic failure mode characteristic of ceramic matrix composites.
5Weight of moving object
If carbon-carbon composite structures are used for lightweight applications, then weight is reduced, but oxidation and burn resistance worsens
Solution Approach 1:
By embedding carbon fibers in a nickel or cobalt metal matrix, the patent protects the carbon fibers from oxidation and burn while maintaining the lightweight advantage. The metal matrix acts as a protective barrier against oxidative environments.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting MMC parts exhibit increased strength, elastic modulus, and extended high-temperature application capabilities, surpassing those of carbon fiber reinforced plastics and ceramic matrix composites, while maintaining a density similar to titanium alloys and offering improved toughness and stiffness.
Implementation Method 1
plating dry reinforcement fiber with an electroless or electrodeposited nickel matrix and/or electrodeposited nickel or cobalt matrix
Implementation Method 2
plating dry reinforcement fiber with an electroless or electrodeposited nickel matrix and/or electrodeposited nickel or cobalt matrix
Implementation Method 3
The vacuum sealed envelope may be heated to the desired curing or fusing temperature and pressure to metallurgically bond and consolidate the bundle of MMC laminates or plies into a single cured/consolidated or fused part
Implementation Method 4
hot consolidated into an MMC part via diffusion bonding of plies to one another
Data Source
AI summary
A method of manufacturing metal matrix composite (MMC) parts, including the steps of applying a metallic sheath around a bundle of MMC laminates, heating the bundle of MMC laminates in the metallic sheath at a curing or fusing temperature to consolidate the bundle of MMC laminates into a single cured or fused part, and then cooling the cured or fused part. The bundle of MMC laminates may be formed by removing surface contamination from the dry reinforcement fibers, creating a plurality of individual MMC laminates by plating dry reinforcement fibers with electroless nickel, and/or electrodeposited nickel or cobalt, and stacking each of the plurality of individual MMC laminates into a bundle. Autocatalytic and/or electroplating may be used as the primary means to incorporate fiber reinforcement into the metal matrix composite by covering and bonding fiber reinforcement into MMC laminates/plies and/or 3-D woven parts.