Metal Matrix Composite Preform with Segmented Ceramic Reinforcement

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Solution Overview

Problem

Existing metal matrix composite preforms suffer from fatigue, inconsistent density, and weak points due to entanglement and conglomeration of reinforcing materials, leading to inadequate mechanical properties and increased production costs, particularly in applications requiring high wear resistance and lightweight components.

Innovation Solution

A preform composed of ceramic particles and ceramic fibers with a multi-screw extruder for mixing, where ceramic fibers are randomly oriented and homogeneously dispersed to enhance infiltration and strength, reducing the need for additional reinforcing elements and minimizing production costs.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If small reinforcing materials are used to enable consistent mixing during preform formation, then mixing consistency is improved, but mechanical properties such as wear resistance deteriorate

Engineering Contradiction:

Improvemixing consistencyVSAvoidwear resistance

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The preform is divided into two distinct zones: a first zone containing small reinforcing materials for consistent mixing and fabrication, and a second zone containing large reinforcing materials for enhanced mechanical properties. This segmentation allows each zone to serve its specific function without compromise

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different regions of the preform are assigned different reinforcing material sizes based on local requirements: the first zone (typically the interior) uses small materials for fabrication consistency, while the second zone (typically the exterior) uses large materials for wear resistance and mechanical strength

Inventive Principle:

Principle #3Local quality

2Strength

If additional external reinforcing elements are added to existing preforms to remedy performance issues, then mechanical properties are improved, but production costs increase

Engineering Contradiction:

Improvemechanical propertiesVSAvoidproduction costs

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The preform is manufactured with the correct distribution of reinforcing materials (small in the first zone, large in the second zone) from the beginning, preventing performance deficiencies before they occur and eliminating the need for costly post-formation repairs or additions

Inventive Principle:

Principle #10Preliminary action

3Ease of manufacture

If entanglement and conglomeration of reinforcing materials occur in preforms, then production is simplified, but mechanical strength and stiffness deteriorate

Engineering Contradiction:

Improvepreform productionVSAvoidmechanical strength and stiffness

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The preform structure creates distinct zones with different reinforcing material characteristics: the first zone with small materials maintains flexibility and ease of fabrication, while the second zone with large materials provides the necessary mechanical strength and stiffness without entanglement issues

Inventive Principle:

Principle #3Local quality

4Strength

If preforms are designed for high wear resistance applications, then wear resistance is improved, but weight increases

Engineering Contradiction:

Improvewear resistanceVSAvoidpreform weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

Large wear-resistant reinforcing materials are concentrated in the second zone where they are most needed for surface durability, while the first zone uses lighter small materials, achieving high wear resistance without uniformly increasing the weight of the entire preform

Inventive Principle:

Principle #3Local quality

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 preform achieves uniform strength and density, enabling efficient metal infiltration and reducing production costs, while providing excellent wear resistance and strength at elevated temperatures, suitable for applications like brake drums and aerospace components.

Implementation Method 1

A preform composed of ceramic particles and ceramic fibers with a multi-screw extruder for mixing, where ceramic fibers are randomly oriented and homogeneously dispersed

Methodology Applied

Scientific EffectMixing:

Implementation Method 2

The metal of the support element impregnates the preform by infiltrating through an outer surface of the preform to an inner surface of the preform

Methodology Applied

Scientific EffectInfiltration:

Data Source

PatentUS9145938B2Metal matrix composite

Publication Date: 2015.09.29 ROYAL BANK OF CANADA

AI summary

A metal matrix composite (MMC), such as a brake drum, includes a preform having ceramic particles and ceramic fibers and defining a plurality of voids. The metal matrix composite also includes a support element, such as a metal, disposed within the voids of the preform. The MMC has a wear surface defined by both the preform and the support element.