Methods of forming fiber-reinforced composite parts and fiber-reinforced composite parts formed thereby

A method of forming a fiber-reinforced composite part comprising:

• extruding a hollow metal shape at an extrusion temperature and an extrusion force;
• forming and positioning a hollow fiber-reinforced preform within the hollow metal shape, wherein the fiber-reinforced preform is rigidly held in position with a counter-force to the extrusion force;
• extruding the hollow metal shape onto the fiber-reinforced preform while the fiber-reinforced preform is rigidly held in place;
• and
• applying consolidation pressure and heat to the hollow fiber-reinforced preform and curing the hollow fiber-reinforced preform, wherein the consolidation pressure and heat is applied to the hollow fiber-reinforced preform by thermal contraction of and heat from the hollow metal shape, respectively, cooling from the extrusion temperature to a temperature less than the extrusion temperature.

A method of forming a fiber-reinforced composite part comprising:

• extruding a hollow metal shape at an extrusion temperature and an extrusion force;
• forming and positioning a fiber-reinforced preform within the hollow metal shape, wherein the fiber-reinforced preform is rigidly held in position with a counter-force to the extrusion force;
• extruding the hollow metal shape onto the fiber-reinforced preform while the fiber-reinforced preform is rigidly held in position;
• and
• cooling the hollow metal shape extruded onto the fiber-reinforced preform from the extrusion temperature to a temperature less than the extrusion temperature, wherein the hollow metal shape thermally contracts and provides a consolidation pressure onto the fiber-reinforced preform during the cooling of the hollow metal shape from the extrusion temperature to the temperature less than the extrusion temperature, heat from the cooling of the hollow metal shape is conducted into the fiber-reinforced preform, and the thermal contraction and heat from the cooling hollow metal shape cure the fiber-reinforced preform.