Chemically bonded amorphous interface between phases in carbon fiber and steel composite
AssigneeToyota Motor Engineering & Manufacturing North America, Inc.
InventorsMichael Paul Rowe, Nikhilendra Singh
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Abstract
Carbon fiber reinforced steel matrix composites have carbon fiber impregnated in the steel matrix and chemically bonded to the steel. Chemical bonding is shown by the presence of a unique amorphous carbon layer at the carbon fiber/steel interface, and by canting of steel crystal edges adjacent to the interface. Methods for forming carbon fiber reinforce steel composites include sintering steel nanoparticles around a reinforcing carbon fiber structure, thereby chemically bonding a sintered steel matrix to the carbon fiber. This unique bonding likely contributes to enhanced strength of the composite, in comparison to metal matrix composites formed by other methods.
Claims20
A composite material comprising:
- a continuous steel matrix of sintered steel nanoparticles;
- at least one reinforcing carbon fiber component that is at least partially encapsulated within the continuous steel matrix;
- and
- an interface region disposed between the continuous steel matrix and a surface of the at least one reinforcing carbon fiber component, the interface region comprising an amorphous carbon layer.
A composite material comprising:
- at least one reinforcing carbon fiber component;
- a continuous steel matrix, of sintered steel nanoparticles, disposed around the at least one carbon fiber component;
- and
- an interface region disposed between the continuous steel matrix and a surface of the at least one reinforcing carbon fiber component, the interface region comprising an amorphous carbon layer.
A method for making a composite material, the method comprising:
- providing steel nanoparticles;
- combining the steel nanoparticles with a reinforcing carbon fiber component to produce an unannealed combination;
- and
- sintering the steel nanoparticles to convert the steel nanoparticles to a continuous steel matrix, and to form an interface between the continuous steel matrix and the reinforcing carbon fiber component, the interface comprising an amorphous carbon layer chemically bonding a surface of the reinforced carbon fiber component with the continuous steel matrix.
Dependencies are inferred from the claim text.