Metal matrix composite tape fabrication, braiding, and consolidation to form metal matrix composite parts
AssigneeThe Boeing Company
InventorAntonio Carlos Rufin
Life of this patent
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Abstract
Systems and methods are provided for braiding Metal Matrix composite (MMC) tape. One method includes drawing multiple lanes of MMC tape, comprising a matrix of metal reinforced by fibers, from bobbins arranged around a mandrel. The method also includes braiding the multiple lanes to form a preform at the mandrel for an MMC part and consolidating the preform via application of heat and pressure.
Claims20
A process of forming a Metal Matrix Composite (MMC) tape configured for heating and forming a preform, the process comprising:
- forming a lane of MMC tape, by spraying a molten metal within a plasma and combining the molten metal with a metal backing into a matrix of metal;
- and
- reinforcing the lane by disposing, within the matrix of metal between the metal backing and the plasma, fibers extending along a length of the lane.
A process of forming a Metal Matrix Composite (MMC) tape, the process comprising:
- feeding fibers from spools into a chamber;
- feeding a metal backing into the chamber;
- forming a precursor tape by pressing, in the chamber, the fibers onto the metal backing;
- forming a metal matrix by encapsulating the fibers onto the metal backing by spraying, in the chamber, the precursor tape with a plasma comprising a molten metal;
- solidifying the molten metal;
- and
- after solidifying the molten metal, consolidating the MMC tape by pressing the tape with additional rollers.
A process of forming a Metal Matrix Composite (MMC) tape, the process comprising:
- mounting on spools, fibers comprising continuous strands comprising:
- carbon, graphite, silicon carbide, silicon nitride, boron, aluminum oxide, ceramic oxides, or other ceramic or refractory fibers, or continuous individual monofilament fibers comprising:
- boron, silicon carbide, silicon nitride, aluminum oxide, or other ceramic or refractory materials, with a diameter of the fibers being between one thousandth of an inch and five thousandths of an inch;
- coating the fibers, before entering a chamber, with a coating promoting a wettability and limiting an adverse interaction of the fibers with a metal matrix during a consolidation;
- feeding the fibers from the spools through a collimator and into the chamber;
- feeding a metal backing comprising a foil comprising:
- an aluminum, a titanium, a copper, a magnesium, a beryllium, or a nickel, alloy, comprising a width in a range of one-eighth to one-quarter of an inch and a range of one thousandth of an inch and five thousandths of an inch, into the chamber;
- forming a precursor tape by pressing, using rollers comprising temperature sensors in the chamber, the fibers onto the metal backing and thereby partly deforming the metal backing to become physically integral with the fibers;
- forming a molten metal by heating a metal powder to a melting temperature of the metal powder;
- forming a matrix of metal by encapsulating the fibers onto the metal backing by spraying, in the chamber, the precursor tape with a plasma comprising the molten metal, wherein the chamber is either a vacuum or filled with an inert gas for controlling chemical reactions occurring during spraying the plasma in the chamber;
- solidifying the molten metal;
- and
- after solidifying the molten metal, consolidating the MMC tape by pressing the tape with additional rollers.
Dependencies are inferred from the claim text.