# US 2020/0399748 A1 · Metal Matrix Composite Comprising Nanotubes And Method Of Producing Same > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 2020/0399748 A1 - Document ID: US20200399748A1 - Status: Published application - Kind: A1 - Application number: 16/468,363 - Filed: 2017-12-29 - Published: 2020-12-24 - Earliest claimed: 2016-12-30 - Assignees: American Boronite Corporation - Applicants: American Boronite Corporation - Inventors: Pavel Bystricky; David S. Lashmore; Iva Kalus-Bystricky - Web page: https://patentgrep.com/patent/US20200399748A1 ## CPC - C22C 49/14: characterised by the fibres or filaments - C22C 47/04: by coating, e.g. with a protective or activated covering - C22C 47/08: by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould {(C22C47/16 takes precedence)} - C22C 47/14: by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments - C22C 49/02: characterised by the matrix material - D02G 3/04: Blended or other yarns or threads containing components made from different materials - D04C 1/02: made from particular materials - C22C 2026/002: {Carbon nanotubes} - D10B 2101/122: Nanocarbons - D10B 2101/14: Carbides; Nitrides; Silicides; Borides - D10B 2101/20: Metallic fibres - C22C: ALLOYS (treatment of alloys C21D, C22F) - D02G: CRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS - D04C: BRAIDING OR MANUFACTURE OF LACE, INCLUDING BOBBIN-NET OR CARBONISED LACE; BRAIDING MACHINES; BRAID; LACE (machines for making soles from strips of material A43D29/00; cane working B27J1/00) - D10B: INDEXING SCHEME ASSOCIATED WITH SUBLASSES OF SECTION D, RELATING TO TEXTILES ## Abstract A metal matrix composite comprising nanotubes; a method of producing the same; and a composition, for example a metal alloy, used in such composites and methods, are disclosed. A method for continuously infiltrating nanotube yarns, tapes or other nanotube preforms with metal alloys using a continuous process or a multistep process, which results in a metal matrix composite wire, cable, tape, sheet, tube, or other continuous shape, and the microstructure of these infiltrated yarns or fibers, are disclosed. The nanotube yarns comprise a multiplicity of spun nanotubes of carbon (CNT), boron nitride (BNNT), boron (BNT), or other types of nanotubes. The element that infiltrates the nanotube yarns or fibers can, for example, be alloyed with a concentration of one or more elements chosen such that the resulting alloy, in its molten state, will exhibit improved wetting of the nanotube material. ## Claims ### Claim 1 A metal matrix composite, the composite comprising: a metal; and a plurality of nanotube reinforcements present in a volume fraction of between about 10% by volume and about 90% by volume of the metal matrix composite; the metal matrix composite comprising a continuous structure comprising the metal and the plurality of nanotube reinforcements. ### Claim 2 (depends on 1) The metal matrix composite of claim 1, wherein the plurality of nanotube reinforcements comprise at least one of carbon nanotubes, boron nitride nanotubes, boron nanotubes, boron carbo-nitride nanotubes, silicon nanotubes, titanium oxide nanotubes and gallium nitride nanotubes. ### Claim 3 (depends on 1, 2) The metal matrix composite of claim 1 or 2, wherein the metal comprises at least one of copper, aluminum, silver, gold, tin, cobalt, nickel and iron. ### Claim 4 The metal matrix composite of any preceding claim, wherein the plurality of nanotube reinforcements is present in a volume fraction of between about 40% by volume and about 60% by volume of the metal matrix composite. ### Claim 5 The metal matrix composite of any preceding claim, wherein the metal comprises at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, cobalt, iron, silicon, ruthenium and zirconium. ### Claim 6 (depends on 5) The metal matrix composite of claim 5, wherein the metal comprises an alloy of a metal of at least about 90% purity and the at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, cobalt, iron, silicon, ruthenium and zirconium. ### Claim 7 (depends on 6) al matrix composite of claim 6, comprising between about 0.5% by weight and about 15% by weight of the at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, cobalt, iron, silicon, ruthenium and zirconium. ### Claim 8 (depends on 7) The metal matrix composite of claim 7, comprising between about 0.5% by weight and about 2% by weight of the at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, cobalt, iron, silicon, ruthenium and zirconium. ### Claim 9 The metal matrix composite of any preceding claim, wherein the plurality of nanotube reinforcements comprises a continuously spun nanotube yarn or a continuous nanotube tape, and wherein the metal comprises copper alloyed with at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, cobalt, iron, silicon, ruthenium and zirconium. ### Claim 10 (depends on 1, 2, 3, 4, 5, 6, 7, 9) The metal matrix composite of any of claims 1 through 7 and 9, wherein the continuously spun nanotube yarn or the continuous nanotube tape comprises a carbon nanotube continuous yarn or tape, and wherein the metal comprises a copper-titanium alloy comprising between about 0.1% by weight titanium and about 5% by weight titanium. ### Claim 11 (depends on 1, 2, 3, 4, 5, 6, 7, 8) The metal matrix composite of any of claims 1 through 8, wherein the plurality of nanotube reinforcements comprises a continuously spun nanotube yarn or a continuous nanotube tape, and wherein the metal comprises substantially pure aluminum. ### Claim 12 (depends on 9, 10, 11) The metal matrix composite of any of claims 9 through 11, wherein the continuously spun nanotube yarn or continuous nanotube tape is embedded in a matrix of the metal. ### Claim 13 The metal matrix composite of any preceding claim, the metal wetting the plurality of nanotube reinforcements. ### Claim 14 (depends on 13) The metal matrix composite of claim 13, wherein beads of the metal form a contact angle of less than 90 degrees with nanotubes of the plurality of nanotube reinforcements. ### Claim 15 The metal matrix composite of any preceding claim, comprising a first layer of metal coating the plurality of nanotube reinforcements, and a second layer of metal coating the first layer of metal. ### Claim 16 (depends on 15) The metal matrix composite of claim 15, wherein the first layer of metal comprises at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, copper, cobalt, iron, silicon, ruthenium and zirconium; and wherein the second layer of metal comprises a pure metal. ### Claim 17 (depends on 16) The metal matrix composite of claim 16, wherein the second layer of metal comprises copper of at least about 90% or greater purity, and wherein the plurality of nanotube reinforcements comprises a continuous carbon nanotube wire or yarn. ### Claim 18 The metal matrix composite of any preceding claim, wherein the continuous structure of the metal matrix composite comprises at least one of a continuous yarn, a continuous wire, a continuous cable, a sheet, and a preformed nanotube shape. ### Claim 19 (depends on 15, 16, 17) An interdiffused alloy composite resulting from heating of the metal matrix composite of any of claims 15 through 17, the interdiffused alloy composite comprising materials of the first layer of metal and of the second layer of metal infiltrated into the plurality of nanotube reinforcements. ### Claim 20 An interdiffused alloy composite resulting from heating of a composite structure comprising a metal including one or more of chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, copper, cobalt, iron, silicon, ruthenium and zirconium, coated onto a carbon structure, sufficiently to infiltrate the metal into the spaces surrounding the carbon structure. ### Claim 21 (depends on 20) The interdiffused alloy composite of claim 20, wherein the carbon structure comprises at least one of a nanotube yarn, a nanotube tape, a nanotube wire, a nanotube cable, and a graphene yarn. ### Claim 22 (depends on 21) The interdiffused alloy composite of claim 21, further comprising a carbon fiber. ### Claim 23 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22) A braided yarn or cable comprising the metal matrix composite of any of claims 1-18 or the interdiffused alloy composite of any of claims 19-22. ### Claim 24 (depends on 23) The braided yarn or cable of claim 23, further comprising insulation and at least one connector. ### Claim 25 A method of forming a metal matrix composite, the method comprising: combining a continuous nanotube structure with a metal to create an infiltrated metal matrix nanotube structure and heating the infiltrated metal matrix nanotube structure to a temperature exceeding a melting point of a metal of the infiltrated metal matrix nanotube structure, the heating comprising at least one of: (i) passing the infiltrated metal matrix nanotube structure through a heated die, at least a portion of which exceeds a melting point of a metal of the infiltrated metal matrix nanotube structure; (ii) heating the infiltrated metal matrix nanotube structure in a tube furnace; (iii) laser heating the infiltrated metal matrix nanotube structure; (iv) plasma heating the infiltrated metal matrix nanotube structure; or (v) resistive heating of the infiltrated metal matrix nanotube structure; the method being performed in a controlled atmosphere. ### Claim 26 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 25) The method of claim 25, the method comprising forming a metal matrix composite of any of claims 1-18 or the interdiffused alloy composite of any of claims 19-22. ### Claim 27 (depends on 25, 26) The method claim 25 or 26, the method comprising passing the continuous nanotube structure via pulleys through the molten metal. ### Claim 28 (depends on 25, 26, 27) The method of any of claims 25 through 27, wherein the continuous nanotube structure comprises at least one of a nanotube yarn, a nanotube wire, a nanotube cable, a nanotube sheet, and a preformed nanotube shape. ### Claim 29 (depends on 25, 26, 27, 28) A method of any of claims 25-28, further comprising braiding the metal matrix composite to form at least a portion of a hollow tube, a braided yarn or a cable. ### Claim 30 A method of forming a metal matrix composite, the method comprising: surrounding a continuous nanotube structure with a metal structure; and in a controlled atmosphere, heating the surrounded continuous nanotube structure to a temperature exceeding a melting point of a metal of the metal structure or a temperature high enough to cause interdiffusion of a metal of the metal structure and to fill space around the nanotubes, the heating comprising at least one of: (i) passing the surrounded continuous nanotube structure through a heated die, at least a portion of which exceeds a melting point of a metal of the metal structure; (ii) heating the surrounded continuous nanotube structure in a tube furnace; (iii) laser heating the surrounded continuous nanotube structure; (iv) plasma heating the surrounded continuous nanotube structure; or (v) resistive heating of the surrounded continuous nanotube structure. ### Claim 31 (depends on 30) The method of claim 30, comprising surrounding the continuous nanotube structure with the metal structure, prior to heating, by at least one of: (1) electrochemical coating of the continuous nanotube structure with the metal structure using metal from aqueous electrolytes, organic electrolytes or fused salts; and (2) sputtering an alloy composition onto the continuous nanotube structure; or (3) plasma coating; or (4) powder infiltration or (5) physical vapor deposition coating. ### Claim 32 (depends on 30, 31) The method of claim 30 or 31, wherein the continuous nanotube structure comprises at least one of: a nanotube yarn, a nanotube wire, a nanotube sheet, a nanotube cable, and a preformed nanotube shape. ### Claim 33 (depends on 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 30, 31, 32) The method of any of claims 30-32, the method comprising forming a metal matrix composite of any of claims 1-18 or the interdiffused alloy composite of any of claims 19-22. ### Claim 34 (depends on 29, 30, 31, 32, 33) The method of any of claims 29-33, further comprising braiding the metal matrix composite to form at least a portion of a hollow tube, a braided yarn or a cable. ### Claim 35 (depends on 25, 26, 27, 28, 29, 30, 31, 32, 33, 34) A method according to any of claims 25 through 34, comprising forming the metal matrix composite with a slight excess of a metal to produce a pre-impregnated structure; consolidating a plurality of the pre-impregnated structures into a net shape; and heating the net shape, thereby creating a reinforced metal matrix composition structure. ### Claim 36 (depends on 35) The method of claim 35, wherein a plurality of nanotubes of the reinforced metal matrix composition structure are aligned. ### Claim 37 (depends on 35, 36) The method of claim 35 or 36, wherein the reinforced metal matrix composite structure comprises at least one of carbon nanotubes, boron nitride nanotubes, boron nanotubes, boron carbo-nitride nanotubes, silicon nanotubes, titanium oxide nanotubes and gallium nitride nanotubes. ### Claim 38 A method of forming a metal matrix composite, the method comprising: mixing (i) a molten metal, (ii) a carbon source; and (iii) at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, cobalt, iron, silicon, ruthenium and zirconium; thereby producing the metal matrix composite. ### Claim 39 (depends on 38) The method of claim 38, wherein the carbon source comprises at least one of carbon black, graphene, carbon nanotubes and carbon fiber. ### Claim 40 (depends on 38, 39) The method of claim 38 or 39, wherein the metal comprises at least one of copper, aluminum, silver and gold of a purity greater than about 90%. ### Claim 41 (depends on 38, 39, 40) The method of any of claims 38 through 40, comprising mixing the molten metal and the carbon source with between about 0.5% by weight and about 15% by weight of the at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, cobalt, iron, silicon, ruthenium and zirconium. ### Claim 42 (depends on 38, 39, 40, 41) The method of any of claims 38 through 41, comprising mixing the molten metal and the carbon source with between about 0.5% by weight and about 2% by weight of the at least one of: chromium, scandium, titanium, vanadium, hafnium, niobium, aluminum, tungsten, molybdenum, tantalum, nickel, cobalt, iron, silicon, ruthenium and zirconium.