Reactive matrix infiltration of powder preforms

A method, comprising:

• contacting a binder jet preform comprising reinforcement material particles and a binder with an infiltrant comprising an Al—Ce alloy, the reinforcement material particles comprising a metal alloy;
• heating the binder jet preform to a temperature greater than a decomposition temperature of the binder, wherein the temperature is less than a melting point of the infiltrant, thereby decomposing the binder and producing a preform having spaces between the reinforcement material particles;
• increasing the temperature to a temperature greater than a melting point of the infiltrant, whereby the infiltrant fills the spaces between the reinforcement material particles by capillary action and reacts with the reinforcement material particles to produce a form;
• and
• cooling the form to a temperature less than a melting point of the infiltrant.

A composite material form, comprising:

• a plurality of reinforcement material particles comprising a metal alloy or a ceramic;
• a matrix material at least partially filling spaces between the reinforcement material particles, the matrix material comprising Al and Ce;
• and
• at least one intermetallic phase surrounding one or more of the reinforcement material particles, the intermetallic phase including one or more elements of the reinforcement material particles, Al, and Ce.