Low thermal stress engineered metal structures

An engineered multi-phase composite which includes a high thermal conductivity phase and a metal phase;

• said high thermal conductivity phase constitutes over 20 wt.% of said engineered multi-phase composite;
• said high thermal conductivity phase is segregated into isolated pockets forming a discontinuous phase in said engineered multi-phase composite;
• said metal phase is a continuous phase in said engineered multi-phase composite;
• said engineered multi-phase composite has a thermal conductivity that is at least 20% greater than a thermal conductivity of said metal that forms said metal phase;
• said engineered multi-phase composite has a density that is at least 20% less than a density of said metal that forms said metal phase;
• said high thermal conductivity phase includes filler;
• said filler including one or more materials selected from the group consisting of a) hexagonal boron nitride, b) cubic boron nitride, c) boron nitride nanotubes, d) graphene, e) diamond, f) graphite, g) carbon or carbon nanotubes, h) SiC, g) alumina ceramic, h) zirconia ceramic, i) boron oxide ceramic, j) silicon nitride ceramic, k) sialon, 1) SSiC, m) LPS-SiC, n) RBSiC, o) NSiC, p) SiSiC, q) RSiC, r) TiC, s) ZrC, t) Ti2SiC, u) A1N, v) B4C, w) TiB2C, and x) MAX-phase material, wherein said MAX-phase material is layered, hexagonal carbides and nitrides which have the general formula of Mn+1AXn where n = 1 to 4, and wherein M is an early transition metal selected from the group consisting of chromium, hafnium, molybdenum, niobium, scandium, titanium, vanadium and zirconium, and wherein A is a metal selected from the group consisting of aluminum, arsenic, cadmium, copper, gallium, gadolinium, germanium, indium, lead, sulfur, silicon, tin, thallium, vanadium, and zinc, and wherein X is carbon or nitrogen;
• said metal phase having a melting point of at least 1000° C.;
• said metal phase includes one or more metals selected from the group consisting of titanium, niobium, nickel, iron, cobalt, molybdenum, tantalum, hafnium, zirconium, rhenium, and tungsten.

A method for forming an engineered multi-phase composite comprising

• a. providing a metal material to form a metal phase
• b. providing a high thermal conductivity material wherein
• i. said high thermal conductivity material has at least 40% higher thermal conductivity than said metal phase;
• and,
• ii. said high thermal conductivity material contains a CTE material;
• and,
• c. consolidating said high thermal conductivity material with said metal material to form said engineered multi-phase composite,
• wherein the high conductivity and CTE materials may be combined into a composite particle,
• wherein said phase form by said high thermal conductivity material is discontinuous in said engineered multi-phase composite, said metal phase is continuous phase in said engineered multi-phase composite, said engineered multi-phase composite has a CTE that is at least 10% less than the CTE of said metal forming said metal phase, said engineered multi-phase composite has a thermal conductivity that is at least 20% greater than a thermal conductivity of said metal that forms said metal phase, and
• wherein said engineered multi-phase composite is formed into a thermal managing part, said thermal managing part is attached to an insulating structure or layer.