Method for forming metal matrix composite bodies containing three-dimensionally interconnected co-matrices and products produced thereby

A method for forming a metal matrix composite body comprising:

• providing a substantially non-reactive three-dimensionally interconnected material;
• providing at least one substantially non-reactive filler within at least a portion of said three-dimensionally interconnected material;
• providing an infiltrating atmosphere which contacts said three-dimensionally interconnected material and said filler;
• providing a material comprising at least one material selected from the group consisting of an infiltration enhancer precursor and an infiltration enhancer to cause spontaneous infiltration of the matrix metal into said three-dimensionally interconnected material and said filler to occur, when said matrix metal is made molten;
• heating said matrix metal to render it molten;
• contacting molten matrix metal with said three-dimensionally interconnected material;
• and
• spontaneously infiltrating at least a portion of the three-dimensionally interconnected material containing said substantially non-reactive filler with said molten matrix metal.

A method for forming a metal matrix composite body comprising:

• providing a substantially non-reactive three-dimensionally interconnected material containing porosity;
• placing a material comprising at least one substantially non-reactive filler within at least a portion of said porosity;
• providing an infiltrating atmosphere which contacts said three-dimensionally interconnected material and said material comprising at least one filler material;
• providing at least one infiltration enhancer precursor to at least one of a matrix metal, said three-dimensionally interconnected material, and said at least one filler to cause spontaneous infiltration of the matrix metal into said three-dimensionally interconnected material and said filler to occur, when said matrix metal is made molten;
• heating said matrix metal to a temperature above the melting point of said matrix metal and below the melting point of said three-dimensionally interconnected material and the melting point of said material comprising at least one filler;
• contacting molten matrix metal with said three-dimensionally interconnected material and said material comprising at least one filler;
• and
• spontaneously infiltrating at least a portion of said three-dimensionally interconnected material and said material comprising at least one filler with molten matrix metal.