Method of forming metal matrix composite bodies having complex shapes by a self-generated vacuum process, and products produced therefrom

A method of making a metal matrix composite body comprising the steps of:

• providing an impermeable container having at least one opening therein;
• filling said impermeable container with a solid matrix metal and a filler;
• sealing said impermeable container;
• and
• heating said impermeable container to render said matrix metal molten and to create a self-generated vacuum within said impermeable container, thereby forming a metal matrix composite having a shape conforming at least in part to the interior shape of the impermeable container, said sealing comprising an extrinsic seal comprising at least one glassy material.

A method of making a shaped metal matrix composite body comprising the steps of:

• forming a reaction system comprising a matrix metal, a reactive atmosphere, an impermeable container, a permeable mass comprising at least one material selected from the group consisting of a loose mass of filler and a preform of filler, and a barrier means which contacts at least a portion of at least one surface of said permeable mass and which is at least partially spaced from said matrix metal for establishing at least one surface of said shaped metal matrix composite body;
• sealing the reaction system from an ambient atmosphere which is external to said reaction system so as to achieve a net pressure differential between said reactive atmosphere and said ambient atmosphere, the sealing comprising an extrinsic seal comprising at least one glassy material;
• and
• heating the sealed reaction system to render the matrix metal molten and to create a self-generated vacuum within said impermeable container and at least partially infiltrating said permeable mass with said molten matrix metal up to said barrier means by utilizing said net pressure differential, thereby forming said shaped metal matrix composite body having said at least one surface established by said barrier means.