Synthesis of metal matrix composites by transient liquid consolidation

A method of forming a metal matrix composite, comprising the steps of:

• providing at least two layers of metallic matrix material selected from the group consisting of titanium aluminide alloys, superalloys, iron-aluminide and nickel-aluminide intermetallic alloys, and aluminum alloys;
• providing fibers for consolidation within said metallic matrix material;
• providing at least one of said layers of metallic matrix material with grooves for positioning and holding said fibers;
• providing a transient liquid diffusion bonding agent selected from the group of materials consisting of Ag, Cu, Al, Ti-Cu-Ni, Ag-Al, and Cu-Al for titanium aluminide matrix materials;
• B, Si, P, and alloys thereof for superalloy, iron-aluminide, and nickel-aluminide matrix materials;
• and Zn, Mg, Zn-Al, and Mg-Al for aluminum alloy matrix materials;
• disposing said bonding agent and said fibers in said grooves between layers of said matrix material to form a layered structure;
• heating said layered structure to liquefy said bonding agent;
• wetting said fibers with said liquefied bonding agent;
• and
• isothermally solidifying said bonding agent upon interdiffusion with elements of said metallic matrix material to consolidate said fibers in said metal matrix.

A method of forming a metal matrix composite, comprising the steps of:

• providing layers of a metallic matrix material selected from the group of materials consisting of titanium aluminide alloys, superalloys, iron-aluminide and nickel-aluminide intermetallic alloys, and aluminum alloys;
• providing fibers for consolidation within said layers of matrix material;
• providing a powdered transient liquid diffusion bonding agent selected from the group of materials consisting of Ag, Cu, Al, Ti-Cu-Ni, Ag-Al, and Cu-Al for titanium aluminide matrix materials;
• B, Si, P, and alloys thereof for superalloy, iron-aluminide, and nickel-aluminide matrix materials;
• and Zn, Mg, Zn-Al, and Mg-Al for aluminum alloy matrix materials;
• blending said powdered bonding agent with a powdered filler material to form a blended powder;
• disposing said fibers and blended powder between layers of said matrix material to form a layered structure;
• heating said layered structure to liquefy said bonding agent;
• infiltrating said fibers and said powdered filler material with said liquefied bonding agent;
• forming a bonding alloy by interdiffusion of elements of said bonding agent and said metallic matrix material;
• and
• isothermally solidifying said bonding alloy to consolidate said fibers.