Ultrasonic energy system and method including a ceramic horn

A method of making a continuous composite wire, the method comprising:

• providing a contained volume of molten metal matrix material having a temperature of at least 600° C.;
• immersing at least one tow comprising a plurality of substantially continuous fibers into the contained volume of molten metal matrix material;
• imparting ultrasonic energy with a horn connected to an ultrasonic energy source to cause vibration of at least a portion of the contained volume of molten metal matrix material to permit at least a portion of the molten metal matrix material to infiltrate into the plurality of fibers such that an infiltrated plurality of fibers is provided, wherein the horn is ceramic, wherein the horn is defined by a trailing end and a leading end further defining a horn length extending there-between, wherein the horn length is other than one half a wavelength of the ultrasonic energy source, and further wherein the ultrasonic energy source includes a titanium mounting component consisting of a waveguide for securing the trailing end of the horn in an interference fit with the mounting component such that a junction point between the waveguide and the trailing end of the horn is at a vibrational node of the waveguide, the horn being secured to the mounting component by hoop stresses in the titanium mounting component produced at the temperature of the molten metal matrix material;
• and
• withdrawing the infiltrated plurality of fibers from the contained volume of molten metal matrix material.