International Harvester Company

Keith R Karasek

Maurice F Amateau

Methods are disclosed for manufacturing graphite fiber metal matrix bearing materials using liquid metal pressure infiltration to achieve a high degree of intimate wetting, contact and infiltration of a compliant metal between and around graphite (carbon) fibers to provide graphite fiber metal matrix bearing material having a predetermined volume percentage of graphite fibers. In one embodiment, graphite fibers are wrapped around a removable cylindrical mandrel and the graphite fiber-wrapped mandrel is inserted into a mold and the mold which contains a liquid compliant metal, such as lead, to cause intimate wetting, contact and infiltration of the compliant metal between and around all of the graphite fibers. In another embodiment, graphite fibers in the form of a woven or non-woven mat are coated with a compliant metal, for example by submersing the mat in a molten bath of the compliant metal, to form a conformable graphite fiber metal foil, and a plurality of the foils are inserted in stacked relation, one above the other, onto a backing member disposed in a pressure mold. The pressure mold is filled with suitable graphite fiber compliant metal foils which are heated to a temperature above the solidus of the matrix metal and molded to the backing member causing a high degree of intimate wetting, contact and infiltration of the molten metal between the backing and among the foils.

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Villa Park, IL, United States of America

Keith R Karasek