Toyota Jidosha Kabushiki Kaisha

Toray Industries, Inc.

Art Metal Manufacturing Co. Ltd.

Art Kinzoku Kogyo Kabushiki Kaisha

Tadashi Donomoto

Atsuo Tanaka

Yoshiaki Tatematsu

Mototsugu Koyama

Yoshio Fuwa

Nobuhiro Miura

Tatsuo Sakakibara

Kiyoshi Funatani

Masahiro Kubo

Tetsuyuki Kyono

Shinji Katou

Joji Miyake

Masaaki Nagaoka

Atsushi Kitamura

Masahiro Okada

Tsugio Akai

Light alloy articles comprising a body of light alloy having a composite layer of heat-resistant fibers and light alloy and bonded to said body, and a surface layer of heat-resisting alloy sprayed onto said composite layer exhibit improved integrity and heat resistance when the heat-resisting alloy is plasma sprayed onto one surface of a preform of fibers and the light alloy is then cast to the opposite surface of the preform such that an interfacial layer is defined between the composite layer and the surface layer in which the fibers and light alloy are integrally incorporated with the heat-resisting alloy.

Heat resistant light alloy articles and method of manufacturing same

A method for making a composite material. Porous reinforcing material such as fiber material is charged into a container which has an opening; then substantially all of the atmospheric air in the container and in the interstices of the reinforcing material is replaced by substantially pure oxygen; and then molten matrix metal is admitted into the container through the opening so as to infiltrate into the interstices of the reinforcing material. During this infiltration the oxygen within the container and in these interstices is absorbed by an oxidization reaction, and thus substantially all the gas present within the interstices of the reinforcing material is disposed of, thus not hampering the good infiltration of the molten matrix metal into the reinforcing material. Thus a high quality composite material is formed. The oxidization reaction may either be with the molten matrix metal itself, or with a getter element provided within the container.

Method for making composite material using oxygen

Light alloy articles comprising a body of light alloy having a composite fiber/light alloy layer, a sprayed heat-resistant alloy layer, and a sprayed ceramic base layer formed on the body in this sequence exhibit improved heat resistance and insulation and are very useful in the manufacture of internal combustion engine pistons. A method for producing such a coated light alloy article by spraying is also provided.

Heat resisting and insulating light alloy articles and method of

An alloy is made of a first material and a second material which has a substantially lower melting point than the first material, by (a) forming from the first material a body which has multiple fine interstices; (b) pouring the second material in the molten state around the body formed from the first material; and (c) allowing the resultant mass to cool. Thus, in the parts of the resultant mass in which the body formed from the first material was originally present, an alloy mass comprising the first metal and the second material alloyed together is made. Optionally, the body made from the first material may be preheated, desirably to a temperature higher than the melting point of the second material; and optionally the molten second material may be pressurized so as to enter into the interstices of the body. The first material may desirably be, for example, tungsten, cobalt, chromium, titanium, iron, nickel, silicon, manganese, copper, niobium, tantalum, vanadium, gold, silver, aluminum, molybdenum, zirconium, or zinc; and the second material may desirably be, for example, aluminum, magnesium, copper, lead, tin, or zinc.

Method for alloying substances

Composite material and process for its production

A method for forming metal base composite use a retainer made of water soluble salt with a high melting point. Molten metal and a reinforcement are compounded in the retainer and then solidified. After solidification the retainer is dissolved away by water.

Method for forming metal base composite

A composite material is manufactured from a formed mass of reinforcing material and matrix metal by introducing the reinforcing material mass into a pressure chamber and holding it there, introducing molten matrix metal into the pressure chamber so as to surround the reinforcing material mass, moving the reinforcing material mass from the pressure chamber into a casting chamber of substantially smaller volume than the pressure chamber while it is still being surrounded by molten matrix metal, and then allowing the molten matrix metal to solidify while applying pressure. If the reinforcing material mass is preheated before being put into the pressure chamber, it can be kept away from the walls of the pressure chamber until after the molten matrix metal has been poured into the pressure chamber and thus will not lose heat to them; and, since the casting chamber can quite tightly conform to the size and shape of the reinforcing material mass, little extra matrix metal needs to be solidified around the reinforcing material mass. Accordingly the resulting composite material can be easily isolated without the need for much post machining.

Method and apparatus for manufacturing composite material using pressure

First a reinforcing material mass is formed from a quantity of reinforcing material by binding it together with inorganic binder, and then this reinforcing material mass is compounded with matrix metal to form a composite material mass. Then the composite material mass is heated up so that the proportion of the matrix metal thereof which is in the liquid phase is at least 40%, and while still hot it is subjected to a plastic processing process to form the composite material object.

Method for making composite material object by plastic processing

An engine piston is formed with a top crown surface and a top ring groove. An upper annular land surface is defined between the top ring groove and the edge of the top crown surface. The upper annular land surface and the side walls of the top ring groove are defined by a part of the piston which is formed of a matrix metal reinforced with inorganic fibers. The proportion of the inorganic fibers by volume in the reinforced part of the piston may optionally be approximately between 2% and 10%. A method for making such a piston includes forming a mass of inorganic fiber into an approximately cylindrical shape, placing it against the edge of the bottom surface of a hollow cylindrical lower mold, pouring molten metal into the lower mold to cover the inorganic fiber, sliding an upper mold into the lower mold and pressurizing the molten metal to infiltrate it between the inorganic fibers until complete solidification, removing the solidified mass of metal and entrapped inorganic fiber from the lower mold, and machining it to form a piston, with the fiber reinforced parts defining the upper ring groove side walls and the upper land surface.

Piston with local inorganic fiber reinforcement and method of making the

A composite material is made from a whisker body of silicon carbide whiskers containing not more than 5% by weight of non whisker particles of diameter greater than 150 microns, with a mass of matrix metal infiltrated into the interstices of the whisker body. The matrix metal is selected from the group consisting of aluminum, magnesium, tin, copper, lead, zinc, and their alloys. The bulk density of the silicon carbide whiskers is at least 0.07 gm/cm.sup.3. A method is also disclosed for making this composite material, in which first a quantity of silicon carbide whiskers containing not more than 5% by weight of non whisker particles of diameter greater than 150 microns is formed into a shaped mass with a compressive strength of at least 0.5 kg/cm.sup.2 and with a bulk density of at least 0.07 gm/cm.sup.3, and then this shaped mass is compounded with a quantity of the molten matrix metal by a pressure casting method. This formed mass of silicon carbide whiskers may be bound together by an inorganic binder, whicn may be silica, and whose volume percentage in the shaped mass of silicon carbide whiskers may desirably be less than about 25%.

Silicon carbide whisker composite material with low non whisker particle

A method of producing a composite material from porous reinforcing material and molten matrix metal. First the porous reinforcing material is heated up to a temperature substantially above melting point of the matrix metal. Then the molten matrix metal is infiltrated into the porous structure of the reinforcing material under a substantial pressure. Then the combination of the reinforcing material and the matrix metal infiltrated thereinto is cooled down to a temperature below the melting point of the matrix metal, while maintaining the abovementioned substantial pressure. Optionally, the reinforcing material may be charged into a case; and, again optionally, the case may have one opening only, and a vacant space may be left between another part of the case and the reinforcing material charged in the case, with the reinforcing material interrupting communication between the opening and the vacant space. The case can be made of stainless steel, or of a refractory material such as porous brick. Possible materials for the reinforcing material include fibers of alumina, carbon, boron, or stainless steel; and possible materials for the matrix metal include aluminum and magnesium.

Method for production of composite material using preheating of

First a quantity of reinforcing material is formed into a shaped mass bound together by an inorganic binder. Next, this shaped mass is compounded with a quantity of a molten matrix metal by a pressure casting method. The molten matrix metal includes a quantity of a certain element with a strong tendency to become oxidized, and the inorganic binder includes a metallic oxide which, when brought into contact at high temperature with this certain element, is reduced thereby in an exothermic reaction. Thus, during the pressure casting, extra heat is produced as the certain element reduces the metallic oxide, and this aids good penetration of the matrix metal into the interstices of the reinforcing material. The metal remaining from the oxide is dispersed in the matrix metal. This metallic oxide may be silica, zirconia, chromium oxide, yttrium oxide, cerium oxide, ferric oxide, zirconium silicate, antimony oxide, or a mixture thereof; and the certain element may be lithium, calcium, magnesium, aluminum, beryllium, titanium, zirconium, or a mixture thereof.

Composite material manufacturing method exothermically reducing metallic

A fiber reinforced metal type composite material. The reinforcing fiber is alumina fiber formed from at least 80% by weight alumina and the remainder silica, with the alpha alumina content of the alumina approximately between about 5% and about 60% by weight of the total amount of alumina. The matrix metal is selected from the group consisting of aluminum, magnesium, and their alloys. Thereby mechanical strength, resistance to wear, and workability of the fiber reinforced metal type composite material are good, and also friction wear on elements which frictionally rub against and mate with components made of the fiber reinforced metal type composite material is low.

Composite material including alpha alumina fibers

A fiber reinforced metal type composite material is composed essentially of a mass of reinforcing fibers intimately compounded with a matrix metal. The reinforcing fibers are either alumina fibers, carbon fibers, or a mixture thereof. The matrix metal is an alloy consisting essentially of between about 0.5% and about 4.5% magnesium, less than about 0.2% each of copper and titanium, less than about 0.5% each of silicon, zinc, iron, and manganese, and the remainder aluminum. Preferably, the amount of magnesium is between about 0.7% and about 4.5%, and even more preferably it is between about 1.0% and about 4.0%.

Fiber reinforced metal type composite material with high purity aluminum

A method for manufacturing a composite material which includes carbon material in a matrix metal by first applying tetraisopropyltitanate to the carbon material so as to wet it, next drying the carbon material which is wetted with the tetraisopropyltitanate, and then combining the carbon material with the matrix metal. This drying may be done by heating up the carbon material which is wetted with the tetraisopropyltitanate to a temperature of 50.degree. C. to 200.degree. C. in the atmosphere. The tetraisopropyltitanate may be dissolved in ethanol when it is being applied to the carbon material. The matrix metal may be a metal selected from the group consisting of aluminum, magnesium, aluminum alloy, and magnesium alloy.

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Toyota, Japan

Tadashi Donomoto