A method is disclosed for forming extrudate filament, which consist essentially of fiber, organic binder, and metal and/or ceramic. The extrudate filament can be spooled, or used to form preforms, and/or assemblages of preforms. In further methods, the extrudate filament and/or preforms can be used to fabricate fiber-reinforced metal-matrix or ceramic-matrix or metal and ceramic matrix composite parts, which consist essentially of fiber in a matrix of metal, or ceramic, or metal and ceramic, respectively.

A structured three-phase composite which include a metal phase, a ceramic phase, and a gas phase that are arranged to create a composite having low thermal conductivity, having controlled stiffness, and a CTE to reduce thermal stresses in the composite when exposed to cyclic thermal loads. The structured three-phase composite is useful for use in structures such as, but not limited to, heat shields, cryotanks, high speed engine ducts, exhaust-impinged structures, and high speed and reentry aeroshells.

A structured three-phase composite which include a metal phase, a ceramic phase, and a gas phase that are arranged to create a composite having low thermal conductivity, having controlled stiffness, and a CTE to reduce thermal stresses in the composite when exposed to cyclic thermal loads. The structured three-phase composite is useful for use in structures such as, but not limited to, heat shields, cryotanks, high speed engine ducts, exhaust-impinged structures, and high speed and reentry aeroshells.

A metal microparticle coated with metal nanoparticles is disclosed. Some variations provide a material comprising a plurality of microparticles (1 micron to 1 millimeter) containing a metal or metal alloy and coated with a plurality of nanoparticles (less than 1 micron) or nanoparticle inclusions (potentially larger than 1 micron). The invention eliminates non-uniform distribution of sintering aids by attaching them directly to the surface of the microparticles. No method is previously known to exist which can assemble nanoparticle inclusions onto the surface of a metal microparticle. Some variations provide a solid article comprising a material with a metal or metal alloy microparticles coated with metal hydride or metal alloy nanoparticles, wherein the nanoparticles form continuous or periodic inclusions at or near grain boundaries within the microparticles.

A metal microparticle coated with metal nanoparticles is disclosed. Some variations provide a material comprising a plurality of microparticles (1 micron to 1 millimeter) containing a metal or metal alloy and coated with a plurality of nanoparticles (less than 1 micron) or nanoparticle inclusions (potentially larger than 1 micron). The invention eliminates non-uniform distribution of sintering aids by attaching them directly to the surface of the microparticles. No method is previously known to exist which can assemble nanoparticle inclusions onto the surface of a metal microparticle. Some variations provide a solid article comprising a material with a metal or metal alloy microparticles coated with metal hydride or metal alloy nanoparticles, wherein the nanoparticles form continuous or periodic inclusions at or near grain boundaries within the microparticles.

A syntactic metal foam composite that is substantially fully dense except for syntactic porosity is formed from a mixture of ceramic microballoons and matrix forming metal. The ceramic microballoons have a uniaxial crush strength and a much higher omniaxial crush strength. The mixture is continuously constrained while it is consolidated. The constraining force is less than the omniaxial crush strength. The substantially fully dense syntactic metal foam composite is then constrained and deformation worked at a substantially constant volume. The deformation working is typically performed at a yield strength that is adjusted by way of selecting a working temperature at which the yield strength is approximately less than the omniaxial crush strength of the included ceramic microballoons. This deformation causes at least work hardening and grain refinement in the matrix metal.

A syntactic metal foam composite that is substantially fully dense except for syntactic porosity is formed from a mixture of ceramic microballoons and matrix forming metal. The ceramic microballoons have a uniaxial crush strength and a much higher omniaxial crush strength. The mixture is continuously constrained while it is consolidated. The constraining force is less than the omniaxial crush strength. The substantially fully dense syntactic metal foam composite is then constrained and deformation worked at a substantially constant volume. The deformation working is typically performed at a yield strength that is adjusted by way of selecting a working temperature at which the yield strength is approximately less than the omniaxial crush strength of the included ceramic microballoons. This deformation causes at least work hardening and grain refinement in the matrix metal.

A three-dimensional object comprises stacked substrate layers infiltrated by a hardened material comprising engineered powder that is transformed into a substance that flows and subsequently hardens into the hardened material in a spatial pattern that infiltrates positive regions, and does not infiltrate negative regions, in the substrate layers. The powder may be emulsion aggregation powder, chemically-produced toner powder, or a combination. It may be a thermoplastic or thermosettable polymer and may include nylon, elastomers, polyolefins, polyethylene, polyether ether ketone, polyimide, polyetherimide, polyphenylene sulfide, polystyrene, polypropylene, polymethyl methacrylate, and polyaryletherketone, or a combination. The powder particles may have a pre-specified controlled shape and/or a non-homogenous composition. Surface treatments and/or additives may be used to control powder flow and charge distribution. Each substrate layer may be a sheet-like structure comprising fibers held together by binder. The binder may include sodium silicate.

A structured three-phase composite which include a metal phase, a ceramic phase, and a gas phase that are arranged to create a composite having low thermal conductivity, having controlled stiffness, and a CTE to reduce thermal stresses in the composite when exposed to cyclic thermal loads. The structured three-phase composite is useful for use in structures such as, but not limited to, heat shields, cryotanks, high speed engine ducts, exhaust-impinged structures, and high speed and reentry aeroshells.

A structured three-phase composite which include a metal phase, a ceramic phase, and a gas phase that are arranged to create a composite having low thermal conductivity, having controlled stiffness, and a CTE to reduce thermal stresses in the composite when exposed to cyclic thermal loads. The structured three-phase composite is useful for use in structures such as, but not limited to, heat shields, cryotanks, high speed engine ducts, exhaust-impinged structures, and high speed and reentry aeroshells.