Aluminum-boron nitride nanotube composites and methods of making thereof are disclosed herein. In at least one specific embodiment, the method can include: at least partially coating boron nitride nanotubes with aluminum to make an aluminum-boron nitride nanotube layered structure, where the at least partially coating is performed by sputter deposition, and where the boron nitride nanotubes have a length of about 100 μm to about 300 μm; sintering the aluminum-boron nitride nanotube layered structure to make an aluminum-boron nitride nanotube pellet, where the sintering is performed by spark plasma sintering; and rolling the aluminum-boron nitride nanotube pellet to make the aluminum-boron nitride nanotube composite.

Aluminum-boron nitride nanotube composites and methods of making thereof are disclosed herein. In at least one specific embodiment, the method can include: at least partially coating boron nitride nanotubes with aluminum to make an aluminum-boron nitride nanotube layered structure, where the at least partially coating is performed by sputter deposition, and where the boron nitride nanotubes have a length of about 100 μm to about 300 μm; sintering the aluminum-boron nitride nanotube layered structure to make an aluminum-boron nitride nanotube pellet, where the sintering is performed by spark plasma sintering; and rolling the aluminum-boron nitride nanotube pellet to make the aluminum-boron nitride nanotube composite.

A method of forming a metal matrix composite component comprises: providing a body defining a mould cavity; covering a first surface of the mould cavity with a first reinforcement material; restraining the first reinforcement material relative to the body to restrict movement of the first reinforcement material in the mould cavity; adding a second reinforcement material to the mould cavity, the second reinforcement material being in contact with the first reinforcement material; adding molten metal to the mould cavity such that the first reinforcement material and the second reinforcement material become embedded in a continuous metal matrix when the molten metal solidifies.

A method for forming a reinforced metallic structure includes providing a tool having a formation surface corresponding to a desired structure shape of the reinforced metallic structure. The method also includes positioning a plurality of fibers on the formation surface of the tool. The method also includes depositing a layer of material on the plurality of fibers using a cold-spray technique. The method also includes removing the layer of material with the plurality of fibers from the tool to create the reinforced metallic structure.

A method for forming a reinforced metallic structure includes providing a tool having a formation surface corresponding to a desired structure shape of the reinforced metallic structure. The method also includes positioning a plurality of fibers on the formation surface of the tool. The method also includes depositing a layer of material on the plurality of fibers using a cold-spray technique. The method also includes removing the layer of material with the plurality of fibers from the tool to create the reinforced metallic structure.

A ceramic matrix composite (CMC) is formed using a three-dimensional (3-D) woven preform by removing the set of sacrificial fibers from the 3-D woven preform and allowing a metal or metal alloy infiltrate the 3-D woven preform. The 3-D woven preform is formed by a method that includes providing a woven layer comprising a first set of ceramic fibers oriented in a first (x) direction woven with a second set of ceramic fibers oriented in a second (y) direction; stacking a plurality of woven layers on top of each other, said woven layers providing a two-dimensional (2-D) preform; weaving a set of sacrificial fibers in a third (z) direction with the 2-D preform, said weaving providing the 3-D woven preform; and shaping the 3-D woven preform into a predetermined shape.

A method for manufacturing a turbine engine vane a root connected to a blade extending in a longitudinal direction includes the steps of providing a root; and providing mold with a first cavity and a second cavity that together define a recess in which the vane is formed. The recess includes a first space in which the blade is formed and a second space in which the root (1), c) is formed. The method further includes the steps of providing aluminum strips; positioning a fibrous reinforcement; arranging the vane root in the second space; and injecting a foam comprising aluminum or injecting an aluminum alloy into the first space of the recess of the mold such that the foam impregnates the fibrous reinforcement.

A method for manufacturing a turbine engine vane a root connected to a blade extending in a longitudinal direction includes the steps of providing a root; and providing mold with a first cavity and a second cavity that together define a recess in which the vane is formed. The recess includes a first space in which the blade is formed and a second space in which the root (1), c) is formed. The method further includes the steps of providing aluminum strips; positioning a fibrous reinforcement; arranging the vane root in the second space; and injecting a foam comprising aluminum or injecting an aluminum alloy into the first space of the recess of the mold such that the foam impregnates the fibrous reinforcement.

A method for forming a reinforced metallic structure includes providing a tool having a formation surface corresponding to a desired structure shape of the reinforced metallic structure. The method also includes positioning a plurality of fibers on the formation surface of the tool. The method also includes depositing a layer of material on the plurality of fibers using a cold-spray technique. The method also includes removing the layer of material with the plurality of fibers from the tool to create the reinforced metallic structure.

A method for the fabrication of architected 3D high entropy alloy structures includes deriving a 3D architecture based on at least one physical property of a high entropy alloy; preparing a fabrication powder including a mixture of two or more metallic powders of nearly equal quantities; arranging a first layer of the fabrication powder on a platform proximate to an energy source; directing energy provided by the energy source to one or more portions of the fabrication powder until portions thereof are sufficiently heated to be melted into one or more solid portions; translating the platform relative to the energy source such that the platform is proximate to the energy source and arranging a second layer of the fabrication powder contiguous to the first layer of fabrication powder on the platform; whereby these steps of arranging, directing, and translating are repeated to form a structure with the derived 3D architecture.