Disclosed herein is a composite co-fiber comprising a plurality of ceramic tows; one or more sacrificial yarns; where the sacrificial yarns are operative to undergo dissolution, decomposition or melting upon being subjected to an elevated temperature; and wherein the sacrificial yarns leave open spaces in the co-fiber upon being subjected to decomposition, dissolution or melting.

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.

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.

Provided is a metal matrix nanocomposite comprising: (a) a metal or metal alloy as a matrix material; and (b) multiple graphene sheets that are dispersed in said matrix material, wherein said multiple graphene sheets are substantially aligned to be parallel to one another and are in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein the multiple graphene sheets contain single-layer or few-layer graphene sheets selected from pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein the chemically functionalized graphene is not graphene oxide. The metal matrix exhibits a combination of exceptional tensile strength, modulus, thermal conductivity, and/or electrical conductivity.

Provided is a metal matrix nanocomposite comprising: (a) a metal or metal alloy as a matrix material; and (b) multiple graphene sheets that are dispersed in said matrix material, wherein said multiple graphene sheets are substantially aligned to be parallel to one another and are in an amount from 0.1% to 95% by volume based on the total nanocomposite volume; wherein the multiple graphene sheets contain single-layer or few-layer graphene sheets selected from pristine graphene, graphene oxide, reduced graphene oxide, graphene fluoride, graphene chloride, graphene bromide, graphene iodide, hydrogenated graphene, nitrogenated graphene, doped graphene, chemically functionalized graphene, or a combination thereof and wherein the chemically functionalized graphene is not graphene oxide. The metal matrix exhibits a combination of exceptional tensile strength, modulus, thermal conductivity, and/or electrical conductivity.

Production methods for producing a fiber-reinforced metal component having a metal matrix which is penetrated by a plurality of reinforcing fibers are provided. One method includes depositing in layers reinforcing fibers in fiber layers, depositing in layers and liquefying a metal modelling material in matrix material layers, and consolidating in layers the metal modelling material in adjacently deposited matrix material layers to form the metal matrix of the fiber-reinforced metal component. Here, the metal component is formed integrally from alternately deposited matrix material layers and fiber layers. An alternative method includes introducing an open three-dimensional fiberwoven fabric consisting of reinforcing fibers into a casting mold, pouring a liquid metal modelling material into the casting mold and consolidating the metal modelling material to form the metal matrix of the fiber-reinforced metal component. Here, the metal component is formed integrally from the consolidated metal modelling material and the reinforcing fibers.

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 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 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 ceramic fiber processing apparatus and method for processing ceramic fibers for the manufacture of ceramic matrix composites (CMCs) is provided. The apparatus includes a frame including a plurality of unidirectional ceramic fibers wound thereabout and extending across a void therein the frame to define a first planar array of ceramic fibers and a second planar array of ceramic fibers. During use, the frame is disposed in the ceramic fiber processing apparatus in a manner to enable gripping of the first planar array of ceramic fibers with a first gripper assembly and gripping of the second planar array of ceramic fibers with a second gripper assembly. A cutting mechanism provides cutting of the plurality of unidirectional ceramic fibers to separate the first planar array of ceramic fibers and the second planar array of ceramic fibers from one another.

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.