Composite materials include a non-ferrous metal matrix with reinforcing carbon fiber integrated into the matrix. The composite materials have substantially lower density than non-ferrous metal, and are expected to have appreciable strength. Methods for forming composite non-ferrous metal composites includes combining a reinforcing carbon fiber component, such as a woven polymer, with non-ferrous metal nanoparticles and sintering the non-ferrous metal nanoparticles in order to form a non-ferrous metal matrix with reinforcing carbon fiber integrated therein.

Carbon fiber reinforced metal matrix composite turbine rotors include a planar carbon fiber structure encapsulated within a metal matrix formed of sintered metal nanoparticles. The metal nanoparticles can include a metal having a high sintering temperature that would ordinarily destroy the carbon fiber. Novel techniques for making small uniform nanoparticles for sintering lowers the sintering temperature to a level that can accommodate carbon fiber. The composite rotors possess high strength to weight ratio.

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 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.

Carbon fiber reinforced metal matrix composite turbine rotors include a planar carbon fiber structure encapsulated within a metal matrix formed of sintered metal nanoparticles. The metal nanoparticles can include a metal having a high sintering temperature that would ordinarily destroy the carbon fiber. Novel techniques for making small uniform nanoparticles for sintering lowers the sintering temperature to a level that can accommodate carbon fiber. The composite rotors possess high strength to weight ratio.

Carbon fiber reinforced metal matrix composite gears include a planar carbon fiber structure fully encapsulated within a metal matrix formed of sintered metal nanoparticles. The metal nanoparticles can be composed of a metal having a high sintering temperature that would ordinarily destroy the carbon fiber. Novel techniques for making small uniform nanoparticles for sintering lowers the sintering temperature to a level that can accommodate carbon fiber. The composite gears possess high strength to weight ratio.

A method may comprise: placing a probe in a molten metal melt comprising a thixotropic metal alloy; injecting a gas into the molten metal melt to form a saturated slurry, the saturated slurry being at a temperature above a liquidus temperature of the thixotropic metal alloy after injecting the gas; removing the probe from the molten metal melt; and depositing the molten metal melt through an extruder of an additive manufacturing system.

Composite materials include a steel matrix with reinforcing carbon fiber integrated into the matrix. The composite materials have substantially lower density than steel, and are expected to have appreciable strength. Methods for forming composite steel composites includes combining a reinforcing carbon fiber component, such as a woven polymer, with steel nanoparticles and sintering the steel nanoparticles in order to form a steel matrix with reinforcing carbon fiber integrated therein.

Composite materials include a steel matrix with reinforcing carbon fiber integrated into the matrix. The composite materials have substantially lower density than steel, and are expected to have appreciable strength. Methods for forming composite steel composites includes combining a reinforcing carbon fiber component, such as a woven polymer, with steel nanoparticles and sintering the steel nanoparticles in order to form a steel matrix with reinforcing carbon fiber integrated therein.

Composite materials include a steel matrix with reinforcing carbon fiber formed of individual fibers penetrating into the matrix to substantial depth. The fibers typically have defined diameters and large ratios of penetration depth to fiber diameter. Specified methods for forming the composite materials have a unique ability to achieve the large ratios of penetration depth to fiber diameter.