A reinforced magnesium composite, and a method of producing thereof, wherein the reinforced magnesium composite comprises elemental magnesium particles, elemental nickel particles, and one or more ceramic particles with elemental nickel particles being dispersed within elemental magnesium particles without having intermetallic compounds therebetween. Various embodiments of the method of producing the reinforced magnesium composite are also provided.

A metal matrix composite comprises and/or consists of a uniform distribution of calcined ceramic particles having an average particle size of between 0.30 and 0.900 microns and a metal or alloy uniformly distributed with the ceramic particles and wherein the ceramic particles include oxides of two separate metals selected from the group consisting of Al, Li, Be, Pb, Fe, Ag, Au, Sn, Mg, Ti, Cu, and Zn, and in which said ceramic particles comprise at least 15 volume percent of the metal matrix sintered together and wherein said metal-matrix being machinable with a high speed steel (HSS) bit for greater than about one minute without excessive wear to the bit.

The present disclosure relates to new metal powders for use in additive manufacturing, and aluminum alloy products made from such metal powders via additive manufacturing. The composition(s) and/or physical properties of the metal powders may be tailored. In turn, additive manufacturing may be used to produce a tailored aluminum alloy product.

A method for preparing nano-SiO.sub.2 reinforced aluminum matrix composites, includes the following: Step-1, powder mixing: mixing aluminum matrix powder with nano-SiO.sub.2 powder to obtain raw material powder, wherein the aluminum matrix powder has an average particle size between 30 m to 100 m, the nano-SiO.sub.2 powder has an average particle size between 5 nm to 145 nm, mass percentage of nano-SiO.sub.2 in the raw material powder is 0.01% to 5% and the remaining raw material powder is the aluminum matrix powder; Step-2, shaping: press shaping the powder obtained in the Step-1 to obtain base bodies; Step-3, sintering: sintering the base bodies obtained in the Step-2 in an atmosphere of N.sub.2 at 550 C. to 660 C., preserving the temperature for a period of 5 min to 60 min, and cooling in a furnace at end of the period under protection of N.sub.2 for 0.5 h to 3 h; and Step-4, heat treatment.

The invention is a process for manufacturing a nano aluminum/alumina metal matrix composite and composition produced therefrom. The process is characterized by providing an aluminum powder having a natural oxide formation layer and an aluminum oxide content between about 0.1 and about 4.5 wt. % and a specific surface area of from about 0.3 and about 5 m.sup.2/g, hot working the aluminum powder, and forming a superfine grained matrix aluminum alloy. Simultaneously there is formed in situ a substantially uniform distribution of nano particles of alumina. The alloy has a substantially linear property/temperature profile, such that physical properties such as strength are substantially maintained even at temperatures of 250 C. and above.

The disclosure provides aluminum alloys with high tensile strength and appealing cosmetics and improved tensile yield strength. The aluminum alloys include 0.5 to 3.0 wt % Mg and 0.2 to 3.0 wt % Si. The alloys have a weight ratio of Mg to Si ranging from 2 to 4.

A metal matrix composite material and associated methods are disclosed. In one example, the metal matrix composite material includes ceramic particles distributed in multiple phases. In selected examples, the metal matrix composite material is formed by a process including applying a rotational force and an axial force to a feedstock at an interface and plasticizing a portion of the feedstock at the interface.

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 matrix nanocomposite includes: 1) a matrix including one or more metals; and 2) nanostructures uniformly dispersed and stabilized in the matrix at a volume fraction, including those greater than about 3% of the nanocomposite.

Metallic matrix composites include a high strength titanium aluminide alloy matrix and an in situ formed aluminum oxide reinforcement. The atomic percentage of aluminum in the titanium aluminide alloy matrix can vary from 40% to 48%. Included are methods of making the metallic matrix composites, in particular, through the performance of an exothermic chemical reaction. The metallic matrix composites can exhibit low porosity.