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

A multi-ratio gearbox housing for a vehicle is made of light metal material and includes a first bearing seat having a cylindrical inner surface, and a reinforcement member having a first cylindrical inner surface surrounding the first bearing seat for reducing thermal radial expansion of the first bearing seat, the reinforcement member being of a material the coefficient of thermal expansion of which is less than the coefficient of thermal expansion of the light metal material of the housing. The reinforcing member is a cast-in insert arranged in the housing, and a radial distance between the first cylindrical inner surface and the cylindrical inner surface of the first bearing seat is substantially constant along circumferential lines of the first bearing seat, facilitating improved form stability of the cylindrical inner surface of the first bearing seat over the temperature operating range of the housing.

A multi-ratio gearbox housing for a vehicle is made of light metal material and includes a first bearing seat having a cylindrical inner surface, and a reinforcement member having a first cylindrical inner surface surrounding the first bearing seat for reducing thermal radial expansion of the first bearing seat, the reinforcement member being of a material the coefficient of thermal expansion of which is less than the coefficient of thermal expansion of the light metal material of the housing. The reinforcing member is a cast-in insert arranged in the housing, and a radial distance between the first cylindrical inner surface and the cylindrical inner surface of the first bearing seat is substantially constant along circumferential lines of the first bearing seat, facilitating improved form stability of the cylindrical inner surface of the first bearing seat over the temperature operating range of the housing.

An armor plate and method of making an armor plate is provided having the steps of: suspending a carbon fiber weave within a mold; heating aluminum 6061 or 7075 alloy to a molten state; pouring the molten aluminum into the mold having ceramic particulates in the range of 1 to 60 percent by volume of the molten aluminum and in the range of 3-44 microns in diameter; cooling the resultant matrixed aluminum to ambient temperature; and laminating at least two layers of ballistic fiber to the matrixed aluminum.

An armor plate and method of making an armor plate is provided having the steps of: suspending a carbon fiber weave within a mold; heating aluminum 6061 or 7075 alloy to a molten state; pouring the molten aluminum into the mold having ceramic particulates in the range of 1 to 60 percent by volume of the molten aluminum and in the range of 3-44 microns in diameter; cooling the resultant matrixed aluminum to ambient temperature; and laminating at least two layers of ballistic fiber to the matrixed aluminum.

There are provide a metal/ceramic bonding substrate wherein the bonding strength of an aluminum plate bonded directly to a ceramic substrate is higher than that of conventional metal/ceramic bonding substrates, and a method for producing the same. The metal/ceramic bonding substrate is produced by a method including the steps of: arranging a ceramic substrate 10 in a mold 20; putting the mold 20 in a furnace; lowering an oxygen concentration to 25 ppm or less and a dew point to −45° C. or lower in the furnace; injecting a molten metal of aluminum into the mold 20 so as to allow the molten metal to contact the surface of the ceramic substrate 10; and cooling and solidifying the molten metal to form a metal plate 14 for circuit pattern of aluminum on one side of the ceramic substrate 10 to bond one side of the metal plate 14 for circuit pattern directly to the ceramic substrate 10, while forming a metal base plate 12 of aluminum on the other side of the ceramic substrate 10 to bond the metal base plate 12 directly to the ceramic substrate 10.

An exemplary method for making a metal matrix composite vehicle component includes: using a mold including male and female die portions having mold surfaces and a plurality of spacers; heating the mold to a casting temperature; placing a ceramic preform on the plurality of spacers, the ceramic preform being spaced apart from at least one of the mold surfaces by the spacers; closing the mold to form a mold cavity between the mold surfaces of the male and female die portions, the ceramic preform being disposed within the mold cavity; providing molten metal into the mold cavity; and pressurizing the molten metal to a casting pressure for a casting duration to infiltrate the ceramic preform thereby forming the metal matrix composite vehicle component.

An exemplary method for making a metal matrix composite vehicle component includes: using a mold including male and female die portions having mold surfaces and a plurality of spacers; heating the mold to a casting temperature; placing a ceramic preform on the plurality of spacers, the ceramic preform being spaced apart from at least one of the mold surfaces by the spacers; closing the mold to form a mold cavity between the mold surfaces of the male and female die portions, the ceramic preform being disposed within the mold cavity; providing molten metal into the mold cavity; and pressurizing the molten metal to a casting pressure for a casting duration to infiltrate the ceramic preform thereby forming the metal matrix composite vehicle component.

Embodiments of the present invention provide apparatus for forming a component from a solidified fluid medium. The apparatus comprises a body defining a cavity into which the fluid medium may be introduced, the cavity optionally being shaped to define a shape of the component, and a carrier for supporting one or more elements to be embedded in the component. The carrier is arranged to be introduced into the cavity to support the one or more elements within the cavity while the fluid medium is introduced into the cavity. Embodiments of the invention are useful in a range of fabrication technologies including casting of metals and injection molding operations.

Embodiments of the present invention provide apparatus for forming a component from a solidified fluid medium. The apparatus comprises a body defining a cavity into which the fluid medium may be introduced, the cavity optionally being shaped to define a shape of the component, and a carrier for supporting one or more elements to be embedded in the component. The carrier is arranged to be introduced into the cavity to support the one or more elements within the cavity while the fluid medium is introduced into the cavity. Embodiments of the invention are useful in a range of fabrication technologies including casting of metals and injection molding operations.