A method for making a joint structure including embedding a portion of at least two layers of a third component into a first component and interleaving at least one layer of a second component with an unembedded portion of the at least two layers of the third component, wherein the third component inhibits galvanic corrosion between the first and second components, the first component has a first CTE, the second component has a second CTE that is different from the first CTE, the third component has a third CTE that is between the first CTA and the second CTE, and the third component comprises a mesh component.

A system is disclosed for use in additively manufacturing a composite structure. The system may include a head configured to discharge a continuous reinforcement at least partially coated with a matrix. The head may have a matrix reservoir, and a nozzle connected to an end of the matrix reservoir. The system may further include a support configured to move the head during discharging, and a supply of matrix. The system may also include at least one sensor configured to generate a signal indicative of a matrix characteristic inside of the head, and a controller configured to selectively affect the supply of matrix based on the signal.

A method of forming an aircraft component includes providing an aluminum alloy. The method further includes mixing a shape memory alloy (SMA) with the aluminum alloy to form a combination of the SMA and the aluminum alloy. The method further includes forming the aircraft component with the combination of the SMA and the aluminum alloy.

The present disclosure discloses a continuous electrophoretic deposition modified carbon fiber reinforced multi-matrix composite and a preparation method thereof, composing of a carbon fiber with a volume fraction of 30-55%, an inorganic powder with a volume fraction of 3-25% and a matrix with a volume fraction of 20-67%, wherein the inorganic powder is wrapped on the surface of the carbon fiber filament or embedded in the carbon fiber bundle, and the concentration gradually decreases from the fiber filament to the surface of the fiber bundle. The preparation method of the composite is as follows: (1) pretreating the carbon fibers; (2) preparing a slurry of the inorganic powder; (3) widening the pretreated carbon fiber to form a carbon fiber strip, and then carrying out electrophoretic deposition on the inorganic powders; (4) preparing a preform from the deposited carbon fibers; and (5) compounding a matrix in the preform.

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 fiber-reinforced thermoplastic resin filament for a 3D printer is formed by impregnating a thermoplastic resin into a plurality of continuous reinforcing fibers, wherein: an average value S of a roundness parameter s of a cross section is 60% to 100%, the average value S being evaluated by (i) taking a photograph of the cross section perpendicular to the axial direction of the filament, (ii) drawing an inscribed circle and a circumscribed circle of the filament in a cross-sectional image and determining the diameter length of each, (iii) calculating the roundness parameter s defined by equation (1), and (iv) repeating (i)-(iii) at a plurality of locations on the filament and calculating the average value S of the roundness parameter s; and the coefficient of variation of the diameter length of the circumscribed circle is 0% to 10%.

A compressor blade of a gas turbine includes a compressor blade portion including a plurality of layers; and a carbon fiber reinforcement embedded in the plurality of layers of the compressor blade portion and oriented in a direction of stress fields of the compressor blade when in operation. A method of manufacturing the compressor blade includes preparing a composite material including fiber-reinforced layers; forming a first layer of the composite material to extend in a radial direction of the compressor blade; and stacking a second layer of the composite material on the first layer in an axial direction of the compressor blade. The compressor blade is 3D-printed by forming each composite material layer in a radial direction, which layers are stacked in an axial direction. Fiber reinforcement in the composite compressor blade is oriented in line with the stress fields inherent in the operation of the compressor blade.

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.