Patent ID: 6399018
Filing Date: 2002-06-04
Classification: B22F,C22C,Y10T

Abstract:
A method for making a solid object, said method comprising the steps of:a) forming a liquid mixture with a composition comprising a binder, a powdered first metal, and a particulate ceramic or cermet material by maintaining the temperature of said mixture above the melting temperature of said binder; b) filling a cavity having the shape of said solid object with said liquid mixture; c) degassing said liquid mixture; d) maintaining the temperature of said degassed liquid mixture in said cavity above the melting temperature of said binder to partially separate by settling said first metal and said particulate ceramic or cermet material from said binder, and cooling to form a solid precursor; e) removing said solid precursor from said cavity; f) increasing the temperature of said solid precursor to form a porous, three dimensional rigid matrix with interconnected porosity, said porous matrix being comprised of said ceramic or cermet material and, at least partially sintered said first metal; g) introducing a molten second metal to said porous matrix such that said molten second metal infiltrates the interconnected porosity of said porous matrix to form an infiltrated matrix; and h) cooling said infiltrated matrix to form said solid object, said solid object comprising solidified said second metal, at least partially sintered said first metal and a rigid matrix of said ceramic or cermet material.