Patent ID: 8535604

Claim:
A method of producing a metal matrix composite having at least one desired and controlled application specific property, the method comprising the steps of: selecting at least one micro-engineered particulate; mixing the micro-engineered particulate with a powder substrate; pre-consolidating the mixed powder to form an article or near net shape article; consolidating the article or near net shape article to produce the metal matrix composite exhibiting the at least one desired and controlled application specific property; wherein the consolidating step comprises dual mode Dynamic Forging, said dual mode Dynamic Forging comprising the steps of: in a first mode, applying a pressure to the near net shape article in a range of 5 to 200 Tons within a heated pressure transmitting media while maintaining a temperature from 100 degrees Centigrade to 1400 degrees Centigrade; during the first mode, maintaining the temperature below a melting point of a material used to form the micro-engineered particulate, the powder substrate, and any coatings applied thereto; in a second mode, applying a pressure to the near net shape article in a range of 2 to 2500 Tons within a heated pressure transmitting media while maintaining a temperature range of 100 degrees Centigrade to 1400 degrees Centigrade; during the second mode, maintaining the temperature below a melting point of a material used to form the micro-engineered particulate, the powder substrate, and any coatings applied thereto; controlling a rate of applied pressure during the first and second modes by means selected from the group consisting of: integrated hydraulic valves, electrical relays and mechanical limit switches; controlling a pressurization rate in a range of 2″/min to 120″/min; and, controlling a decompression rate so as not to exceed 120″/min.