Patent ID: 7771547

Claim:
A method for producing an in-situ composite solder having an intermetallic component, comprising the steps of: (a) providing a mixture comprising the components of a eutectic or near-eutectic matrix solder and the components of an intermetallic component present at greater than or equal to about 10 volume % and less than or equal to about 95 volume %, wherein said intermetallic component is selected to have a density within 10% of a density of said eutectic or near-eutectic matrix solder; (b) heating said mixture so as to melt all components of said mixture forming a non-solid mixture; and (c) cooling said non-solid mixture at a rate sufficiently fast so as to form said intermetallic components having a particle size of less than about 10 microns, wherein said intermetallic components are homogenously distributed throughout said matrix solder to form the composite solder.