Patent ID: 7435376

Claim:
A method comprising: admixing at least one secondary phase having a particle size with a porosity agent and an organic binding agent to form a mixture; shaping the mixture in a mold to form a green body; heating said green body to remove the porosity agent and to harden and solidify the green body to yield a porous green body having a multimodal structure formed by the removed porosity agent; and infiltrating the multimodal pore structure of the porous green body with a molten metal to produce a metal matrix composite; wherein said at least one secondary phase is selected from the group consisting of a metal, an oxide, a carbide, a nitride, a boride and a silicide; wherein said molten metal is selected from the group consisting of aluminum, aluminum alloy, magnesium, magnesium alloy, titanium and titanium alloy; wherein the particle size of said at least one secondary phase is from 5 to 500 nanometers, and wherein a polyform structure is produced in the composite which is an image of the tree-like structure of the porosifying agent that is produced by a combination of various granulation processes.