Analytically motivated process improvements in continuous metal–matrix composite wire fabrication

A recently developed process allows the production of continuous fiber reinforced metal matrix composite (MMC) wire. Ceramic fiber tows are infiltrated with metal as the fiber tow is drawn through a pressurized crucible of molten metal. Initial production runs allowed fabrication of only limited lengths, due to fiber tow breakage at the crucible entrance. In this paper, a simple analytical model of the fluid mechanics at the entrance to the pressurized crucible has been developed to understand and improve the process, and to avoid fiber tow breakage at the crucible entry orifice. As a result of this analysis, subsequent MMC wire production maintains a faster pull speed, with corresponding yield lengths of 350 m. The microstructure and properties of the MMC wire produced are similar or improved when faster tow pull speeds are employed.