Novel Fabrication Method for Interconnect Materials

A novel method of fabricating thin sheets of metallic and metallic matrix composite materials is described. A near net shape powder metallurgy process is used to roll compact a blend of powders directly into a thin sheet. A sintered bond is subsequently formed and the initially porous sheet is taken to full density, or intermediate density if desired, by a series of thermo-mechanical steps. A number of examples are presented, including an iron aluminide intermetallic composition having excellent high temperature oxidation resistance and creep strength. Properties of copper molybdenum and copper tungsten composites having a range of thermal expansion values according to composition are given. A nickel chromium alloy, difficult to prepare by melt and cast methods, is described.