The purpose of this work was to investigate production of composite materials by electroforming. It is potentially a very useful method since it is possible to form completed parts using this technique and bypass several fabrication steps. The material studied include boron and carbon filaments in nickel, copper, and aluminum matrices. A nickel sulfamate bath was used for plating nickel and an aluminum-ether bath for plating aluminum. The results indicate that the strength of the boron in nickel composite material obeys the law of mixtures. There may be a loss of adhesion at very close spacing of the filaments, however. Results of annealed nickel with boron filaments indicate that a NiB layer is formed and the kinetics of the reaction were investigated. Preliminary results are also given on fatigue and toughness properties of the nickel-boron composites. Carbon cloth and yarn were plated to show the applicability of the electroforming technique to these materials. The strength of these composite specimens was very low, however, due to the low strength of the fiber presently available. It is concluded that the electroforming process shows promise for producing boron-nickel, boron-aluminum, and carbon-nickel composites.
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