This project seeks to scale-up the manufacturing technology for HyperMMCTM, a discontinuously reinforced aluminum (DRA) composite, exhibiting exceptional room temperature yield strength (555 MPa) at 0.2 volume fraction reinforcement. The reinforcement is a proprietary titanium-based particulate which provides wetting and chemical bonding to the matrix alloy, in this instance aluminum alloy A 354. Further, HyperMMC has the lowest cost-to-performance ratio amongst all DRA composites evaluated to date. The main goal of Phase I work is to demonstrate the feasibility of manufacturing net- shape HyperMMC components which exhibit reliable mechanical properties. Current research at Ohio State University on the processing and mechanical behavior of metal matrix composites will be brought to bear in this project to achieve this goal. The following are the anticipated results for Phase I work Experimentally scale up the weight of the processed composite to 15 kg batches; Experimentally determine process parameters suitable for producing sound components from investing casting and die casting; Identify by computed tomography the flaw size resulting from each casting process; Determine the fracture and fatigue properties of the cast composite, as a means to validate the efficacy of the selected process parameters, and establish a predictive life model of HyperMMC.
Potential Commercial Applications: Space structures: truss joints, beams; Engine propulsion systems: frame, injector dome for combustion chamber; Transportation systems: compressor rotor for turbochargers, brake calipers and pads; Electronic packaging: semiconductor heat sink module; Recreation and leisure goods: bicycle frame
