U.S.-Egypt Cooperative Research: Light Weight Lead Calcium Alloys- Microballoon Fly Ash Composites for Automotive Batteries Operating Under High Temperature

美埃合作研究：用于高温汽车电池的轻质铅钙合金-微球粉煤灰复合材料

• 批准号: 0710981
• 负责人: Pradeep Rohatgi
• 金额: $ 3万
• 依托单位: University of Wisconsin-Milwaukee
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2007
• 资助国家: 美国
• 起止时间: 2007-08-01 至 2013-07-31
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0710981&HistoricalAwards=false
• 关键词: U.S.; Egypt; Cooperative; Research; Light

0710981RohatgiDescription: This project supports collaborative research by Dr. Pradeep Rohatgi, Department of Materials Science & Engineering, University of Wisconsin at Milwaukee (UWM), Milwaukee, Wisconsin. The collaborating scientist is Dr. Atef Daoud, Central Metallurgical Research and Development Institute, Helwan, Egypt. They plan to synthesize lightweight lead calcium alloys incorporating microballoons (from flyash, glass or alumina) in the form of composites, for use in automotive and industrial batteries operating under increasingly high temperatures. The grid containing microballoons will be designed to enhance battery life, while decreasing battery weight. The PIs will investigate fundamentals related to solidification synthesis and structure-property relationships in Pb-Ca-microballoon composites. Research will be conducted on the theoretical analysis of transfer microballoons into alloy melts, and solidification of lead-calcium alloy matrices containing microballoons. They will carry out experiments on introduction and transfer of microballoons in the melts of lead-calcium alloys, using mixing, and pressure infiltration processes followed by solidification to create lead-calcium/microballoon composites. Solidified material will be examined by optical and electron microscopy to characterize the distribution of microballoons, interfaces, matrix grain size, dendrite size and microsegregation. Assessment of mechanical and electrical properties will be made to provide a benchmark for optimizing processing parameters.Intellectual Merit: The project will analyze the applicability of the existing knowledge base on synthesis, processing and properties of microcomposites to lead-calcium alloy-microballoon composite materials, and propose new models on synthesis, structure-property relationships in lead calcium alloy based syntactic foams. The characterization of microstructures will help to understand nucleation, growth, microsegregation, particle pushing, and interface formation when solidification of the lead calcium alloy occurs in the small spaces between microballoons. These studies will help to understand the relationships between processing, microstructure and the creep and corrosion behavior of these alloys. The research will elaborate the effect of composition, volume, percent, size and distribution of microballoons on conductivity, modulus strength, creep and corrosion resistance of lead-calcium alloys. Broader Impact: The results are likely to lead to the development of lightweight lead calcium alloys reinforced with microballoons for battery applications. These batteries, which can be produced by companies in the U.S. and Egypt, will lead to weight reduction in vehicles, and especially in trucks. The project will help educate undergraduate and graduate students, including minorities and women, postdoctoral associates, high school students and teachers about lead-calcium alloy-microballoon composites for high temperature battery applications. Instructional modules will be developed for existing courses at UWM and other U.S. institutions. The results will be disseminated through research publications and conferences. The infrastructure developed at UWM for manufacturing of these components will be made available to other researchers. This work on producing high performance syntactic foam components can help to revive the metal casting industry in the U.S.A. This project is being supported under the US-Egypt Joint Fund Program, which provides grants to scientists and engineers in both countries to carry out these cooperative activities.

0710981 Rohatgi描述：该项目支持威斯康星州大学密尔沃基分校（UWM）材料科学工程系Pradeep Rohatgi博士的合作研究。 合作科学家是埃及赫勒万中央冶金研究和发展研究所的Atef Daoud博士。 他们计划以复合材料的形式合成含有微球（来自粉煤灰，玻璃或氧化铝）的轻质铅钙合金，用于在越来越高的温度下运行的汽车和工业电池。包含微球的网格将被设计为提高电池寿命，同时降低电池重量。PI将研究与Pb-Ca-微球复合材料的凝固合成和结构-性能关系相关的基本原理。研究了微球向合金熔体中转移的理论分析，以及含微球的铅钙合金基体的凝固过程。他们将进行在铅钙合金熔体中引入和转移微球的实验，使用混合和压力渗透过程，然后固化以创建铅钙/微球复合材料。将通过光学和电子显微镜检查凝固材料，以表征微球、界面、基体晶粒尺寸、枝晶尺寸和显微偏析的分布。 本项目将分析现有的关于微复合材料的合成、加工和性能的知识库对铅钙合金-微球复合材料的适用性，并提出关于铅钙合金基复合泡沫塑料的合成、结构-性能关系的新模型。微观结构的表征将有助于理解成核，生长，显微偏析，颗粒推动，和界面形成时，发生在微球之间的小空间凝固的铅钙合金。这些研究将有助于理解这些合金的加工、显微组织和蠕变与腐蚀行为之间的关系。研究了微球的组成、体积、百分比、尺寸和分布对铅钙合金电导率、模量、强度、蠕变和耐腐蚀性能的影响。更广泛的影响：这些结果可能会导致开发用于电池应用的用微球增强的轻质铅钙合金。这些电池可以由美国和埃及的公司生产，将导致车辆，特别是卡车的重量减轻。该项目将帮助教育本科生和研究生，包括少数民族和妇女，博士后助理，高中生和教师关于高温电池应用的铅钙合金微球复合材料。将为UWM和其他美国机构的现有课程开发教学模块。研究结果将通过研究出版物和会议传播。在UWM开发的用于制造这些组件的基础设施将提供给其他研究人员。这项生产高性能复合泡沫塑料部件的工作有助于振兴美国的金属铸造业。该项目得到美国-埃及联合基金方案的支持，该方案向两国的科学家和工程师提供赠款，以开展这些合作活动。