SBIR Phase I: Improved Manufacturing Methodology for Aluminum Ash Metal Matrix Composite Materials

小企业创新研究(SBIR)一期项目将利用经过深度加工的飞灰与搅拌铸造技术相结合，促进粉煤灰-铝基复合材料(MMC)的制造。飞灰是燃烧煤炭时产生的一种陶瓷玻璃球体，它将使用一种新的分类系统被分类为粒度范围较窄的产品，几乎没有细材料(即直径5微米的灰)。被分类的灰粒子的低表面积将促进铝基质内的分散，同时减缓相关的还原反应。提出的铝-飞灰MMC将表现出优异的刚性、硬度和导热性能。此外，成功地创造出一种可以用传统工具加工的具有更高硬度的材料将是一项突破。如果成功，拟议的铝飞灰MMC将使其在汽车应用(刹车转子)中成为一种有吸引力的球墨铸铁替代品。这种材料还有可能在活塞、发动机机体和发动机头部等应用中与过共晶铝合金竞争。飞灰-铝基复合材料将使汽车变得更轻，并对油耗和成本产生积极影响。此外，这些复合材料的生产将是环保的。

The Small Business Innovation Research (SBIR) Phase I project will utilize highly processed fly ash in combination with the stir-casting technology to advance the manufacturing of coal ash-aluminum metal matrix composites (MMC). Fly ash, a ceramic glass sphere is produced when coal is burned, will be classified into a product with a narrow size range and little to no fine material (i.e. ash 5 micron in diameter) using a novel classification system. The low surface area of the classified ash particles will facilitate dispersion within the aluminum matrix while simultaneously slowing associated reduction reactions. The proposed aluminum-fly ash MMC will exhibit superior stiffness, hardness, and thermal conductivity. Furthermore, the successful creation of a material with increased stiffness that can be machined with conventional tooling would represent a breakthrough. If successful, the proposed aluminum-fly ash MMC would make it an attractive alternative to ductile iron in automotive applications (brake rotors). This material also has the potential to compete with hyper eutectic aluminum alloys in applications such as pistons, engine blocks, and engine heads. Fly ash-aluminum MMC would make automobiles lighter, and positively impact fuel consumption and cost. Additionally, the production of these composites would be environmentally friendly.