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

小企业创新研究（SBIR）第一阶段项目将利用高度加工的粉煤灰与搅拌铸造技术相结合，以推进煤灰-铝金属基复合材料（MMC）的制造。 粉煤灰是煤燃烧时产生的一种陶瓷玻璃球，将使用一种新的分类系统分类为具有窄尺寸范围和很少或没有细材料（即直径为5微米的灰）的产品。 分级的灰分颗粒的低表面积将促进在铝基质内的分散，同时减缓相关的还原反应。 所提出的铝粉煤灰MMC将表现出上级的刚度、硬度和导热性。 此外，成功地制造出一种可以用传统工具加工的具有更高刚度的材料将是一个突破。 如果成功，所提出的铝粉煤灰MMC将使其成为汽车应用（制动盘）中球墨铸铁的有吸引力的替代品。 这种材料还具有在活塞、发动机缸体和发动机缸盖等应用中与超共晶铝合金竞争的潜力。 粉煤灰-铝MMC将使汽车更轻，并对燃料消耗和成本产生积极影响。 此外，这些复合材料的生产将是环境友好的。

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.