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

该奖项是根据2009年美国复苏和再投资法案（公法111-5）资助的。这个小企业创新研究（SBIR）第二阶段项目旨在克服飞灰和铝的金属基复合材料（MMC）质量不一致的主要障碍。该项目利用高度加工的灰衍生陶瓷（ADC）作为增强相的铝金属基复合材料与粉末冶金（P/M）的方法制造。经处理的ADC具有窄的尺寸分布，并且不含碳、磁铁矿和空心微珠。在粉末金属技术中，ADC改变铝的强度、刚度和硬度。当与铝粉混合并压制成零件时，铝MMC材料可以制造出与球墨铸铁一样的刚度特性。可以操纵烧结参数以控制铝-ADC反应及其生成的硅金属和尖晶石，从而产生耐磨性和硬度。然后MMC表现得像超铀合金。该项目的主要目标是制定一个或多个高性能ADC-铝金属基复合材料，准备用于商业部署。达到这种性能水平将允许ADC？该项目的更广泛的影响/商业潜力将是获得高质量的灰衍生陶瓷（ADC）的能力，这些陶瓷从燃煤灰中回收，用于新的轻质高强度复合材料。这些材料在重量、成本和性能至关重要的运输行业中是必需的。ADC-铝金属基复合材料可用于制造运输行业的部件，例如制动转子和传动系部件，这些部件目前由球墨铸铁或过氧化氢合金制成，这些材料较重和/或难以加工。这种材料的变化将降低车辆的整体重量，从而提高其燃油效率和性能，同时提高零部件制造商的利润率。这项技术将创造一种新的商品，从而创造新的就业机会，并帮助支持汽车和运输行业的需求。

This award is funded under the American Recovery and Reinvestment Act of 2009 (Public Law 111-5).This Small Business Innovation Research(SBIR)Phase II project seeks to overcome the principal impediments of the inconsistent quality of metal matrix composite (MMC) materials from fly ash and aluminum. This project utilizes highly processed ash derived ceramics (ADC) as a reinforcing phase in aluminum MMCs manufactured with powder metallurgy (P/M) methods. The processed ADC has a narrow size distribution and is free of carbon, magnetite, and cenospheres. In powder metal technology the ADC alters the strength, stiffness, and hardness of the aluminum. When blended with aluminum powders and compacted into parts, aluminum MMC materials can be fabricated with stiffness properties like ductile iron. Sintering parameters can be manipulated to control the aluminum-ADC reaction and the silicon metal and spinel that it generates, thus creating wear resistance and hardness. The MMC then behaves like a hypereutectic alloy. The primary objective of this project is to formulate one or more high performance ADC-aluminum MMCs that are ready for commercial deployment. Achieving this level of performance will allow ADC?aluminum MMCs to compete directly with hypereutectic alloys and ductile iron in the production of parts for the transportation industry.The broader impact/commercial potential of this project will be the ability to derive high quality, ash derived ceramics (ADC) that are recovered from coal combustion ash for use in new light weight high strength composite materials. These materials are needed in the transportation industry where weight, cost, and performance are critical. ADC-aluminum metal matrix composites can be used to manufacture parts for the transportation industry such as brake rotors, and drive train components that are currently made from ductile iron or hypereutectic alloys, materials that are heavier and/or difficult to machine. This material change will decrease the overall weight of the vehicle, thereby improving its fuel efficiency and performance while improving the margins for parts manufacturers. This technology will create a new commodity that will lead to the creation of new jobs and help support the needs of the automotive and transportation industries.