EAGER/Collaborative Research: Nanocomposite Copper Tooling for Faster Cycle and Improved Precision in Plastic Molding - Proof of Concept

这个早期概念探索性研究（EAGER）合作研究奖的研究目标是测试连续介质力学定律在熔化铜的微孔中成立的假设，当将单壁碳纳米管引入微孔时，由于其高宽高比，它们将沿着流体流线并在凝固时保持这种排列。纳米管在铜基体中的排列对纳米管/铜复合材料的力学性能有重要影响。实现这一目标的方法是使用高亮度激光在铜衬底上制造直径50微米、深度200微米的熔孔，然后将纳米管引入微孔中。计算机模拟结果表明，激光诱导微井中存在垂直层流流型。将检查复合材料的微观结构，以确定垂直对齐的完成程度。如果成功，这项研究的好处将包括使技术允许铜合金用于许多需要高机械强度和高导电性和导热性的应用中。对于价值650亿美元的模具制造行业来说，这是一个潜在的变革性收益。用纳米复合材料制造模具将简化制造过程，缩短交货时间，延长模具寿命，并创造新的模具和模具制造商队伍。

The research objective of this EArly-concept Grants for Exploratory Research (EAGER) collaborative research award is to test the hypothesis that the laws of continuum mechanics hold inside a micro-well of molten copper such that, when Single Wall Carbon Nanotubes are introduced into the micro-well, because of their high aspect ratio they will follow the fluid streamline and cling to this alignment upon solidification. The mechanical properties of this nanotube/copper composite are critically influenced by the alignment of the nanotubes in the Copper matrix. The approach to achieving this objective will be to employ a high brightness laser for creating a molten well of 50 micron diameter and 200 micron deep on a copper substrate and then introduce the nanotubes into the micro-well. It has been shown through computer simulation that there exists a vertical laminar flow pattern in the laser-induced micro-well. The microstructure of the composite will be examined to determine how well the vertical alignment is accomplished.If successful, the benefits of this research will include enabling technologies to allow copper alloys to be used in a number of applications that require high mechanical strength in combination with high electrical and thermal conductivities. A potentially transformative benefit is for the $65 billion die and mold making industry. Building dies and molds enforced by the nanocomposite will simplify the manufacturing process, reduce the lead time, prolong die life, and create a new workforce of die and mold makers.