SBIR Phase I: Development of a Selectively Reinforced Aluminum Composite Brake Rotor

这个小企业创新研究第一阶段项目的重点是开发一种一体式功能分级混合（纤维/颗粒）增强铝合金基体汽车制动转子。复合制动转子具有很大的减重潜力，但成本和性能限制了它们的采用。在这个项目中，我们将探索一体式混合增强转子的概念。由于制动表面的功能增强梯度（FRG）和定制的宏观界面，与传统材料相比，新型转子将具有更好的性能和寿命。虽然该项目将受益于我们在FRG摩托车制动转子方面的经验，但由于与之相关的独特挑战，拟议的工作并非直接延伸。制动转子有三个功能区：A)摩擦界面（加热区），b)排气（冷却区）和c)安装轮毂（扭矩传递区）。这些区域中的每一个都必须具有特定的材料属性，以使转子正常工作。这些区域之间的FRG转换界面的开发是第一阶段工作的重点。这项工作将解决与挤压铸造工艺、模具和预成形设计以及上述区域和界面的微观结构和性能控制相关的挑战。该项目的更广泛影响/商业潜力包括减轻汽车重量、提高燃油效率和减少排放。该技术还将有助于减轻军用车辆的重量，从而增加其装载能力，降低燃料消耗并增加任务长度。还预计，拟议的制动转子的更长的寿命将减少相关的维护需求。该公司与纽约大学理工学院（Polytechnic Institute of New York University）合作，让学生获得实践培训。这种功能分级的一体式转子将是该细分市场的首创产品，预计将为我们的团队创造强大的竞争地位。这项技术的应用也有助于推动其他轻量化汽车部件的发展。最后，该产品的成功开发以及随后在第二阶段的商业转型将为国内经济创造高薪就业机会。

This Small Business Innovation Research Phase I project is focused on developing a one-piece functionally graded hybrid (fiber/particle) reinforced aluminum alloy matrix automobile brake rotor. Composite brake rotors have substantial weight savings potential, but costs and performance have limited their adoption. In this project we will explore the concept of a one-piece, hybrid reinforced rotor. The new rotor will have significantly better properties and lifespan compared to conventional materials due to the functional reinforcement gradient (FRG) across the braking surface and the tailored macro-interfaces. While the project will benefit from our experience with FRG motorcycle brake rotors, the proposed work is not a direct extension because of unique challenges associated with it. A brake rotor has three functional zones: a) friction interface (heating zone), b) venting (cooling zone) and c) mounting hub (torque transfer zone). Each of these zones must have specific material attributes for the rotor to function properly. The development of the FRG transition interfaces between these zones is the focus of the Phase I effort. This work will address challenges related to the development of the squeeze casting process, die and preform design, and the control of the microstructure and properties of the aforementioned zones and interfaces. The broader impact/commercial potential of this project includes weight savings in automobiles, increased fuel efficiency, and reduced emissions. This technology will also help in reducing weight in military vehicles, which will increase their loading capacity, reduce fuel consumption, and increase mission lengths. It is also expected that the longer life of the proposed brake rotors will reduce the related maintenance requirements. The company has partnered with the Polytechnic Institute of New York University, which will allow students to gain hands-on training. This functionally-graded one piece rotor will be a first-of-its-kind product in this market segment, which is expected to create a strong competitive position for our team. The deployment of this technology may also help to spur the development of other lightweight automobile components. Finally, successful development of this product, and the subsequent commercial transition in Phase II will result in the creation of high-paying jobs in the domestic economy.