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

小企业创新研究（SBIR）第一期项目将利用高度处理的粉煤灰与搅拌铸造技术相结合，推进煤灰-铝金属基复合材料（MMC）的制造。粉煤灰是煤燃烧后产生的一种陶瓷玻璃球，采用一种新颖的分类系统将其分类为粒径范围窄、几乎没有细料（即直径为5微米的灰）的产品。分类灰颗粒的低表面积将促进铝基体内的分散，同时减缓相关的还原反应。所提出的铝-粉煤灰MMC将表现出优越的刚度、硬度和导热性。此外，成功制造出一种硬度更高的材料，可以用传统工具进行加工，这将是一项突破。如果成功，拟议的铝-粉煤灰MMC将使其成为汽车应用（制动转子）中球墨铸铁的有吸引力的替代品。这种材料在活塞、发动机缸体和发动机缸盖等应用领域也具有与过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.