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

该小型企业创新研究第一阶段项目的重点是开发一件式功能梯度混合（纤维/颗粒）增强铝合金基汽车制动转子。 复合材料制动盘具有显著的重量节省潜力，但成本和性能限制了它们的采用。 在这个项目中，我们将探讨一个单件，混合增强转子的概念。与传统材料相比，由于制动表面的功能增强梯度（FRG）和定制的宏观界面，新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摩托车制动盘方面的经验，但由于与之相关的独特挑战，拟议的工作并不是直接扩展。制动盘有三个功能区：a）摩擦界面（加热区），B）通风（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。这些区域之间的联邦德国过渡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的发展，模具和预成型件设计，以及上述区域和界面的微观结构和性能的控制有关的挑战。该项目更广泛的影响/商业潜力包括减轻汽车重量，提高燃油效率和减少排放。 这项技术还将有助于减轻军用车辆的重量，这将增加其装载能力，减少燃料消耗，并增加使命长度。 此外，预期拟议的制动盘的较长寿命将减少相关的维修需求。该公司已与纽约大学理工学院合作，该学院将允许学生获得实践培训。 这种功能分级的一体式转子将成为该细分市场中的首款同类产品，预计将为我们的团队创造强大的竞争地位。 这项技术的部署也可能有助于刺激其他轻型汽车部件的开发。 最后，这一产品的成功开发以及随后在第二阶段的商业过渡将在国内经济中创造高薪就业机会。

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.