SBIR-STTR Award

Develop a method and apparatus to hot squeeze cast a homogenous magnesium and discontinuous fiber or aluminum and discontinuous fiber metal matrix component. A generic test bar or mechanism will be developed to test separately cast specimens to correlate test data. Phase i will consist of fabrication of the generic test bar mechanism with a fixed fiber fraction at various squeeze pressures. Phase ii will consist of fabricating a full scale component using the integrated composite flow cast system. The test device fabricated in phase i will be used to correlate test data where test bars can't be extracted practically from the full scale composite component.

Keywords:
composite mater flow casting metal matrix hot squeeze cas fibers discontinuous strength ratio fabric

Thompson Aluminum Casting Company proposes to use an Integrated Composite Flow Squeeze Casting System (developed under a previous U.S. ArmySBIR Program) to cast near net shape production items made of metal matrix composites. Our proposal is to demonstrate squeeze casting as aviable manufacturing process for metal matrix composites in the manufacture of turbine engine blades. Our plans are to employ techniques which will break clusters, improve distribution of SiC composite reinforcements and eliminate porosity. Phase I consisted of squeeze casting tensile bars of aluminum metal matrix-SiC particulate. This Phase yielded test bars which characterized the solidification, micro-structure and permitted measurement of tensile properties of the test bars demonstrating improved qualities of the squeeze cast metal matrix composite aluminum. Initial Phase I test bar samples also demonstrate that Squeeze Casting as a manufacturing methodology for production items isa viable concept. Phase II will primarily consist of proving squeezecasting as a manufacturing process capable of full scale production. Phase II will utilize Al-SiC particle composite to manufacture actual turbine engine blades using the Integrated Flow Squeeze Casting System.