Aeroprobe Corporation proposes a highly scalable consolidation process, termed friction-stir fabrication (FSF), for fabricating large-scale, complex structures using Mg alloy powders. FSF is a continuous powder consolidation process that yields thick fully-dense, wrought metal consolidated structures from powder feedstock and produces an ultrafine-grain microstructure. FSF will enable the production of complex geometries, suitable for direct integration with existing vehicle armor systems. The process has already been shown to enable functional grading of the structure by controlling both the geometry and composition of the alloy, including the mechanical alloying of a metal matrix composite surface layer to increase wear resistance. The development of functionally graded material will enable utilization in a broad range of applications currently not feasible for Mg. Finally, FSF has the potential to produce advanced functionally-graded structures if the geometry and composition of the finished structures can be more closely controlled. All required deliverables will be produced during the base period. During the Option Period, additional samples will be delivered to the Army and our commercial partner for independent testing. The process will be improved and detailed system upgrade designs initiated. Initial feasibility of functional grading, improved geometric control and welding will be demonstrated during the option period.
Keywords: Magnesium Armor, Near-net-shape,Powder metallurgy, Rapid prototyping,Digital manufacturing,Functionally graded structures, Ultrafine-grain,Friction Stir Fabrication
