SBIR-STTR Award

Advanced Refractory Technologies, Inc (ART) is currently proposing the Development and Implementation of a Lightweight/Durable Aluminum MMC Track System for the AAAV. ART, teaming with Keweenaw Research Center (KRC) at Michigan Technological University is in an excellent position to supply an track system which meets the AAAV program office needs. ART is currently in the final stages of completing a lightweight MMC track system design (52 pounds/ft) for the M2 Bradley. It will be a direct replacement for their current T157I track system, but with a weight reduction of 25% and a doubling of track life (6000 miles). Shoe strength and wear are significantly enhanced utilizing selective SiC whisker reinforcement and high pressure squeeze casting. Shoe life is enhanced through improved shoe design and rubber components. It is proposed to leverage the technology and track design developed under this program to optimize a track system for the AAAV. Both single and double-pin track systems will be addressed to meet the weight requirements. This effort will commence by reviewing the requirements of the current track design and identifying changes/improvements which are not constrained by the AAAV. It is envisioned that the shoe body, track pins, track pad, and bushing sleeves can be lightened compared to the M2 track. Based on these considerations, the ART/KRC team feels confident that a track system can de developed in phase I and fabricated in Phase II meeting a 3000 mile track life, 42-45 pounds/ft weight (30% reduction compared to steel), and 21 inch width.

In Phase I the ART/KRC team developed two viable selectively reinforced SiCw/Al MMC track shoe system designs for the AAAV. Al MMC shoe concept design weights of 44.8 lbs./ft. for the single-pin and 47.4 lbs./ft for the double-pin are significantly reduced from the T157I weight of 71 lbs./ft and 51.3 lbs./ft of the UDLP forged aluminum shoes. In Phase II the team will continue detailed design work to optimize the Al MMC AAAV track designed in Phase I to ensure that weight and durability requirements (< 48 lbs/ft. and 3000 miles) are met. Squeeze casting die and preform design activities will be completed to enable the track shoe squeeze cast dies and SiCw reinforcement preform dies to be fabricated. Three Al MMC track shoes will be fabricated for visualization purposes followed by 20 shoes for laboratory testing. Hubs and sprockets will also be designed to allow the fabrication and/or modification of existing components to mate with the Al MMC track. Following laboratory testing, one complete track set will be fabricated, assembled, and delivered to the AAAV DRPM for field testing. The team will provide support to AAAV DRPM during testing throughout the duration of the Phase II program.

Benefits:
Anticipated benefits of this program include utilization of the Al MMC technology team to design and fabricate the ultimate lightweight/durable track for the AAAV. The use of selective reinforcement allows for enhanced wear and strength in regions requiring these enhancements while allowing the lightweight, easily machineable, ductile characteristics of pure aluminum to be utilized in the majority of the track shoe. Although this Phase II effort is limited to Al MMC track shoes, this technology can be applied to other AAAV components including lightweight road wheels and hubs which utilize SiCw reinforcement in the wear ring location.

Keywords:
Aluminum MMC Durable track Silicon Carbide Whiskers Lightweight track Selectively Reinforced MMC Squeeze Cast aluminum