Lightweight Aluminum/Nano composites for Automotive Drive Train Applications

Chelluri, Bhanumathi ; Knoth, Edward A. ; Schumaker, Edward J.

关键词: Aluminum;    Al MMC;    Light weight;    DMC;    Energy savings;   

DOI  :  10.2172/1057396
RP-ID  :  DOE/ER/84540- Final Report
PID  :  OSTI ID: 1057396

学科分类：能源（综合）

美国|英语

来源: SciTech Connect

【 摘 要 】

During Phase I, we successfully processed air atomized aluminum powders via Dynamic Magnetic Compaction (DMC) pressing and subsequent sintering to produce parts with properties similar to wrought aluminum. We have also showed for the first time that aluminum powders can be processed without lubes via press and sintering to 100 % density. This will preclude a delube cycle in sintering and promote environmentally friendly P/M processing. Processing aluminum powders via press and sintering with minimum shrinkage will enable net shape fabrication. Aluminum powders processed via a conventional powder metallurgy process produce too large a shrinkage. Because of this, sinter parts have to be machined into specific net shape. This results in increased scrap and cost. Fully sintered aluminum alloy under this Phase I project has shown good particle-to-particle bonding and mechanical properties. We have also shown the feasibility of preparing nano composite powders and processing via pressing and sintering. This was accomplished by dispersing nano silicon carbide (SiC) powders into aluminum matrix comprising micron-sized powders (<100 microns) using a proprietary process. These composite powders of Al with nano SiC were processed using DMC press and sinter process to sinter density of 85-90%. The process optimization along with sintering needs to be carried out to produce full density composites.