Metal-Matrix-Composites for Lighter Weight Designs
There is always a learning curve when working with a new material for the first time. Al MMCs are no exception. What ultimately distinguishes Al MMCs is an ease of manufacturing (machining, joining, and finishing) not normally associated with composite materials. If your part can be made from aluminum, titanium, or steel, it can be made from a DWA-USA Al MMC.
Al MMCs retain almost all the manufacturing characteristics of conventional aluminum. The biggest departures are associated with machining and joining.
Manufacturing Ease Index- Machining
The presence of SiC particles in the aluminum matrix changes machining response and tool wear. Polycrystalline Diamond (PCD) cutting tools are highly recommended for maximum tool life. With experience, machining Al MMCs is a routine operation, using parameters similar to hard alloy aluminum.
Manufacturing Ease Index- Joining and Finishing
Fusion welding techniques such as TIG and MIG are not recommended for Al MMCs. An adverse reaction between the aluminum matrix and SiC particles can lead to gas evolution and porosity in the weld zone. Friction welding, adhesive bonding and fastening are excellent joining options for Al MMCs.
Case Studies
Fielded Applications
DWA-USA specializes in new aluminum-based powder metallurgy materials and applications development. We serve our customers throughout the entire development cycle, whether it be an upgrade to an existing design or starting from the ground up. Our track record for transitioning prototyping efforts to real world serial production is unparalleled.
View our Case StudiesDensity Adjusted Properties of Aluminum MMCs Compared to Steel, Titanium and Aluminum
One of the clear advantages of Al MMCs compared to conventional metallic materials is greatly enhanced strength and stiffness. These property gains are achieved without impacting material density, so the specific properties of Al MMC are dramatically increased. Al MMCs are also isotropic composite materials. Their design space is not dependent on reinforcement orientation.
DWA Aluminum Composites
Aluminum Metal-Matrix-Composites Manufacturing
The Al MMC manufacturing process can be divided into three elements- primary processing, secondary processing and finishing. Unlike other composite materials, after primary processing of the billet, Al MMCs offer a high level of “fit, form and function” when inserted into the industrial manufacturing stream, making use of conventional facilities and equipment.
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