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Metal-Matrix-Composites for Lighter Weight Designs
Highly Loaded Al MMCs
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Highly Loaded Al MMCs contain SiC particle contents of 40 Vol% and greater. Matrix alloy selection is based on specific manufacturing and application requirements. AA6091 is selected to maximize forgeability, AA6092 for maximized strength in the billet form, and 6063 for high thermal conductivity. Minimum Coefficient-of-Thermal-Expansion (CTE) and maximum elastic modulus are the material property objectives of highly loaded Al MMCs.

Highly Loaded Al MMCs are powder metallurgy Al MMCs comprised of AA6091, AA6092 or AA6063 aluminum and either 40, 44 or 50 Vol% Silicon Carbide particles. They are available in vacuum-hot-pressed billet, extruded, and forged product forms.

  • CTE equivalent to Be and Cu-W
  • Elastic modulus 2-2.5X conventional aluminum
  • Aluminum thermal conductivity
Units:
Eng

TYPICAL AND MINIMUM MECHANICAL PROPERTIES FOR EXTRUSION AND FORGINGS

6091 & 6092/SiC/40p-T6
Density= 0.1054 lb/in3		 F, ty
ksi		 F, tu
ksi		 elong.
%
6091/SiC/40p-T6
Extrusion, 3in2
Closed Die Forging, 6in		 Typical L, LT 62 78 1.9
6092/SiC/40p-T6
Extrusion, 3in2		 Typical L, LT 75 82 1.5
Minimum Properties Minimum L, LT 55 65 1
Notes:
1) Young's Modulus is typically 20 msi in both the L and LT orientations.
2) Coefficient-of-Thermal-Expansion (CTE) is typically 6.7 ppm/°F.
3) Typical Rockwell B hardness is 86-88.
Data is representative for 1 inch maximum section thickness during heat treatment. Mechanical properties will be dependent on the Al MMC material system, product form, geometry
and heat treatment method.
Si

TYPICAL AND MINIMUM MECHANICAL PROPERTIES FOR EXTRUSION AND FORGINGS

6091 & 6092/SiC/40p-T6
Density= 2.92 g/cm3		 F, ty
MPa		 F, tu
MPa		 elong.
%
6091/SiC/40p-T6
Extrusion, 19.4cm2
Closed Die Forging, 152mm		 Typical L, LT 427 538 1.9
6092/SiC/40p-T6
Extrusion, 19.4cm2		 Typical L, LT 517 565 1.5
Minimum Properties Minimum L, LT 379 448 1
Notes:
1) Young's Modulus is typically 138 GPa in both the L and LT orientations.
2) Coefficient-of-Thermal-Expansion (CTE) is typically 12.1 ppm/°C.
3) Typical Rockwell B hardness is 86-88.
Data is representative for 25 mm maximum section thickness during heat treatment. Mechanical properties will be dependent on the Al MMC material system, product form, geometry
and heat treatment method.

 

 

MATRIX ALLOY CHEMICAL COMPOSITION FOR 6091 & 6092/SiC/40p

6091 & 6092/SiC/40p
Density= 0.1054 lb/in3 (2.92 g/cm3)
  Al Cu Mg Si Fe Zn Ti Ni Cr Mn O Other,
Each		 Others,
Total
6091 Bal 0.15-
0.40		 0.8-
1.2		 0.40-
0.8		 0.7
max		 0.25
max		 0.15
max		 -- 0.15
max		 0.15
max		 0.050-
0.50		 0.05
max		 0.15
max
6092 Bal 0.7-
1.0		 0.8-
1.2		 0.40-
0.8		 0.30
max		 0.25
max		 0.15
max		 -- 0.15
max		 0.15
max		 0.050-
0.50		 0.05
max		 0.15
max
Notes:
1) Compositional limits shown as weight percent (wt%).
2) Silicon carbide particle content shall be maintained at 40 ±1.0 Vol%.
Highly Loaded Al MMCs Data Sheet File Format: pdf
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The CTE of Al MMCs decreases with increasing volume loading. At a 40% SiC content, Al MMC CTE is equivalent to Beryllium. At a 50% SiC content, Al MMC CTE begins to approach that of far heavier electronic packaging materials such as Copper-Tungsten (Cu-W).

 

SiC Vol% CTE ppm/°C CTE ppm/°F
0p 23.4 13.0
17.5p 16.6 9.2
25p 13.8 7.7
40p 12.1 6.7
44p 11.7 6.5
50p 9.6 5.3

Al MMC Coefficient-of-Thermal-Expansion (CTE) as a Function of SiC Particle Loading

Al MMC CTE Chart
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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.

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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.

Primary Processing
Primary Processing
Secondary Processing
Secondary Processing
Finishing
Finishing
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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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