Five innovations are offered: 1) Pressure in filtration casting of net-shaped components with sapphire reinforced NiA1 and alumina multifilament tow reinforced In 718 superalloy, 2) low cost tooling concepts, 3) exact geometric positioning of fibers during processing, 4) the elimination or reduction… More

Near-absolute net-shape processing utilizing MIT/MMCC's high rate pressure infiltration casting process for manufacturing brake calipers is proposed, with Allied-Signal providing design and mechanical testing support gratus. The first objective is to demonstrate the ability to manufacture… More

Metal matrix composites (MMCs) are the proposed replacement materials for the ferromagnetic parts that exist in an outboard engine. MMCs have specific stiffness properties 2 to 4 times that of aluminum alloys, steel, and titanium, while having equal or greater specific strength. The resulting… More

Proposed here is a method by which large area, thick sectioned, whisker and particulate reinforced, aluminum matrix composites may be produced for lightweight armor applications. The first objective of this work is to conduct preliminary process optimization producing reinforced specimens 6" by 6"… More

Graphite/Al phased array antenna rnodules will reduce rnodule launch mass from 154 kg (for W/Cu modules) to 19.7 kg. At $40,000/kg launch rnass, savings would be $5,400,000/launch. A team of users, graphite suppliers, casting house, and evaluation/analytical organizations, will develop and bring to… More

Three-dimensional printed preforms will be used as mold patterns for MMCC's high-density, pressure resistant, castable refractory. Hard tooling will be eliminated from the Advanced Pressure Infiltration Casting process (APIC ). Cost for Al/Sic electronic housings will be slashed 75% over… More

"The rise of next generation electronics depends on advances in microelectronic packaging materials. Power, frequency, and functionality are increasing while cost, size, and margin for error are declining. Military and commercial electronics are reachingperformance limitations since conventional… More

"Mg alloys reinforced with high modulus graphite fibers have nearly 1.5 times the specific stiffness of beryllium. Since the EKV sunshade is a stiffness critical application, a sunshade manufactured from graphite fiber reinforced magnesium could weigh athird less than the current Be design. Using… More

"This proposal shows how innovations in producing a family of CTE controlled, high thermal graphite aluminum composites will reduce manufacturing costs and improve system performance for specific BMDO, Navy, and commercial applications. Technologiesdeveloped by a graphite fiber producer, paper… More

"Manufacturing technology development and integration of MMCC's 3- DPT, Tool-Less MoldT and Advanced Pressure Infiltration(APICT) technologies are proposed. Investment casting of preforms printed directly from a CAD or laser file and subsequent pressureinfiltration will enable parts to be… More

"MMCC will develop an isotropic graphite fiber reinforced magnesium rigid mirror material that will result in an areal density of 5 kg/m2, reduce lead times for paraboloid blanks by two-thirds, and cut mirror costs by at least 50% over Be mirror systems.Phase I will design, build, and test graphite… More

Manufacturing technology development of 3DPT, injection molding, Tool-Less MoldT and Advanced Pressure Infiltration(APICT) technologies are proposed. Investment casting of injection molded preforms or preforms printed directly from a CAD file andsubsequent pressure infiltration will enable parts to… More

Thermal expansion can be designed into a graphite fiber reinforced Al or Cu composite over a range of 2 to 10 ppm/K by controlling the fiber architecture an volume loading. Discontinuous graphite fibers have been arranged into a random in-planearchitecture to produce planar isotropic properties… More

Graphite fiber reinforced Mg alloys show high specific stiffness, CTE less than 2 ppm/K and higher conductivity than competing mirror materials. Mg/Gr was coated with Si and polished to less than 10 angstroms RMS. Most important, the material is cast tonear final figure and is easily machined and… More

Graphite fiber reinforced Mg alloys with quasi-isotropic architecture has nearly the same specific stiffness (Young's modulus/density) as beryllium and 12 x the thermal stability (thermal conductivity/coef. thermal expansion). Compared to beryllium, Sicoated and polished Mg-Gr mirrors will be… More

Magnesium reinforced with a quasi-isotropic high stiffness graphite preform has the highest combination of specific stiffness (E/r) and thermal stability (thermal conductivity/CTE) of any material other than expensive CVD/SiC.This unique combination of properties coupled with ease of fabrication and… More

An order of magnitude increase in heat flux of multi-die passive heat sink materials is proposed. High performance graphite fiber reinforced aluminum and copper alloys are precisely CTE matched to diverse substrates such as CVD diamond, SiC, Si, GaN,GaAs, alumina and beryllia, by varying the volume… More

An order of magnitude increase in heat flux of multi-die passive heat sink materials is proposed. High performance graphite fiber reinforced aluminum and copper alloys are precisely CTE matched to diverse substrates such as CVD diamond, SiC, Si, GaN,GaAs, alumina and beryllia, by varying the volume… More

In Phase I, we demonstrated that Mg-AZ31 alloy reinforced with graphite fibers has over 27% higher specific stiffness than beryllium. Since EKV sunshade is a stiffness critical application, sunshades manufactured from graphite/Mg could weigh 27% less than the current Be design. Further, testing at… More

Magnetron sputtering of "Invar-like" nanolaminates onto a pre-finished/figured mandrel is proposed to produce strong, stiff, damage tolerant, low CTE replicas. The structural substrate will be a high performance discontinuous graphite fiber reinforced Mg AZ31 metal matrix composite manufactured by… More

By combining discontinuous graphite fiber preforms with inserts of ultra high thermal conductivity materials, we will create hybridized composites with thermal expansion matching to GaAs, SiC or GaN semiconductor amplifiers in advanced radar systems. Specifically, we will use a conventional MetGraf… More

Hybrid metal matrix composites are offered to meet the needs of high thermal conductivity heat sinks for electronic processors in advanced interceptor systems. MMCC's graphite fiber reinforced composite MetGraf 4-230 will serve as a skin to highly conductive cores of advanced graphitic materials. … More

Discontinuous pitch-based graphite fiber reinforced copper (Cu/Gr) composites have been under development for semiconductor thermal management. The composites consist of a high thermal conductivity copper-chromium alloy matrix and short pitch-based graphite fibers randomly oriented in planar… More

The results of Phase I showed that a 900 W/mK mechanically stable and CTE matched heat sink for T/RIMM module could be upgraded to 1200 W/mK. Phase II work is aimed at 1) establishing the manufacturing and producibility bases for design and deployment of advanced radar and RF components; 2)… More

A manufacturing technique is developed to strategically embed thermal pyrolytic graphite (TPG) insert into copper graphite composite. TPG will then be located in the critical thermal path of the power amplifier heat sink so that heat can be conducted from its edge into the radio chassis. The… More

A manufacturing technique is developed to strategically embed thermal pyrolytic graphite (TPG) insert into copper graphite composite. TPG will then be located in the critical thermal path of phase array radar antenna slat so that the slat is allowed to be cooled from its edge. The enhancement of… More

Discontinuous graphite fiber reinforced aluminum magnesium matrix composite with microscopically dispersed add-on oxidizer coating is proposed for the application of enhanced lethality munitions. The composite with the coating is light-weight and reactive, which will generate high reaction… More

MMCC will manufacture its standard discontinuous graphite fiber reinforced Mg alloy AZ31 optimized to a CTE of 2 ppm/K for evaluation by Raytheon Missile Systems for EKV mirror and Be applications. Additionally, MMCC will provide Raytheon evaluation panels of its new products based upon filament… More

MMCC is proposing herewith a hybrid structured mirror that combines the advantages of SiC membrane and magnesium graphite composite. The significance of magnesium graphite composite is that it can be produced with quasi-isotropic properties and closely matched CTE down to cryogenic temperatures. … More

In Phase I, MMCC combined discontinuous graphite fiber preforms with ultra high thermal conductivity (1700 W/mK TPG) inserts and created hybrid composites with thermal expansion matching to GaAs, SiC and GaN semiconductors and thermal conductivities from 800 to 1200 W/mK. A conventional Cu MetGraf… More

The main issue preventing widespread use of x-band antennae systems throughout various military platforms is cost. Cheaper assembly processes, such as automated pick and place, are needed to produce antennas using wideband gap semiconductor materials such as GaN and SiC. Higher power and frequency… More

Copper-graphite composite is proposed for a thin liquid-cooled cold plate for high density electronic thermal management. The proposed cold plate will have CTE in the range of 2~9x10-6 / degrees C to match those of semiconductors such as SiC, silicon, GaAs, as well as ceramic substrates. The… More

Pressure infiltration casting technology will used to develop low density continuous fiber reinforced structural metal matrix composites in the form of tubes and plates. Three different reinforcement systems will be investigated with the idea of producing a spectrum of choices for a wide range of… More

The main issue preventing widespread use of x-band antennae systems in military platforms is cost. Cheaper assembly processes, e.g. automated pick and place and larger formats are needed to implement wideband gap semiconductor devices (GaN and SiC). Lessons learned in GaAs based systems are… More

This Small Business Innovation Research (SBIR) Phase I project will use recycled or natural graphite to develop low cost graphite/aluminum composites with high thermal conductivity for electronic thermal management applications. Highly conductive graphite flakes randomly dispersed at ~75 volume… More

Two approaches to high performance base plates for advanced thermal management applications are proposed. Inexpensive high performance Al/Gr composites have been developed with a quasi-isotropic thermal conductivity (TC) of 600 to 750 W/mK and corresponding thermal expansion (CTE) of 7 to 3 ppm/K. … More

The Small Business Innovation Research (SBIR) Phase II project will develop and present for commercialization natural graphite (NG) reinforced Al (AlGr). In this project, inexpensive natural graphite flake (NGF) will be manufactured into a preform and pressure infiltrated with Al-Si alloys to form… More

This Small Business Innovative Research Phase I project is to develop extremely high thermal conductivity heat sinks that are thermal expansion matched to advanced semiconductors for high performance electronic and electro-optical systems. With low cost natural graphite platelet reinforcement, CuGrp… More

Ultra high thermal conductivity low-cost materials with thermal expansion matched to electronic devices, actuators and thermal electric cooling systems are proposed. These passive materials enable other technologies but provide for the thermal leveling required for advanced optics and sensing… More

Pressure infiltration cast graphite fiber and platelet reinforced Al materials are proposed. Structural materials that have high stiffness, low thermal expansion, very high thermal conductivity and low density will be developed for use as a satellite structural frame. The same composite preform… More

High stiffness structural composite skins with high thermal conductivity thermal cores (>800 W/mK) for mounting satellite sensors and electronics were demonstrated. Further hybridization with 800 W/mK"z"inserts with local thermal expansion matching provides for thermal management. … More

Multi walled carbon nanotubes MWNTs will be coated to enable wetting by molten OFHC copper. Coated MWNTs will be made into a preform and pressure infiltration cast with molten Cu to form a Cu/MWNT master composite. Master composites will be added to molten Cu and shear dispersed/diluted to form a… More

Thermal Management, CTE control, and mechanical stability are critical for lightweight aerospace/defense printed circuit board (PCB) applications. Current materials for PCBs do not adequately address thermal, reliability, and weight reduction in a single material solution. Historically, the… More

High efficiency heat-sinks for thermal management of high energy solid state lasers are proposed. Advanced heat sink technology enables increased performance of directed energy solid state lasers. Efficient high performance thermal management materials representing next generation thermal… More

Thermal management, CTE control, and mechanical stability are critical for lightweight aerospace/defense printed circuit board (PCB) applications. Current materials for PCB"s such as copper and graphite epoxy laminates with copper foil cladding do not adequately address thermal requirements,… More

This proposal addresses a critical need to develop low cost packaging solutions to reduce size, weight, and increase performance in hybrid electric vehicle (HEV) and electric vehicle (EV) motor drive power electronics. IGBT (integrated gate bipolar transistor) and inverter/converter devices for… More

Two approaches to high performance base plates for advanced thermal management applications are proposed. Inexpensive high performance Al/Gr composites have been developed with a quasi-isotropic thermal conductivity (TC) of 600 to 750 W/mK and corresponding thermal expansion (CTE) of 7 to 3 ppm/K. … More