Enhanced High Volume Reinforced Al/SiC Metal Matrix Composites

This Small Business Technology Transfer (STTR) project will develop advanced, nano-engineered thermal spray powders for producing composite coatings with revolutionary enhancements in performance. The Phase I project demonstrated the production of high volume reinforced (25-65 wt % SiC) aluminum and nickel matrix composite materials using CVD fluid bed coated powders and low cost consolidation techniques. Dramatic increases in flexure strength and modulus were achieved, with results showing greater than 5% (80% increase) ductility and a 600% increase in flexural strength compared to current metal matrix composite state of the art. A greater understanding of the nano-engineered particles being produced, and the relationship between nano-structural features and the resulting mechanical property improvements will be developed leading to repeatable, predictable performance and application to additional composite and coatings systems.