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Centrifugal Casting for High Volume Fraction Ceramic Metal Composite Parts Overview Goals and Methods Design and Materials Theory Processing Part Characterization Goals Our goal was to design a manufacturing process to create a high ceramic volume fraction metal matrix composite (MMC). The project took the process developed by Dr. Jessada Wannasin and scaled it up for part production. Background on MMCs Combine High moduli of ceramics High toughness of metals Applications Sports equipment Wear-resistant parts for automobiles Packaging materials for space applications Methods Fabrication methods Stir casting Pressure infiltration: gas, mechanical, centrifugal We chose centrifugal pressure infiltration for high pressures and safety Mold Design Two identical aluminum molds designed using CAD, machined on lathes and a milling press Mold interiors coated with boron nitride to ease removal Mating surfaces of molds separated by graphite o-rings to prevent metal leakage Assembly Design Molds were each connected to a half-inch diameter steel tube via Swagelok connectors Added a tower to our centrifugation system held more metal in order to infiltrate complete parts black tube was used to stabilize the assembly in the centrifuge Materials - Metal Aluminum – optimal choice for MMCs Aluminum has problems Requires high processing temperatures Can be reactive Our metal choice: tin-lead Tin - 15 wt% lead Tin - 22 wt% lead Materials - Ceramic SiC, BC, Al2O3 particles Most experiments done with SiC particles 50 – 100 microns in diameter Ceramic preforms Ceramic combined with ethyl silicate binder Sintered at 1500o C for 1 hour Theory – Threshold Pressures Used data on aluminum infiltration from Dr. Wannasin’s PhD thesis Minimum infiltration pressures: SiC particles, 7–155 microns: 2–22 atm Al2O3 particles, 5–20 microns: 8–11 atm Based on moment of inertia we estimated we could achieve P = 50 atm, so P Pth Theory – Infiltration Time Darcy’s La