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The objective was to demonstrate the feasibility of producing near net shape components from particulate reinforced aluminium alloy using casting processes relevant to high volume applications. The consortium comprised an automotive manufacturer, a metal matrix composite producer, a material processor, a foundry products supplier and a contract research and development institute. 6 casting processes were considered and 7 different matrix alloy formulations were used in the casting trials. Casting and melt handling practice was optimized, properties measured and automotive demonstrator components assessed. Recycling trials demonstrated methods for melt cleaning and reuse within the foundry and for total reclamation of matrix and particulate. Advances were made in experimental techniques for measurement of entrapped oxide and particle dispersion in castings.
It is hoped to exploit the results in fields across the European foundry industry with a view to tailoring the technology to specific applications.
The main areas of interest are:
particle settling behaviour;
particle melt separation techniques;
fluidity of semisolid particulate metal matrix composite (PMMC);
casting and testing of conrods;
PMMC physical metallurgy;
measurement of entrapped oxide and particle dispersion in castings.
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