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Content archived on 2024-04-15

DEVELOPMENT OF HIGH PERFORMANCE ALUMINIUM ALLOYS AND ALUMINIUM MATRIX COMPOSITES USING A SPRAY DEPOSITION APPROACH

Objective

To develop new aluminium with improved properties, especi ally strength at room temperature and Metal Matrix composites with high strength and high stiffness by using a Spray Deposition Process. This process allows high solidification rates and produces fine microstructure and is potentially more economical than the P/M route developed so far.
The spray deposition process was successful in producing massive high density preforms of high solute aluminium/zinc/magnesium/copper alloys with low residual gas and inclusion contents. However, despite the successful development of these alloys, it was found that the mechanical properties were not suitable for aerospace applications because of the relatively low values of ductility and fracture toughness. Preliminary data suggests that the damage tolerance properties of spray deposited products could be considerably improved.
THE PROJECT SHOULD SATISFY PROJECTED FUTURE DEMANDS FOR MATERIAL WITH AN IMPROVED COMBINATION OF SPECIFIC STRENGTH AND CORROSION RESISTANCE.

THE APPROACH EMPLOYS A UNIQUE SPRAY-DEPOSITION PROCESS DEVELOPED BY ONE OF THE PARTNERS (OSPREY). A STREAM OF MOLTEN METAL IS ATOMISED AND DEPOSITED IN AN INERT ATMOSPHERE AT A HIGH FLOW RATE INTO COHERENT PREFORM SHAPES SUCH AS CYLINDRICAL BILLETS OR STRIPS. THE SOLIDIFICATION RATE IS HIGH AND NON-METALLIC PARTICLES CAN BE INJECTED INTO THE ATOMISED METAL SPRAY. THUS, IT IS POSSIBLE TO PRODUCE HIGHLY ALLOYED MATERIALS AND ALLLOY BASED COMPOSITES, WITH EXCELLENT HOMOGENEITY.

IT IS ANTICIPATED THAT IT WILL BE POSSIBLE TO EXTEND CONSIDERABLY THE ALLOY RANGE, AND ACHIEVE SUBSTANTIAL IMPROVEMENTS IN THE SPECIFIC STRENGTH TOUGHNESS, FATIGUE BEHAVIOUR AND CORROSION RESISTANCE, COMPARED WITH MATERIALS PRODUCED BY THE INGOT OR POWDER ROUTES. THERE SHOULD BE AN ADDITIONAL BENEFIT IN SAFETY FOR ALUMINIUM PRODUCTS IN THAT THE HAZARDS OF HANDLING AND STORING ALUMINIUM POWDER CAN BE MINIMIZED.

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Funding Scheme

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CSC - Cost-sharing contracts

Coordinator

Pechiney
EU contribution
No data
Address
Centre de Recherches de Voreppe Zone Industrielle
38340 Voreppe
France

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Total cost

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Participants (2)

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