Aspen Systems, Inc. — Department of Energy SBIR Phase I: Current efforts of DOE to create future lightweight systems in order to attain significant

Description

Current efforts of DOE to create future lightweight systems in order to attain significant energy saving, cost reduction and improved efficiency requires development of advanced nanostructured lightweight composite materials with improved ductility and high tensile strength. Magnesium (Mg) with a density of approximately two-thirds of aluminum is the lightest structural material. Despite this advantage, the study of Mg alloys remains fairly limited because of its poor strength as compared to Al-alloys. Aspen Systems Inc. proposes to develop a new class of light weight nanostructured magnesium alloy-ceramic reinforced composite in bulk form that exhibits high strength and superior corrosion resistance suitable for future lightweight structural components in military and various aerospace, automotive and thermal management markets that would result in reduced fuel. Aspen Systems proposed Phase I concept is a marriage between Mg based nanophase matrix alloy and a metal matrix composite (MMC) that will utilize cryo-milling approach combined with a low cost bulk consolidation technology to develop a super high strength nanostructured Mg-alloy-ceramic composite that would exhibit a minimum tensile strength around 500-600 MPa, good ductility (at least 5%) and better corrosion resistance in the bulk alloy ingot. Suitable optimization of the process parameters for cryomilling and rapid consolidation will be identified and extensive mechanical testing and analysis will be conducted to establish structure-property relationship of the material. During the Phase II program, we will develop and demonstrate a successful cost effective technology with proven optimized process parameters based on Phase I data to produce a prototype large billet with superior properties. We also use state of the art consolidation technique to produce nano-grained sheet for commercial application. This material thus developed a new class of lightweight, high strength reinforced Mg nanocomposite material with high toughness and desired ductility can substitute Al and Ti alloys in many aerospace components and most typical components of satellites, space stations and launch vehicles as well as potential component replacements such as bulkhead, spars tube, etc. with significant benefit from the weight savings (Energy savings) and dramatically reduced overall cost. Our material will also be a potential candidate for many other automotive engine components such as wrist pins, rocker arms, turbocharger impellers, timing sprockets, intake valves and crankcase housings etc.