D3: 3-D textile reinforced Al-matrix composites by high pressure die casting

• Applicant: Professor Dr.-Ing. Robert F. Singer (†)
• Subject Area: Materials in Sintering Processes and Generative Manufacturing Processes ; Engineering Design, Machine Elements, Product Development
• Term: from 2008 to 2014
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 57157353

Complex 3-D carbon fibre preforms are to be infiltrated with aluminium in a high pressure die casting process. If our approach is successful, it will represent a major breakthrough compared to gas pressure infiltration, the state-of-the-art technology to manufacture fibre reinforced metal parts. Compared to the above mentioned technology, pressure die casting offers several advantages. The short cycle times characteristic for this process are not only of a substantial economic advantage, but also constrict the kinetically controlled deleterious reactions between the fibre-preforms and the aluminium matrix. Based on results of preliminary die casting experiments and numerical simulations of the infiltration process, an advanced mould design was realized in the past project phase further improving fibre preform preheating. In combination with advanced alloy compositions and fibre coatings developed by the project partners the main aims of the proposed continuation are to realize metal matrix composites (MMC) with improved transversal strength and ductility. A detailed understanding of the interface reactions is necessary to relate processing parameters, alloy and coating composition to the mechanical properties of the obtained MMC. In order to rationalise results, advanced microstructural investigations like SEM-FIB, high resolution TEM and numerical calculations of the infiltration process with Flow-3D and ABAQUS are envisaged.

• DFG Programme: Research Grants
• Participating Person: Dr.-Ing. Christian Rottmair