Manufacturing of Al-Ce/Metal-Matrix-Composites (MMC) for Harsh Environments

An integrated modeling/simulation and experimental approach will be used to design and synthesize Al-Ce/MMC for use in key technologies where improved energy efficiency and performance is harsh environments is required. Modeling and simulation work including thermodynamic modeling, DFT calculations, and continuum modeling of casting processes and mechanical behavior, will be combined with lab-scale synthesis to identify potential matrix and reinforcing phase compositions for large-scale synthesis. The experimental synthesis work will rely on lab-scale casting and gas atomization to identify the optimal matrix compositions for pilot/commercial-scale synthesis is Al-Ce/MMC. Selected Al-Ce/MMC will be synthesized by commercial scale melt processing, powder metallurgy and thermomechanical processing. The corrosion resistance, mechanical properties as a function of temperature, and thermal conductivity of the composites will be characterized to validate target properties are met or exceeded. This work will focus on two selected applications; however, the design framework will have broad applicability for composites for numerous harsh service condition applications. We will have synthesized Al-Ce/MMC that exhibit better performance in harsh environments than currently used materials.. Authors: Ott, Ryan [Ames Laboratory (AMES), Ames, IA (United States)] (ORCID:0000000271592328); Kaczmarsky, Myron [Holtec Government Services, LLC., Camden, NJ (United States)]; Weiss, David [Intelligent Composites, Milwaukee, WI (United States)]; Mannig, Jorg [Eckart Effect Pigment, Louisville, KY (United States)]; Loukus, Adam [Loukus Technologies, Calumet, MI (United States)]. DOE Contract: AC02-07CH11358. Subjects: 36 MATERIALS SCIENCE