Field effects in processing lightweight materials with superior mechanical properties and microstructures

Innovative methods are required for the processing of aluminum alloys with ultra-high strength and ductility for wide usage in energy savings and light weighting in many DOD and commercial applications. Conventional techniques for achieving the range of chemical and physical material properties have reached a plateau and are producing only incremental improvements. This SBIR Phase II project, proposes an innovative processing approach of powder compaction and sintering with fields to process ultra-high strength aluminum alloys with strength properties that are double that of wrought materials. The method involves blending aluminum powder alloys with alnico (magnetic particles) as reinforcement, powder alignment during green body forming, and subsequent field assisted sintering approaches for full densification and grain boundary engineering for higher strength, ductility, and texture. The project also establishes commercial viability for production at the conclusion of Phase II. The Phase I results have demonstrated that aluminum alloys processed via this route have 50 % higher strength than conventional press and sintered alloys of the same base composition. The processing approach can be suitably developed for other light-weight alloys such as magnesium and titanium.