Advanced Magnesium Matrix Composites for Lightweight Vehicles

Light weight ceramic hollow spheres-filled metal alloy syntactic foams have potential to replace heavy metal structures used in load bearing structural applications. These syntactic foams have a combination of low density and high strength, modulus, and damage tolerance. Aluminum/hollow ceramic composite is the most commonly investigated system for light weight applications. Magnesium, with the lower density structural metal, can replace aluminum for further reduction in weight. In the proposed Phase I project, novel syntactic foams based on magnesium alloys filled with high strength ceramic hollow microspheres and microtubes will be prepared and their mechanical properties as a function of fillers will be investigated. Phase II will involve scaling up the technology for applying the selective composite material(s) to passenger and commercial vehicles. Commercial Applications and Other Benefits: Light weight metal matrix composites can find application in the automotive, aerospace, and electronic packaging industries. The proposed syntactic foams can provide drastic weight savings without compromising on the mechanical properties. Potential aerospace applications include ventral fins for aircrafts, as well as fan exit guide vanes for commercial airline jet engines and applications in automotive industry include brake system components, intake and exhaust valves, and piston liners.