Composite Aluminum Aircraft Matting for High-Temperature Applications

ABSTRACT: Current mats are manufactured from aluminum 6061 because of its relatively high strength-to-weight ratio and durability. However, 6061 does not maintain these desirable characteristics when exposed to higher temperatures, where it loses strength significantly above 150 degrees C. This makes 6061 very undesirable for high temperature applications, where the mats could be exposed to temperatures of up to 1700 degrees F. It is also desirable that aircraft landing mats have high thermal conductivity so that concentrations of high temperatures can be quickly dissipated to the surrounding material. Currently, the top surface of the mat is coated with an epoxy-based, non-skid coating. This coating requires frequent replacement due to wear or breakdown from the environment. Powdermet, along with its subsidiary/spin-out MesoCoat Inc, propose to demonstrate an extrudable, nanocomposite, aluminum metal matrix composite as a high temperature, high strength-to-weight ratio matting material which can be directly substituted for 6061 aluminum and reduce weight in landing mats by 20% or more. Furthermore we propose to demonstrate the application of a thermally insulating low density (microballoon-reinforced) superalloy metal matrix syntactic composite thermal protection coating system (with non-skid properties) to reduce mat temperatures and extend matting life when used in jet exhaust wash environments. BENEFIT: There are multiple applications for high temperature aluminum to replace titanium and higher density materials in transportation and aerospace systems, including nanocomposite aluminum landing mats, and thermal barrier non-skid topcoat, refurbishment or OEM landing mat coating and refurbishment services, applying the metallic non-skid to both existing and original parts. A non-skid surface with enhanced heat resistant capabilities will be required, to meet the operational envelope of the Joint Strike Fighter and MV-22 aircraft. Specifically, nozzle exhaust gas temperatures will be much higher than produced by previous Vertical Take-Off and Landing aircraft.