High Strength Cast Aluminum Alloys

ORBITEC proposes to develop high strength cast aluminum alloys for use in Expeditionary Fighting Vehicle (EFV) structures. Using a new casting technique developed by MSOE, the cast alloys HPAC structures will achieve material properties similar to those of forged structures. The casting process is well suited to the fabrication of components from existing metallic alloys and also facilitates the use of new cast alloys, particle and fiber reinforcements to create metal matrix composites to tailor the mechanical properties of the materials. In addition, designers will have the ability to optimize the alloys composition and properties at different points within the structures. The mature alloys are expected to offer low cost, high strength, aluminum castings that will allow for more efficient manufacturing of Navy EFV components. The Phase I effort will involve the selection of candidate materials and manufacturing techniques, the fabrication of material specimens for nondestructive and mechanical testing, the analysis of the material composition and test results, and the development of Phase II fabrication, test, and analysis plans.