Innovative Concepts for Lightweight Composite Sandwich Systems for Complex Shapes

The TM2 team proposes Alcv, an innovative Al composite material with stellar corrosion resistance, better elongation, formability, and strength performance beyond most Al alloys. High strength Al covetic is an Al alloy infused with 5% or more covalently bonded nano Carbon. TM2 coined the term"Covetic"to describe the alloy microstructure where nano C is infused into the molecular structure and serves as a covalent net that binds the Al. This material offers favorable nano tailored properties including thermal conductivity. Alcv material has synergistic properties due to the nano C infusion that produces a fine grain structure. Alcv 6061 covetic extruded lab samples have demonstrated exceptional elongation, toughness and corrosion resistance superior to the baseline Al 6061-T6. Alcv foam will be fabricated with the same technique as for commercial Al foam. Alcv foam can be fabricated because lab experiments show that when the Alcv is melted the Al and nano Carbon do not separate and thus the foam will retain the covetic corrosion resistant and thermal conductivity properties. The high specific surface area, low density and closed cell Alcv foam offers a combination of properties ideally suited for this Navy application when coupled with Alcv face sheets.