Corrosion Resistant Squeeze Cast Net Shape Magnesium Composite Components

In this Phase II Innovation research program, MER will design light weight, high strength and high stiffness magnesium matrix composites for full scale prototype components utilized in the 81mm mortar design for feet and bipod legs and for other components such as light weight armor. Actual size prototype parts will be cast at MER using our squeeze casting facility. Design criteria will involve modeling effort by the army to determine stress state of the parts during service conditions which will be used as guidance for choosing specific fiber orientations and types for hybrid composite parts. A data base of Mg composite material properties gathered in Phase I will be used to down select local reinforcement type and orientation. Testing of the prototype parts will be conducted under simulated field conditions of impact loading, corrosion resistance and flammability both by the Army and MER to allow optimization of the design for a second generation design to be completed within the duration of Phase II. Strategies will be developed to minimize potential galvanic corrosion, using selected high strength fillers and high purity level alloys. Net shape parts with volume loading of filler ranging from 20-75% will be constituted from particulate and fiber including carbon fiber, alumina and SiC by low cost squeeze casting.