Inducing Retained Compressive Stresses for the Design of Lightweight Tough Composite Material Structures

Shape memory alloy (SMA) fiber reinforced aluminum composites, SMA-MMC offer excellent properties, particularly, fracture toughness and damage tolerance which are due to induced compressive residual stresses. In Phase I, we have demonstrated through casting and warm rolling that viable SMA-MMC can be dveloped with desirable mechanical properties. In Phase II, we plan to model the behavior of these new class of composites to develop material design tools and to explore three competing processing methods e.g., (1) deformation processing, (2) powder/hydroforming and (3) squeeze casting for producing MMC to determine which one is most efficient to produce SMA composites with improved thermomechanical properties. One of these processing methods will be selected to develop demonstration articles such as track-shoe inserts e.g., in Future Combat System (FCS)- an advanced next generation vehcile for the US Army. Newaz Technologies, Inc. has teamed up with University of Washington (Professor Minoru Taya), Cast Metal Composites, Inc. (CMCI) of Cleveland with considerable experience in MMC component development for Army and Dr. Xin Wu (consultant)- an expert in manufacturing technology with advanced materials. The team involves national and international experts to provide Army with this unique technology of SMA composites for structural applications. Phase II success in this program is expected to lead to a Phase III program. The proposed program is unique in that this is the only SMA-MMC R&D effort in the US for potential DoD and commercial applications.