Discontinuously Reinforced Aluminum Composite Structures by Pulsed Spray Forming

BMDO seeks innovative fabrication approaches to cut structure cost and innovative use of advanced materials to minimize structure weight. UTRON proposes to develop a new pulsed spray forming technique to establish a new means of fabricating DRA composites. The pulsed nature of the device will enable it to selectively use a high momentum flux medium to atomize molten aluminum droplets and spray ceramic powders, thus tailoring the microstructure of a spray formed DRA composite. In addition, this spray forming technique can be integrated with Rapid Prototyping technology. The proposed technique will allow the fabrication of finished DRA component parts with 1) fine microstructure, 2) excellent uniformity, 3) tailor made composition, and 4) desired material properties. During Phase I, UTRON proposes to: 1) Perform analysis to establish point design requirements and experimental parameters to spray form DRA composite structures. 2) Design a prototype device to spray form a 1/4 hase II objectives will be to: 1) Build an engineering prototype and fabricate a large scale DRA composite structure, and 2) Integrate a CAD system with the pulsed spray forming system to establish rapid prototyping capability.