Graphite Fiber Reinforced Al and Cu Alloys for Replacement of W/Cu in Electronic Thermal Mangement -

Graphite/Al phased array antenna rnodules will reduce rnodule launch mass from 154 kg (for W/Cu modules) to 19.7 kg. At $40,000/kg launch rnass, savings would be $5,400,000/launch. A team of users, graphite suppliers, casting house, and evaluation/analytical organizations, will develop and bring to commerical readiness Gr/Al and Gr/Cu composites for electronic thermal management applications. Technical objectives are: 1) Reduce launch mass of antenna modules by a factor of 7. 2) Increase the thermal conductivity by 40%. 3) Engineer the coefficient of thermal expansion to match the die, PCB, or ceramic substrate. 4) Reduce processing costs by half. MMCC's Advanced Pressure Infiltration Casting process (APICTM ) will be used to cast prototypes and evaluation coupons. MMCC's new low cost carbon matrix composite tooling will slash tooling materials processing cost by a factor of 10 and lead to commercialization. Micromechanical models will be applied toward materials design and definition of matrix alloys and heat treatment schedules to provide dimensional stability during processing and thermal cycling. Prototype modules for MILSATCOM phased array antenna will be manufactured to demonstrate the Gr/Al technology. A major electronic packaging house will specify a Gr/Cu prototype component for an application requiring high temperature brazing to ceramic substrates.