Development of a Low Cost Process by Which Greater Than Two-Inch Thick Particulate and Whisker Aluminyum Matrix Composites can be Produced

Discontinuous aluminum metal matrix composites (AL MMCs) have demonstrated promising behavior for ballistic structural armor applications. A fine grain matrix, low-cost processing and prevention of agglomeration of the reinforcement is lacking in current processing to produce Al MMCs. Low-cost processing with extensive flexibility in process control for tailoring reinforcement loading and matrix grain size while producing thicknesses up to but not limited to two-inches of ceramic particle and whisker reinforced Al MMCs is required for structural armor applications. The proposed processing has already produced over two-inch thick sections of Al MMCs for other applications as well as some ballistic testing. This processing will be further developed to produce thicknesses of over two-inches with the flexibility to control ceramic particle loading from low to high including gradation and whiskers in the interstices with a fine grained aluminum matrix. Thick section MMCs will be produced, ballistically tested and further optimized with the delivery of six 12 x 12 x over one-inch thick plates of one or more MMC compositions.