Aluminum Composites for Hybrid Electric Systems

CPS Technologies Corp. (CPS) will optimize Fiber Reinforced Aluminum (FRA) metal matrix composites (MMCs) for use across diverse hybrid electric powertrains, power, and propulsion systems. FRA consists of a high strength aluminum (Al) matrix reinforced with 25-30 vol% discontinuous, randomly oriented ceramic fibers (Figure 1A). FRA has ultimate tensile strengths (UTS) that exceed 80 ksi at room temperature, and it retains >80% of its strength at 400 °F (more than 3X the strength of typical Al alloys). Additional benefits include dramatically superior wear resistance compared to hardened steel alloys at 1/3rd the density, a 30% reduced CTE compared to unreinforced Al alloys, and greater machinability/forgeability/weldability compared to other composites. Despite these benefits, FRA has been limited in its implementation due to high manufacturing costs. In the proposed work CPS will transition FRA processing from the fabrication of billet stock to net shape component manufacturing, simultaneously driving down costs and increasing product performance for complex hybrid electric ground and aerial vehicles. Performance and process improvements will be optimized for small component manufacturing, such as bushings and liner components that significantly reduce part wear and tear due to increased cyclic loading from motor actuation and regenerative charging.