SBIR Phase I: Injection Molded Copper Composites for High K Structures

This Small Business Innovation Research (SBIR) Phase I project proposes to develop copper-graphite and copper-SiC composites with 40-50V% reinforcement loading using a microencapsulated powder metallurgy process. These microencapsulated powders will be combined with injection molding for the low cost fabrication of highly complex parts such as a finner radiator. The project will demonstrate an economical solution to metal matrix composite microstructural control and reliability problems, and will develop a new, high performance class of materials able to be used with injection molding and rapid prototyping equipment. The broader impacts from this technology would be first demonstration of injection molded metal matrix composites, opening up and entirely new range of properties/cost for performance materials. The combination of high thermal performance and low cost solves a number of problems with waste heat management in automotive/transportation, space vehicle, heating and climate control, as well as electronics and power conditioning applications. Furthermore, the ability to injection mold highly loaded metal matrix composites will be immediately translatable into structural, optical, and wear/mechanical components.