Additive Manufacturing of Carbon Nanotube Metal Matrix Composites

Abstract: Additive Manufacturing has been identified as a manufacturing technology that can have a significant impact on both the commercial and military industrial bases of the United States.  Over the past few decades, the decline of the industrial capacity of the United States and the rise of near peer adversary nations has resulted in a situation that requires a change in the way commercial and military systems are produced, maintained and sustained. Additive Manufacturing offers this change. However, the Additive Manufacturing process does not allow for the obtainment of wrought mechanical properties.  To address this issue, SHEPRA and the University of Dayton have developed a process to incorporate carbon nanotubes into the metal powder used in the Additive Manufacturing process.  Through multiple phase I and phase II SBIR / STTR programs with the Army, Navy and the Air Force, SHEPRA and the University of Dayton have demonstrated the ability to improve the mechanical properties of multiple metal alloys including aluminum, stainless steel and Haynes 230. This phase II STTR program will focus on the use of carbon nanotube to enable the use of materials such as non-eutectic aluminum alloys (6061 Aluminum) and refractory alloys (Haynes 230) that are prone to thermal cracking during the Additive Manufacturing process.   Additive Manufacturing of 6061 alloy has commercial applications in the automotive and civilian aerospace industries and military applications in the maintenance and sustainment of currently deployed systems.  Hayes 230 has application and interest from the commercial space launch industry and military application in hypersonic systems.