The Additive Layer Manufacture of Superalloy based Metal Matrix Composites

 

Premise

ALM can provide significant geometric freedom and complexity benefits to the manufacture of high value aerospace and automotive components.

The tool-less additive nature of the process is particularly beneficial in the economic production of superalloy materials with low machinability.

However higher performance superalloys strengthened by the gamma prime phase exhibit poor weldability, and so cannot be successfully processed by ALM.

The objective of this research is to develop a composite material, which provides both higher performance mechanical properties and the attendant benefits of ALM production.

 

What is ALM?

The layer by layer manufacture of functional components by laser consolidation of a powder feedstock.

Seiving & re-use of powder means minimal material waste.

Traditional limitations of machining or casting are lifted & geometry can become more complicated - but not necessarily more expensive!

Component is formed by melting powder with a laser, so low machinability alloys are less difficult to process than by machining, as no tools need be involved.

 

What are MMCs?

Metal Matrix Composite or MMC materials are defined as being a metallic material, containing some form of reinforcing material (usually ceramic).

The reinforcement may be continuous (long fibres) or discontinuous (short fibres, whiskers or particulates). By combining matrix & reinforcement the intent is to provide a composite with the ductility of the metallic matrix, but the high strength & stiffness of the reinforcement - a "best of both worlds" material.

Main Supervisor:

Dr. G. J. Gibbons

g dot j dot gibbons at warwick dot ac dot uk

 

Co-supervisor:

Dr. S. Maggs

steve dot maggs at warwick dot ac dot uk

 

Industrial Sponsors:

EOS UK Ltd - www.eos.info