Project Title:

Graphite-Magnesium, Metal-Matrix-Composites for Space Structural Joints with Built-In

04.15-3200
912106
Graphite-Magnesium, Metal-Matrix-Composites for Space Structural Joints with Built-In
Metallic Inserts
Foster-Miller, Inc.
350 Second Avenue
Waltham
MA
02154-1196
Uday
Kashalikar
617-890-3200
MSFC
NAS8-39319
062

04.15-3200
912106

Abstract:

Graphite-Magnesium, Metal-Matrix-Composites for Space Structural Joints with Built-In
Metallic Inserts
A low-cost MMC fabrication method for net-shape fabrication of space structural joints
with built-in metallic inserts will be developed. Two innovations will be demonstrated
during Phase I: low-cost, reusable tooling to pressure cast Gr-Mg components to net
shape, and "built-in" metallic inserts in the component to produce strong and reliable
MMC joints using conventional metal joining. The firm has pressure cast Gr-Al and
Gr-Mg components exhibiting a complete preform infiltration and a controlled fiber-matrix
interface chemistry. The MMC specimens have shown rule-of-mixtures modulus and a
high strength (>100 ksi). The major issues that need to be resolved to encourage
widespread utilization of MMCs in space systems are reducing the cost of tooling
and processing, and developing joining techniques for MMC parts by virtue of its
reusability. Incorporation of metallic inserts will enable assembly of the MMC components
using existing techniques such as welding, bolting, brazing, and so on. A complex
shaped Gr-Mg joint component with metallic fittings will be selected, fabricated,
and evaluated during Phase I. The process will be optimized to demonstrate repeatability
in component properties during Phase II.
The successful development of low-cost, easily "joinable" Gr-Mg components will open
up commercial applications in automotive and aircraft engines, avionics and electronic
packages as well as in high-performance sporting equipment. Phase I will identify
candidate commercial applications that will be further investigated during Phase
II.
The successful development of low-cost, easily "joinable" Gr-Mg components will open
up commercial applications in automotive and aircraft engines, avionics and electronic
packages as well as in high-performance sporting equipment. Phase I will identify
candidate commercial applications that will be further investigated during Phase
II.
pressure casting, Gr-Mg, metal-matrix composites, space structures, joints, built-in
inserts, fittings, tooling