Higher Pressure Combustion Driven Powder Consolidation Manufacturing and Materials Behavior Aspects of Lightweight Aluminum Alloys

We present the manufacturing and materials behavior aspects of select higher performance aluminum alloys of 5083, and 7000 series (e.g., 7090) of conventional and cryomilled powders using UTRON Kinetics’s patented Combustion Driven Powder Compaction up to 150 tsi. The CDC compaction is done using 300/400 Ton Combustion Driven Compaction (CDC) Press. The process advantages of higher pressure CDC compaction (e.g., up to 150 tsi) as compared to conventional low pressure (<50-55 tsi) powder metallurgical techniques include: much higher part densities in green and sintered conditions, less part shrinkages, ability to press powders of various sizes (e.g., macro, micro, nano) and morphologies, single/layered materials fabrication, minimal grain growth (e.g., depending on the alloy compositions), improved fine grained microstructures and mechanical behavior, scalability for automation (1 to 6 parts/minute) together with cost-effectiveness in manufacturing. Efforts to optimize the CDC compaction process for select aluminum alloys under optimal process conditions together with effects on geometrical, physical, mechanical and fatigue behavior and microstructures will be discussed and technological advantages of higher pressure powder compaction for defense, energy and commercial applications will be highlighted. Potential commercial applications of CDC technology include high temperature valves, laser optical mirror substrates/heat sinks, x-ray targets, rocket motor components, high temperature parts, wear resistant and tougher parts, offshore-oil field tooling, ceramic composite armors with improved ballistic resistance and soft magnets with better permeability, permanent magnets with enhanced remnance, coercivity and BHmax properties. The CDC processing and properties of aluminum alloys of both conventional and cryomilled powders have been investigated up to 150 tsi with higher part densities and improved microstructural and mechanical properties than attainable by conventional P/M techniques.