Fly ash-enhanced aluminum composites for automotive parts. [Reports for October to December, 1997, and January to March, 1998

Abstract

The objectives of this report are to produce and evaluate the use of aluminum ''ashalloys''--metal matrix composites that incorporate coal fly ash--in the commercial manufacture of cast automotive parts. Some highlights of this report are: Results of the team coordination meeting in October included--(1) Determination of casting techniques from the candidates of squeeze, high pressure, low pressure, sand casting, and gravity pour; (2) Selection of the low stress/high stress automotive parts from the candidates of brake rotors, intake manifolds, and engine mounts; (3) Integration of the tasks essential for evaluating the fly ash characteristics and appropriate percentages of cenospheres or precipitator in the parts. Fly ash from two plants of Wisconsin Electric Power Company (WEPCo) was dispatched to the laboratories of JTM and UW-M for screening, characterization, and beneficiation. The fly ash was classified into different size fractions and is being analyzed for chemical composition and microstructure. Currently, fly ash beneficiation is removing the carbon, magnetic fractions, and sulfur. After classification and screening, JTM will deliver the processed fly ash to UW-M. Foundries are providing UW-M with information on the specific alloys needed for parts. Thompson Aluminum sent the base alloy 356 to UW-M where, in turn, small size ingots were prepared with fly ash from WEPCo. UW-M will continue process development and preparation of specific MMC ingots for foundries' parts production. Many of the program tasks are iterative over quarters, but findings considered milestones were: Collection and processing of fly ash; and Predictions on microstructure and alloy composites including type, size, and amount of fly ash for component property requirements.