Engineering topics
Publications and source records attributed to Divecha, A. P..
Effective fabrication methods for aluminum/boron and aluminum/graphite composites have been investigated. Drawing and rolling were found to be adaptable to Al/B fabrication. Although graphite composites are not amenable to standard metal processing methods, it may be possible to reduce fabrication costs of Al/C through electron-beam heating.
Attempts made to develop processes capable of producing metal composites in structural shapes and sizes suitable for space applications are described. The processes must be continuous and promise to lower fabrication costs. Special attention was given to the aluminum boride (Al/b) composite system. Results show that despite adequate temperature control, the consolidation characteristics did not improve as expected. Inadequate binder removal was identified as the cause responsible. An Al/c (aluminum-graphite) composite was also examined.
Deformation processing has not been seriously considered as applicable to composite fabrication, particularly if the filament (e.g., boron) lacks plasticity. When, however, the brittle filament is clad with a ductile matrix such as 6061 Al, the underlying filament is protected from damage even when cold worked severely as in drawing and rolling. These two metal-working processes have been applied successfully to produce seven ply aluminum 50 vol % boron tubes up to 2 in. O.D. by 3 feet in length and flats 1 in. in width by 2 feet in length respectively. Although adequate densification is achieved via drawing and rolling, the former has been given major emphasis. Mechanical properties of rolled and drawn flats and tubes compare favorably with those prepared by static methods. However, the objective of the presentation is to focus on lower processing costs. In specific terms, 2 in. tubes in lengths up to 12 feet can be produced for as little as $150/lb. This is possible only because standard drawbench and carbide dies can be utilized. Furthermore, the major steps including cladding, preform preparation and drawing are conducive to automation.
The continuing efforts in upscaling to produce larger diameter Al/B tubes are described. While the basic methodology remains unchanged, the larger volume of acrylic binder material and its removal by dissolution in toluene had to be performed by dynamic scrubbing. Similarly, the boron and MCF continuous length requirements increased when a 6 foot long by 7 inches wide mat was needed. These modifications and associated problems are described fully with schematics. Also included are seven experiments conducted to prepare larger tubes. The thermal profile, drawing speeds, and furnace positions in the draw bench bay are presented along with metallographic evidence of composite cross sections.