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Engineered Metal Matrix Composites and Fabrication Methods for Automotive Applications
Keywords: Engineered Metal Matrix Composites, Particulate Reinforced Aluminum, Joining MMC to metals and ceramics
Advanced metal matrix composites developed by combining superior properties of selected particulate materials, chopped fibers and aluminum yield significant performance advantages over competing electronic material systems in automotive electronic applications. Metal matrix composites such as SiC-reinforced aluminum, graphite reinforced aluminum and diamond reinforced aluminum are among these engineered materials. Reduced weight, high thermal conductivity, high stiffness, tailored coefficient of thermal expansion, tight dimensional control, reliability in harsh environments, lower cost are the desired characteristics for many automotive applications. Engineering methods used for tailoring the properties to meet desired design requirements and to reach tight dimensional control will be outlined in this paper. This paper also describes fabrication methods how to develop these engineered metal matrix composites including perform manufacturing, pressure infiltration casting and secondary operations such as plating, coating anodizing etc. Pressure infiltration casting process is a net shape casting process not only to produce electronic housings with demanding thermal performance requirements expected from electronic material systems such as IGBT modules, but also large heat spreaders as thin as 0.010 thick used in weight sensitive electronic applications. Net shape casting process is valuable for its ability to create more complicated part geometries such as pockets, O-ring channels, embedded channels, pedestals, raised bosses etc. In-situ joining of different materials with these engineered composites is another core capability of pressure infiltration casting. Methods used to in-situ join ceramics or other metals such as titanium steel and aluminum to these engineered composites will be described in this paper.
Dr. Birol Sonuparlak, Technical Manager
Rogers Corporation
Chandler, AZ

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