MMC HammerMMC HammerGroup members:Group members:

Ed BarnardEd BarnardLizzie HagerLizzie HagerJenny LichterJenny Lichter

Kevin McComberKevin McComber

2-26-04

OverviewOverview

GoalGoal Material PropertiesMaterial Properties Centrifugal Casting ProcessCentrifugal Casting Process Short Term ObjectivesShort Term Objectives Prototype Design and MoldPrototype Design and Mold ProgressProgress Upcoming ExperimentsUpcoming Experiments

Halstead

GoalGoal

The goal of our project is to The goal of our project is to manufacture a light-weight, high manufacture a light-weight, high fracture toughness hammer using fracture toughness hammer using metal matrix composites.metal matrix composites.

Carpenter, Koczak p. 310

Material PropertiesMaterial Properties Conventional steel hammer:Conventional steel hammer: Carpenter 20Cb-3® Stainless Steel

MMC hammer:MMC hammer: SiC / Ti-6Al-4V, V(%)=35SiC / Ti-6Al-4V, V(%)=35SiC / 6061 Alum, V% = 0.48SiC / 6061 Alum, V% = 0.48

Important properties for a Important properties for a hammer:hammer: DensityDensity Tensile strengthTensile strength ModulusModulus Wear resistanceWear resistance Fracture toughnessFracture toughness

Carpenter, Koczak p. 310

Material PropertiesMaterial Properties Conventional steel hammer:Conventional steel hammer: Tensile Tensile

measurements at RTmeasurements at RT MMC hammer:MMC hammer: Tensile measurements at 0° C Tensile measurements at 0° C

Centrifugal Casting Centrifugal Casting ProcessProcess

Centrifugal Casting Centrifugal Casting ProcessProcess

Poco

Pressure Vessel Pressure Vessel CalculationsCalculations

22

22

max .. io

ioUTS

rr

rr

FSP

MaterialMaterial σσUTS UTS (ksi)(ksi) Outer Outer radiusradius< < σσUTSUTS >>

Outer Outer radiusradius(σ(σUTSUTS))minmin

BrassBrass 30-9030-90 1.081.08 1.161.16

Stainless Stainless steelsteel

60-15060-150 1.041.04 1.081.08

AluminumAluminum 45-8045-80 1.071.07 1.101.10

GraphiteGraphite 7-107-10 1.771.77 2.092.09

Pmax = 2200 psi = 150 atm

S. F. : safety factor = 2ri : inner radius = 1 inch

"Home"

Short Term ObjectivesShort Term Objectives

Making moldMaking mold sizesize stabilitystability

Ceramic scaffoldCeramic scaffold packingpacking formationformation

Prototype designPrototype design

Hammer headHammer head simple designsimple design radially radially

symmetric symmetric (conical)(conical)

More complex More complex designs can be designs can be implemented laterimplemented later

Prototype MoldPrototype Mold Two-piece Two-piece

moldmold Conical to aid Conical to aid

in the releasein the release Sealed with Sealed with

an O-ring and an O-ring and bolted shutbolted shut

Swagelok Swagelok connector to connector to runnerrunner

Prototype MoldPrototype Mold

Top Mold

ProgressProgress

Two ceramic layers per Two ceramic layers per castingcasting

Investigating interfacesInvestigating interfaces 2µm TiC has been 2µm TiC has been eliminatedeliminated

Hardness testsHardness tests

Upcoming ExperimentsUpcoming Experiments

Hardness testHardness test SEMSEM Machine moldMachine mold Find an effective break-out ceramic Find an effective break-out ceramic

for mold releasefor mold release Use and test new ceramic particlesUse and test new ceramic particles

Projected Work ScheduleProjected Work Schedule2/5 2/12 2/19 2/26 3/4 3/11 3/18 3/25 4/1 4/8 4/15 4/22 4/29 5/6 5/13

MaterialsMetal choiceCeramics choice

Part productionCADInvestment casting

Steel machined mold

Ceramic preform

Volume fraction Time PermittingSize distribution "

Final testing

CODE:Task Sub-task Gradation Testing

Works CitedWorks Cited ““Carpenter 20Cb-3® Stainless Steel, Bar.” Accessed 22 Feb 2004. Carpenter 20Cb-3® Stainless Steel, Bar.” Accessed 22 Feb 2004. MatWeb.com, The Online Materials MatWeb.com, The Online Materials

DatabaseDatabase. 2004. <http://www.matweb.com/search/SpecificMaterialPrint.asp?bassnum=NCAR90 >.. 2004. <http://www.matweb.com/search/SpecificMaterialPrint.asp?bassnum=NCAR90 >.

Halstead, Gary. “Pictures from Dictionaire PaisonnHalstead, Gary. “Pictures from Dictionaire Paisonné du Mobilier Français.” Accessed 24 February 2004. é du Mobilier Français.” Accessed 24 February 2004.

Medieval and Renaissance Woodworking. Medieval and Renaissance Woodworking. 2003. 2003. <http://www.medievalwoodworking.com/vld_tools.htm >.<http://www.medievalwoodworking.com/vld_tools.htm >.

““Home > Centrifuges < Centrifuges, Floor > RFQ Form.” Accessed 23 Feb 2004. Home > Centrifuges < Centrifuges, Floor > RFQ Form.” Accessed 23 Feb 2004. Used-Line.Com : Used Hi-Used-Line.Com : Used Hi-

Tech and Scientific Equipment. <Tech and Scientific Equipment. <http://used-line.com/cgi-bin/used/~4055271_/IEC_CRU_5000.htm >.http://used-line.com/cgi-bin/used/~4055271_/IEC_CRU_5000.htm >.

Koczak, et al. “Metal-Matrix Composites for Ground Vehicle, Aerospace and Industrial Koczak, et al. “Metal-Matrix Composites for Ground Vehicle, Aerospace and Industrial Applications.” Applications.”

Fundamentals of Metal Matrix Composites. Fundamentals of Metal Matrix Composites. Boston: Butterworth-Heinemann, 1993. Boston: Butterworth-Heinemann, 1993. Eds. Suresh, S., Mortensen, Eds. Suresh, S., Mortensen,

A. and A. Needleman. 297-326.A. and A. Needleman. 297-326.

““Poco Graphite AXM-5Q Specialty GraphitePoco Graphite AXM-5Q Specialty Graphite.” Accessed 25 Feb 2004. .” Accessed 25 Feb 2004. MatWeb.com, TheMatWeb.com, The

Online Materials DatabaseOnline Materials Database. 2004. . 2004. <http://www.matweb.com/search/SpecificMaterialPrint.asp?<http://www.matweb.com/search/SpecificMaterialPrint.asp?

bassnum=NCAR90 >.bassnum=NCAR90 >.